diag: bounded passage carve reach rejected (L93); R43 Unreal SW startup notes

Explicit carve reach R (diagnostic, default unbounded): R=2.5 m -> 1.56 cm max displacement,
106 deg max normal change; R=4 m -> 0.63 cm but 53 deg normals. Fails the bar; readiness gain
small and inconsistent (TN -5%, VS +6-7%). No world change (v214). Fast tier PASS.
R43: Unreal SW bReady 2.16 s = serial sign-edge repair (1.94 s, 10.9M corrections;
parallelSignEdgeRepair exists but off); ~0.45 s of SerializeResolvedWorld = adapter SW route search.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_016dhxM43dnWvUu2B5Ph1iG1

Standalone/Core/src/ShapeWorldInternal.h

@@ -84,6 +84,20 @@ static double VF_L91PassageSourceFloorVoxels()
     return Value;
 }
 
+static double VF_L93PassageCarveReachMetres()
+{
+    static const double Value=[]
+    {
+        const char* Raw=std::getenv("VOXELFORGE_L93_PASSAGE_CARVE_REACH_METRES");
+        if(!Raw||!*Raw)return 0.0;
+        char* End=nullptr;
+        const double Parsed=std::strtod(Raw,&End);
+        return End!=Raw&&*End=='\0'&&std::isfinite(Parsed)&&Parsed>0.0
+            ?Parsed:0.0;
+    }();
+    return Value;
+}
+
 // Standalone-only world compiler. It compiles the runtime room/tunnel/passages into
 // axis-line intervals, composes rock/cave signs into packed Z-column words, then displaces
 // only the conservative surface band. The copied Unreal generator remains the A/B reference.
@@ -241,14 +255,18 @@ public:
             const std::array<std::int64_t,3>& minimumSubvoxels,
             const std::array<std::int64_t,3>& maximumSubvoxels,
             VoxelForgeCore::TileGenerationStats* profileStats=nullptr,int32 profileLod=0,
-            double passageSourceFloorVoxels=-1.0)
+            double passageSourceFloorVoxels=-1.0,
+            double passageCarveReachMetres=-1.0)
             :shape_(&shape),minimumSubvoxels_(minimumSubvoxels),
              maximumSubvoxels_(maximumSubvoxels),previous_(ActivePassageTileQueries),
              profileStats_(profileStats),profileLod_(profileLod),
              candidateProfiled_(profileStats!=nullptr&&shape.L90PassageCandidateProgramEnabled),
              passageSourceFloorVoxels_(std::isfinite(passageSourceFloorVoxels)
                  &&passageSourceFloorVoxels>=0.0?passageSourceFloorVoxels
-                    :VF_L91PassageSourceFloorVoxels())
+                    :VF_L91PassageSourceFloorVoxels()),
+             passageCarveReachMetres_(std::isfinite(passageCarveReachMetres)
+                 &&passageCarveReachMetres>=0.0?passageCarveReachMetres
+                    :VF_L93PassageCarveReachMetres())
         {
             if(passageSourceFloorVoxels_>0.0)
                 clampCounters_=std::make_shared<FPassageSourceClampCounters>();
@@ -360,6 +378,7 @@ public:
              previous_(ActivePassageTileQueries),profileLod_(source.profileLod_),
              candidateProfiled_(source.candidateProfiled_),
              passageSourceFloorVoxels_(source.passageSourceFloorVoxels_),
+             passageCarveReachMetres_(source.passageCarveReachMetres_),
              clampCounters_(source.clampCounters_),ownsClampCounters_(false)
         { ActivePassageTileQueries=this; }
         ~FScopedPassageTileQueries()
@@ -479,6 +498,7 @@ public:
         {return profileStats_;}
         bool candidateCensusProfiled() const noexcept{return candidateProfiled_;}
         double passageSourceFloorVoxels() const noexcept{return passageSourceFloorVoxels_;}
+        double passageCarveReachMetres() const noexcept{return passageCarveReachMetres_;}
         void recordPassageSourceClamp(float sourceDensity) const noexcept
         {
             if(passageSourceFloorVoxels_<=0.0)return;
@@ -556,6 +576,7 @@ public:
         int32 profileLod_=0;
         bool candidateProfiled_=false;
         double passageSourceFloorVoxels_=0.0;
+        double passageCarveReachMetres_=0.0;
         mutable std::shared_ptr<FPassageSourceClampCounters> clampCounters_;
         bool ownsClampCounters_=true;
         mutable std::uint64_t l90Queries_=0,l90NoBrickQueries_=0;
@@ -1284,6 +1305,23 @@ public:
             &&passageTileQueries->matches(*this);
         auto* passageProfile=passageTileScopeMatches
             ?passageTileQueries->profileStats():nullptr;
+        const double passageCarveReachMetres=passageTileScopeMatches
+            ?passageTileQueries->passageCarveReachMetres()
+            :VF_L93PassageCarveReachMetres();
+        const bool passageCarveReachEnabled=passageCarveReachMetres>0.0
+            &&std::isfinite(passageCarveReachMetres);
+        const double passageCarveReachQ=passageCarveReachEnabled
+            ?passageCarveReachMetres*qPerMetre
+            :std::numeric_limits<double>::infinity();
+        const auto carveSourceReachQ=[&](float source)
+        {
+            const double sourceReach=source<0.0f
+                ?-static_cast<double>(source)*Q+0.24*qPerMetre
+                :std::max(2.25*qPerMetre,-static_cast<double>(source)*Q
+                    +0.24*qPerMetre);
+            return passageCarveReachEnabled
+                ?std::min(sourceReach,passageCarveReachQ):sourceReach;
+        };
         if(passageProfile)++passageProfile->passageComposerQueries;
         const bool l90CandidateProfiled=passageTileScopeMatches
             &&passageTileQueries->candidateCensusProfiled();
@@ -1335,13 +1373,10 @@ public:
             &&!passageTileQueries->hasAnyMouthSupport()
             &&!passageTileQueries->mayContainUpperMouthSupport())return density;
 
-        // On solid samples, the SDF carve can still move the scalar density far outside the
-        // physical tunnel. The per-passage test below already accounts for this tail using the
-        // incoming density plus the bounded relief allowance. Apply that same proof before
-        // entering the passage loop for points outside the scalar influence reach. Columns and
-        // both mouth-support paths keep their own tile envelopes and therefore disable this
-        // cut. Optional extra padding is only for research sweeps; zero is the exact bound.
-        // Invalid values fail open.
+        // On solid samples, the unbounded SDF carve can move density far outside the tube.
+        // Bound that source-dependent tail, or cap it at the explicit carve reach. Whole-tile
+        // rejection is limited to tiles with no route, column, or mouth feature, so the separate
+        // support and landing paths keep their existing envelopes. Invalid values fail open.
         static const double PassageBoundPaddingVoxels=[]
         {
             constexpr double DefaultPaddingVoxels=0.0;
@@ -1358,7 +1393,9 @@ public:
             &&std::isfinite(PassageBoundPaddingVoxels)
             &&!passageTileQueries->hasColumnZOverlap()
             &&!passageTileQueries->hasAnyMouthSupport()
-            &&!passageTileQueries->mayContainUpperMouthSupport())
+            &&!passageTileQueries->mayContainUpperMouthSupport()
+            &&(!passageCarveReachEnabled
+                ||!passageTileQueries->hasRouteFeatureOverlap()))
         {
             if(passageProfile)++passageProfile->passageTileBoundChecks;
             bool bAnyPassageWithinBound=false;
@@ -1388,8 +1425,11 @@ public:
                     (CarveHigh-Passage.controlPoints.begin())-1);
                 const std::ptrdiff_t CarveEnd=std::min<std::ptrdiff_t>(LowerMouthIndex-1,
                     (CarveLow-Passage.controlPoints.begin())+1);
-                const double SignedDistanceLimit=-static_cast<double>(density)*Q
-                    +0.24*qPerMetre+ExtraPadding;
+                const double rawSignedDistanceLimit=-static_cast<double>(density)*Q
+                    +0.24*qPerMetre;
+                const double SignedDistanceLimit=passageCarveReachEnabled
+                    ?std::min(rawSignedDistanceLimit,passageCarveReachQ)+ExtraPadding
+                    :rawSignedDistanceLimit+ExtraPadding;
                 if(PassageMayAffectDensity(PassageIndex,CarveBegin,CarveEnd,
                     LowerMouthIndex,Constants.mouthSearchBegin,Constants.mouthSearchEnd,
                     Constants.lastIndex,qx,qy,qz,SignedDistanceLimit))
@@ -1686,10 +1726,7 @@ public:
             const std::ptrdiff_t mouthSearchEnd=passageConstants.mouthSearchEnd;
             if(l90CandidateProfiled)
             {
-                const double signedDistanceLimit=density<0.0f
-                    ?-static_cast<double>(composed)*Q+0.24*qPerMetre
-                    :std::max(2.25*qPerMetre,-static_cast<double>(composed)*Q
-                        +0.24*qPerMetre);
+                const double signedDistanceLimit=carveSourceReachQ(composed);
                 const bool sourceProofAvailable=L90PassageCandidateProgramValid
                     &&std::isfinite(signedDistanceLimit)
                     &&signedDistanceLimit<=L90PassageCandidateReachMetres*qPerMetre
@@ -1704,10 +1741,12 @@ public:
             }
             if(density<0.0f&&tilePassageFree)
             {
+                // A tile without this passage's route feature cannot contain its separate
+                // tread/support work, so the carve reach is sufficient for this query skip.
                 if(passageProfile)++passageProfile->passageNegativeBoundChecks;
                 if(!PassageMayAffectDensity(passageIndex,carveBegin,carveEnd,
                     lowerMouthIndex,mouthSearchBegin,mouthSearchEnd,lastIndex,qx,qy,qz,
-                    -static_cast<double>(composed)*Q+0.24*qPerMetre))
+                    carveSourceReachQ(composed)))
                 {
                     if(passageProfile)++passageProfile->passageNegativeBoundRejects;
                     continue;
@@ -1726,8 +1765,7 @@ public:
                 if(passageProfile)++passageProfile->passagePositiveBoundChecks;
                 if(!PassageMayAffectDensity(passageIndex,carveBegin,carveEnd,
                     lowerMouthIndex,mouthSearchBegin,mouthSearchEnd,lastIndex,qx,qy,qz,
-                    std::max(2.25*qPerMetre,-static_cast<double>(composed)*Q
-                        +0.24*qPerMetre)))
+                    carveSourceReachQ(composed)))
                 {
                     if(passageProfile)++passageProfile->passagePositiveBoundRejects;
                     continue;
@@ -1863,10 +1901,7 @@ public:
                     considerCarveSegment(static_cast<std::size_t>(index),3);
             }
             if(!std::isfinite(bestSignedDistance))continue;
-            const double l90SignedDistanceLimit=density<0.0f
-                ?-static_cast<double>(composed)*Q+0.24*qPerMetre
-                :std::max(2.25*qPerMetre,-static_cast<double>(composed)*Q
-                    +0.24*qPerMetre);
+            const double l90SignedDistanceLimit=carveSourceReachQ(composed);
             if(l90CandidateProfiled&&bestSignedDistance<=l90SignedDistanceLimit
                 &&l90SignedDistanceLimit<=L90PassageCandidateReachMetres*qPerMetre)
                 passageTileQueries->recordL90ProofCheck(0,
@@ -2108,6 +2143,17 @@ public:
                 *floorAlignment*floorAlignment*floorBelowWeight*mouthWalkLaneWeight;
             const float fullyCarvedDensity=std::max(composed,
                 static_cast<float>(-roughSignedDistance/Q));
+            double carveReachWeight=1.0;
+            if(passageCarveReachEnabled)
+            {
+                constexpr double ReachBlendWidthMetres=0.5;
+                const double blendWidthQ=std::min(ReachBlendWidthMetres,
+                    passageCarveReachMetres)*qPerMetre;
+                const double fade=std::clamp((passageCarveReachQ-bestSignedDistance)
+                    /std::max(1.0,blendWidthQ),0.0,1.0);
+                if(passageProfile)++passageProfile->passageSmoothstepEvaluations;
+                carveReachWeight=fade*fade*(3.0-2.0*fade);
+            }
             static const bool bL75TraceTnPassage=[]
             {
                 const char* Value=std::getenv("VOXELFORGE_L75_TN_BLOCK_REGRESSION");
@@ -2115,7 +2161,7 @@ public:
             }();
             const float passageInput=composed;
             composed=std::lerp(composed,fullyCarvedDensity,
-                static_cast<float>(floorCarveWeight));
+                static_cast<float>(floorCarveWeight*carveReachWeight));
             if(bL75TraceTnPassage&&X==-80.0f&&Y==-20.0f&&Z==-3218.0f
                 &&composed!=passageInput)
             {