From ca829b8943c0bc313ff757b263440d1840066f61 Mon Sep 17 00:00:00 2001
From: TMHSDigital <154358121+TMHSDigital@users.noreply.github.com>
Date: Tue, 15 Sep 2026 23:25:44 -0400
Subject: [PATCH 1/2] fix: seat the ladder rungs and stop the iron chamfers
 reading as wood

The rung dowels were as deep as the stile they pass through, so each one
erupted through the stile's front and back chamfers as a thin spike in
every joint close-up. Narrowing the dowel to 26 mm corrects the
proportion; a material or camera change would only have hidden it.

Beveling the caps and shoes left every chamfer face in the wood slot.
Bevel does not inherit material_index onto the faces it creates, and the
piece claimed its metal faces from a pre-bevel snapshot, so each iron
fitting rendered as a black block framed in tan. Claim them from the
bevel op's own return instead.

The previous round removed six iron fittings per ladder without
re-fitting the triangle band or the outer AABB, leaving the piece
failing its own gates at exit 4. Both constants are re-fitted to the
measured result: 2184 tris to 936.

Locks all of it in as budgets recomputed from the generated mesh: shell
count, rung-to-stile depth clearance, tenon engagement and breakout
margin, and material face floors that the pre-bevel snapshot would have
failed. --lift-z could never fire, because matrix_world is evaluated
data and the object was moved without a view-layer update; --stray-vert
and --fat-rungs are new, and all four are proven to fire.

Signed-off-by: TMHSDigital <154358121+TMHSDigital@users.noreply.github.com>
Co-authored-by: Cursor <cursoragent@cursor.com>
---
 docs/gallery/assets/wooden-ladder-hero.webp | Bin 9624 -> 12308 bytes
 docs/gallery/index.html                     |   6 +-
 docs/gallery/wooden-ladder/index.html       | 441 +++++++++++++++++---
 showcase/gallery.json                       |   4 +-
 showcase/wooden-ladder/README.md            |  60 ++-
 showcase/wooden-ladder/preview.webp         | Bin 8916 -> 12308 bytes
 showcase/wooden-ladder/wooden_ladder.py     | 413 +++++++++++++++---
 7 files changed, 781 insertions(+), 143 deletions(-)

diff --git a/docs/gallery/assets/wooden-ladder-hero.webp b/docs/gallery/assets/wooden-ladder-hero.webp
index 26b04f459e1370099c91e74b38a599047f9ecd18..c758379d6208a537b1225a123384c9c2aec9f6f5 100644
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zlg>Y;s4)x54;$OKGmYIa0x=5#CSqJt!SQy(ci#0IcZ6B*qKrG&k9{qpQ>2V20#a6*
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O(3hfd-RWQgsQ>^ik)<gB

diff --git a/docs/gallery/index.html b/docs/gallery/index.html
index 8e07123..d6c10fd 100644
--- a/docs/gallery/index.html
+++ b/docs/gallery/index.html
@@ -1151,12 +1151,12 @@ <h2><a href="iron-cauldron/">iron-cauldron</a></h2>
       </article>
       <article class="card" data-tags="mesh export showcase">
         <a class="card-media" href="wooden-ladder/" aria-label="wooden-ladder example detail page">
-          <img src="assets/wooden-ladder-hero.webp" alt="wooden-ladder — A procedural timber ladder with raked stiles, six rungs, and iron shoes through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather…" loading="lazy" decoding="async" />
+          <img src="assets/wooden-ladder-hero.webp" alt="wooden-ladder — A procedural timber ladder with raked stiles, six dowel rungs tenoned into the stiles, and iron shoes and top caps through UVs, bake, LOD, collider, and Unity…" loading="lazy" decoding="async" />
         </a>
         <div class="card-body">
           <h2><a href="wooden-ladder/">wooden-ladder</a></h2>
-          <p class="teaches">A procedural timber ladder with raked stiles, six rungs, and iron shoes through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract.</p>
-          <p class="witnesses"><span class="tag">witnesses</span> Recomputed: 2184 tris, two materials with 1008 wood and 48 metal faces, UVs in 0..1 with zero AABB overlap, outer AABB 0.474×0.361×1.482 m, LOD ratios in band, convex collider 52 tris, non-empty glTF. --skip-decimate exits 9 on the LOD1 ratio budget.</p>
+          <p class="teaches">A procedural timber ladder with raked stiles, six dowel rungs tenoned into the stiles, and iron shoes and top caps through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract.</p>
+          <p class="witnesses"><span class="tag">witnesses</span> Recomputed: 936 tris, two materials with 324 wood and 216 metal faces, UVs in 0..1 with zero AABB overlap, outer AABB 0.472×0.365×1.460 m, grounded at zmin 0, mesh hygiene all zero, 12 shells with every rung clearing the stile chamfer by 3.61 mm, convex collider 24 tris, non-empty glTF. Four falsifiers exit 9, 15, 16, and 17 on the LOD, hygiene, grounded, and joint-fit budgets.</p>
           <a class="card-link" href="wooden-ladder/">View example <span aria-hidden="true">&rarr;</span></a>
         </div>
       </article>
diff --git a/docs/gallery/wooden-ladder/index.html b/docs/gallery/wooden-ladder/index.html
index 1f5d4a3..6383b83 100644
--- a/docs/gallery/wooden-ladder/index.html
+++ b/docs/gallery/wooden-ladder/index.html
@@ -4,18 +4,18 @@
   <meta charset="utf-8" />
   <meta name="viewport" content="width=device-width, initial-scale=1" />
   <title>wooden-ladder — Examples — Blender Developer Tools</title>
-  <meta name="description" content="A procedural timber ladder with raked stiles, six rungs, and iron shoes through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract." />
+  <meta name="description" content="A procedural timber ladder with raked stiles, six dowel rungs tenoned into the stiles, and iron shoes and top caps through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract." />
   <link rel="canonical" href="https://tmhsdigital.github.io/Blender-Developer-Tools/gallery/wooden-ladder/" />
   <link rel="icon" href="../../assets/favicon.svg" type="image/svg+xml" />
   <meta name="theme-color" content="#1a1b1e" />
   <meta property="og:type" content="website" />
   <meta property="og:title" content="wooden-ladder — Examples — Blender Developer Tools" />
-  <meta property="og:description" content="A procedural timber ladder with raked stiles, six rungs, and iron shoes through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract." />
+  <meta property="og:description" content="A procedural timber ladder with raked stiles, six dowel rungs tenoned into the stiles, and iron shoes and top caps through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract." />
   <meta property="og:url" content="https://tmhsdigital.github.io/Blender-Developer-Tools/gallery/wooden-ladder/" />
   <meta property="og:image" content="https://tmhsdigital.github.io/Blender-Developer-Tools/gallery/assets/wooden-ladder-hero.webp" />
   <meta name="twitter:card" content="summary_large_image" />
   <meta name="twitter:title" content="wooden-ladder — Examples — Blender Developer Tools" />
-  <meta name="twitter:description" content="A procedural timber ladder with raked stiles, six rungs, and iron shoes through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract." />
+  <meta name="twitter:description" content="A procedural timber ladder with raked stiles, six dowel rungs tenoned into the stiles, and iron shoes and top caps through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract." />
   <meta name="twitter:image" content="https://tmhsdigital.github.io/Blender-Developer-Tools/gallery/assets/wooden-ladder-hero.webp" />
   <style>
     /* fonts are deployed by the landing build (docs/fonts/) */
@@ -246,35 +246,43 @@
   </div>
   <header class="hero">
     <h1>wooden-ladder</h1>
-    <p>A procedural timber ladder with raked stiles, six rungs, and iron shoes through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract.</p>
+    <p>A procedural timber ladder with raked stiles, six dowel rungs tenoned into the stiles, and iron shoes and top caps through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract.</p>
   </header>
   <main id="main">
     <button class="detail-hero" id="heroZoom" type="button" aria-label="Zoom wooden-ladder render">
       <img src="../assets/wooden-ladder-hero.webp" alt="wooden-ladder render" width="1280" height="720" />
     </button>
     <p class="zoom-hint">Rendered headless by the example itself — click to zoom.</p>
-    <div class="callout"><span class="tag">witnesses</span> Recomputed: 2184 tris, two materials with 1008 wood and 48 metal faces, UVs in 0..1 with zero AABB overlap, outer AABB 0.474×0.361×1.482 m, LOD ratios in band, convex collider 52 tris, non-empty glTF. --skip-decimate exits 9 on the LOD1 ratio budget.</div>
+    <div class="callout"><span class="tag">witnesses</span> Recomputed: 936 tris, two materials with 324 wood and 216 metal faces, UVs in 0..1 with zero AABB overlap, outer AABB 0.472×0.365×1.460 m, grounded at zmin 0, mesh hygiene all zero, 12 shells with every rung clearing the stile chamfer by 3.61 mm, convex collider 24 tris, non-empty glTF. Four falsifiers exit 9, 15, 16, and 17 on the LOD, hygiene, grounded, and joint-fit budgets.</div>
     <div class="runline">
       <pre id="runCmd">blender --background --python showcase/wooden-ladder/wooden_ladder.py --</pre>
       <button class="copy-btn" id="copyRun" type="button">Copy</button>
     </div>
     <section class="detail-section md">
-<p>A showcase piece, not an example. Procedural timber ladder (raked stiles, six rungs, iron shoes and straps) then the shipped pipeline: unique-cell UVs, Cycles high-to-low normal bake, LOD chain, convex collider, Unity glTF export.</p>
+<p>A showcase piece, not an example. Procedural timber ladder (raked stiles, six 26 mm dowel rungs tenoned into the stiles, iron shoes and top caps) then the shipped pipeline: unique-cell UVs, Cycles high-to-low normal bake, LOD chain, convex collider, Unity glTF export.</p>
 <p>It asserts <strong>budget conformance</strong> of the generated result. It does not witness an API contract. &quot;It rendered without error&quot; is not a check.</p>
 <p><strong>Composes</strong> skills <code>mesh-editing-and-bmesh</code>, <code>bake-high-to-low</code>, <code>depsgraph-and-evaluated-data</code>, <code>engine-export-presets</code>, and snippets <code>bake_normal_high_to_low.py</code>, <code>setup_bake_target_image.py</code>, <code>lod_chain.py</code> / <code>decimate_to_budget.py</code>, <code>convex_hull_collider.py</code>, <code>export_preset_unity.py</code> (helpers copied, not imported as a package).</p>
 <h2>Budgets</h2>
 <p>Declared as named constants; every gate <strong>recomputes</strong> from the mesh, materials, UVs, evaluated LOD, collider, or export file.</p>
-<p>| Axis | Declared | Measured (4.5.11 / 5.1.2 / 5.2.1) | | --- | --- | --- | | Base triangles | 2100–2280 | 2184 / 2184 / 2184 | | LOD1 ratio | 0.32–0.62 of base | 0.5000 / 0.5000 / 0.5000 | | LOD2 ratio | 0.10–0.35 of base | 0.2198 / 0.2198 / 0.2198 | | Materials | exactly 2 distinct, ≥24 wood, ≥24 metal | 2 slots, 1008 wood, 48 metal | | UVs | in <code>0..1</code>, AABB overlap ≤ 1e-5 | in range, overlap 0 | | Outer AABB | (0.474, 0.361, 1.482) m ± 0.01 | (0.4740, 0.3612, 1.4823), zmin 0 | | Collider tris | ≤ 120 | 52 | | Export | written, size &gt; 0 | 158256 / 158256 / 158240 bytes |</p>
+<p>| Axis | Declared | Measured (4.5.11 / 5.1.2 / 5.2.1) | | --- | --- | --- | | Base triangles | 900–975 | 936 / 936 / 936 | | LOD1 ratio | 0.32–0.62 of base | 0.5000 / 0.5000 / 0.5000 | | LOD2 ratio | 0.10–0.35 of base | 0.2179 / 0.2179 / 0.2179 | | Materials | exactly 2 distinct, ≥280 wood, ≥180 metal | 2 slots, 324 wood, 216 metal | | UVs | in <code>0..1</code>, AABB overlap ≤ 1e-5 | in range, overlap 0 | | Outer AABB | (0.472, 0.365, 1.460) m ± 0.01 | (0.4720, 0.3649, 1.4597) | | Grounded | <code>abs(zmin)</code> ≤ 1e-4 | 0.0000 | | Mesh hygiene | non-manifold, loose v/e, doubles at 1e-5, zero-area, n-gons all 0 | all 0 | | Parts | exactly 12 shells (2 stiles, 6 rungs, 2 caps, 2 shoes) | 12 (2 / 6) | | Rung depth clearance | ≥ 0.003 m inside the stile faces | 0.00361 | | Tenon engagement | ≥ 0.006 m past the stile inner face | 0.01200 | | Tenon breakout margin | ≥ 0.005 m short of the stile outer face | 0.04600 | | Collider tris | ≤ 120 | 24 | | Export | written, size &gt; 0 | 75140 / 75140 / 75128 bytes |</p>
+<p>Base triangles fell from <strong>2184 to 936</strong> in the quality pass: four iron fittings per stile collapsed to one shoe and one top cap, and the redundant top block came out. No hidden-face removal was involved.</p>
+<p>The rung rims are capped and buried in the stile rather than left open. That costs 144 tris nobody sees, but an open rim is a non-manifold boundary and the hygiene budget forbids it.</p>
+<p>The joint budgets are measured per rung against each stile, from vertex positions in the un-raked construction frame, and the reported value is the worst case over all twelve rung ends. <code>clearance</code> is how far the widest dowel stays inside the stile&#x27;s front and back faces; it must exceed the 2.5 mm chamfer or the dowel erupts through it as a spike.</p>
 <p>DECIMATE COLLAPSE triangle counts are <strong>not</strong> identical across series — the gate is a ratio band, not an exact count. On this mesh the three binaries agreed on LOD ratios. Bake pixels are stochastic; the gate is <code>has_data</code> plus operator <code>FINISHED</code>, not byte-identity. Construction uses no RNG. Export byte counts differ by 16 B on 5.2.1 (glTF serializer), not a gated axis.</p>
-<p><code>--skip-decimate</code> skips the LOD DECIMATE stage so LOD1 ratio is 1.0 and exit 9 fires. That is the named budget the falsifier violates.</p>
+<p>Each falsifier violates exactly one named budget, and each was proven to fire on all three binaries:</p>
+<p>| Falsifier | Budget violated | Exit | Measured failure | | --- | --- | --- | --- | | <code>--skip-decimate</code> | LOD1 ratio band | 9 | ratio 1.0000 | | <code>--stray-vert</code> | Mesh hygiene, loose verts | 15 | <code>loose_v=1</code> | | <code>--lift-z</code> | Grounded zmin | 16 | zmin 0.050000 | | <code>--fat-rungs</code> | Rung depth clearance | 17 | clearance −0.00051 |</p>
+<p><code>--fat-rungs</code> widens the dowels to the full 34 mm stile depth, which is the proportion this piece shipped with before the quality pass.</p>
 <h2>Run</h2>
 <pre><code>blender --background --python wooden_ladder.py --
 blender --background --python wooden_ladder.py -- --skip-decimate
+blender --background --python wooden_ladder.py -- --stray-vert
+blender --background --python wooden_ladder.py -- --lift-z
+blender --background --python wooden_ladder.py -- --fat-rungs
 blender --background --python wooden_ladder.py -- --output ladder.png</code></pre>
-<p>Smoke does not pass <code>--output</code> or <code>--skip-decimate</code>.</p>
+<p>Smoke passes no flags: no <code>--output</code>, no falsifier.</p>
 <h2>Exit codes</h2>
 <p>File-local. <code>9</code> is a valid check code. <code>10</code> is reserved for <code>gallery_framing.check_framing</code> on the <code>--output</code> path.</p>
-<p>| Code | Meaning | | --- | --- | | 0 | Success | | 1 | Uncaught exception (FATAL wrapper) | | 2 | argparse / usage | | 3 | Mesh did not build / no UV layer | | 4 | Base triangle count outside range | | 5 | Material count ≠ 2 distinct slots, or wood/metal faces missing | | 6 | UVs outside 0..1 | | 7 | UV AABB overlap above tolerance | | 8 | World AABB off declared outer size | | 9 | LOD ratio band (<code>--skip-decimate</code> lands here) | | 10 | Framing gate (render path only) | | 11 | Collider triangle count above ceiling | | 12 | Bake did not finish or image has no data | | 13 | Export file missing or empty | | 14 | <code>--output</code> produced no file |</p>
+<p>| Code | Meaning | | --- | --- | | 0 | Success | | 1 | Uncaught exception (FATAL wrapper) | | 2 | argparse / usage | | 3 | Mesh did not build / no UV layer | | 4 | Base triangle count outside range | | 5 | Material count ≠ 2 distinct slots, or wood/metal faces missing | | 6 | UVs outside 0..1 | | 7 | UV AABB overlap above tolerance | | 8 | World AABB off declared outer size | | 9 | LOD ratio band (<code>--skip-decimate</code> lands here) | | 10 | Framing gate (render path only) | | 11 | Collider triangle count above ceiling | | 12 | Bake did not finish or image has no data | | 13 | Export file missing or empty | | 14 | <code>--output</code> produced no file | | 15 | Mesh hygiene (<code>--stray-vert</code> lands here) | | 16 | World AABB min Z off the floor (<code>--lift-z</code> lands here) | | 17 | Part count or rung-to-stile joint fit (<code>--fat-rungs</code> lands here) |</p>
     </section>
     <section class="detail-section src">
       <h2>Source</h2>
@@ -289,8 +297,12 @@ <h2>Source</h2>
 high-to-low normal bake, LOD chain, convex collider, Unity glTF export.
 
 Budgets are declared below and recomputed from the generated result.
-They are not API-contract witnesses. ``--skip-decimate`` skips the LOD
-DECIMATE stage so the LOD-ratio budget fails.
+They are not API-contract witnesses. Each falsifier violates exactly one
+named budget: ``--skip-decimate`` skips the LOD DECIMATE stage so the
+LOD-ratio budget fails, ``--lift-z`` moves the mesh off the floor so the
+grounded budget fails, ``--stray-vert`` adds one unconnected vertex so the
+mesh-hygiene budget fails, and ``--fat-rungs`` widens the dowels to the
+full stile depth so the rung-to-stile joint-fit budget fails.
 
 No RNG. Construction is closed-form. DECIMATE COLLAPSE triangle counts
 are not byte-identical across Blender versions — the LOD gate is a
@@ -298,6 +310,9 @@ <h2>Source</h2>
 
     blender --background --python wooden_ladder.py --
     blender --background --python wooden_ladder.py -- --skip-decimate
+    blender --background --python wooden_ladder.py -- --lift-z
+    blender --background --python wooden_ladder.py -- --stray-vert
+    blender --background --python wooden_ladder.py -- --fat-rungs
     blender --background --python wooden_ladder.py -- --output ladder.png
 &quot;&quot;&quot;</span>
 <span class="k">import</span> argparse
@@ -326,15 +341,37 @@ <h2>Source</h2>
 STILE_D = <span class="n">0.034</span>
 SPAN = <span class="n">0.34</span>
 N_RUNGS = <span class="n">6</span>
-RUNG_R = <span class="n">0.017</span>
-RUNG_SEGS = <span class="n">10</span>
+<span class="c"># A 26 mm dowel in a 34 mm stile. Sized so the widest rung still clears the</span>
+<span class="c"># stile&#x27;s 2.5 mm chamfer by more than a millimetre; at 17 mm the dowel was as</span>
+<span class="c"># deep as the stile and broke through the front and back chamfers as a spike.</span>
+RUNG_R = <span class="n">0.013</span>
+RUNG_SEGS = <span class="n">12</span>
+RUNG_TENON = <span class="n">0.012</span>
+RUNG_RADIUS_SCALE = (<span class="n">0.98</span>, <span class="n">1.02</span>, <span class="n">0.99</span>, <span class="n">1.03</span>, <span class="n">0.97</span>, <span class="n">1.01</span>)
+RUNG_Z_OFFSETS = (<span class="n">0.0</span>, <span class="n">0.0015</span>, -<span class="n">0.0010</span>, <span class="n">0.0010</span>, -<span class="n">0.0015</span>, <span class="n">0.0</span>)
+TOP_CAP_H = <span class="n">0.025</span>
+SHOE_H = <span class="n">0.065</span>
+SHOE_W = <span class="n">0.074</span>
+SHOE_D = <span class="n">0.070</span>
 RAKE = math.radians(<span class="n">12.0</span>)
 BBOX_TOL = <span class="n">0.01</span>
+<span class="c"># 2 stiles + 6 rungs + 2 top caps + 2 shoes, each a closed shell.</span>
+PART_COUNT = <span class="n">12</span>
+<span class="c"># Measured joint contract. Clearance exceeds the 2.5 mm chamfer so the dowel</span>
+<span class="c"># stays on the stile&#x27;s flat face; engagement keeps the tenon seated; breakout</span>
+<span class="c"># keeps it from reaching the outer face.</span>
+RUNG_DEPTH_CLEARANCE = <span class="n">0.003</span>
+TENON_ENGAGE_MIN = <span class="n">0.006</span>
+TENON_BREAKOUT_MIN = <span class="n">0.005</span>
+ZMIN_EPS = <span class="n">1e-4</span>
+DOUBLES_EPS = <span class="n">1e-5</span>
+AREA_EPS = <span class="n">1e-10</span>
+LIFT_Z = <span class="n">0.05</span>
 <span class="c"># Fitted after locking geometry. Recomputed from bound_box.</span>
-OUTER_SIZE = (<span class="n">0.474</span>, <span class="n">0.361</span>, <span class="n">1.482</span>)
+OUTER_SIZE = (<span class="n">0.472</span>, <span class="n">0.365</span>, <span class="n">1.460</span>)
 
-BASE_TRIS_MIN = <span class="n">2100</span>
-BASE_TRIS_MAX = <span class="n">2280</span>
+BASE_TRIS_MIN = <span class="n">900</span>
+BASE_TRIS_MAX = <span class="n">975</span>
 LOD1_RATIO_MIN = <span class="n">0.32</span>
 LOD1_RATIO_MAX = <span class="n">0.62</span>
 LOD2_RATIO_MIN = <span class="n">0.10</span>
@@ -347,8 +384,11 @@ <h2>Source</h2>
 COLLIDER_TRIS_MAX = <span class="n">120</span>
 BAKE_RES = <span class="n">256</span>
 CAGE_EXTRUSION = <span class="n">0.06</span>
-METAL_FACES_MIN = <span class="n">24</span>
-WOOD_FACES_MIN = <span class="n">24</span>
+<span class="c"># The caps and shoes carry far more chamfer than body faces, so a floor above</span>
+<span class="c"># their 24 unbevelled box faces is what catches a bevel whose new faces fell</span>
+<span class="c"># back to the wood slot.</span>
+METAL_FACES_MIN = <span class="n">180</span>
+WOOD_FACES_MIN = <span class="n">280</span>
 
 WOOD_IDX = <span class="n">0</span>
 METAL_IDX = <span class="n">1</span>
@@ -398,7 +438,7 @@ <h2>Source</h2>
     geo = bmesh.ops.create_cone(
         bm,
         cap_ends=<span class="k">True</span>,
-        cap_tris=<span class="k">False</span>,
+        cap_tris=<span class="k">True</span>,
         segments=segments,
         radius1=radius1,
         radius2=radius2,
@@ -462,14 +502,15 @@ <h2>Source</h2>
             )
 
 
-<span class="k">def</span> build_ladder_mesh(name, bevel_offset, bevel_segments):
+<span class="k">def</span> build_ladder_mesh(name, bevel_offset, bevel_segments, rung_radius=RUNG_R):
     bm = bmesh.new()
-    wood_verts = []
+    stile_verts = []
     metal_faces = set()
+    metal_verts = []
     <span class="k">try</span>:
         half = SPAN / <span class="n">2.0</span> + STILE_W / <span class="n">2.0</span>
         <span class="k">for</span> sign <span class="k">in</span> (-<span class="n">1.0</span>, <span class="n">1.0</span>):
-            wood_verts.extend(
+            stile_verts.extend(
                 add_box(
                     bm,
                     (sign * half, <span class="n">0.0</span>, STILE_H / <span class="n">2.0</span>),
@@ -477,34 +518,34 @@ <h2>Source</h2>
                     WOOD_IDX,
                 )
             )
-            wood_verts.extend(
-                add_box(
-                    bm,
-                    (sign * half, <span class="n">0.0</span>, STILE_H + <span class="n">0.012</span>),
-                    (STILE_W + <span class="n">0.008</span>, STILE_D + <span class="n">0.008</span>, <span class="n">0.028</span>),
-                    WOOD_IDX,
-                )
-            )
 
         z0 = <span class="n">0.16</span>
         z1 = STILE_H - <span class="n">0.14</span>
         <span class="k">for</span> i <span class="k">in</span> range(N_RUNGS):
             t = i / (N_RUNGS - <span class="n">1</span>)
-            z = z0 + t * (z1 - z0)
-            wood_verts.extend(
-                add_cylinder(
-                    bm,
-                    (<span class="n">0.0</span>, <span class="n">0.0</span>, z),
-                    RUNG_R,
-                    SPAN + STILE_W * <span class="n">0.55</span>,
-                    RUNG_SEGS,
-                    WOOD_IDX,
-                    euler=(<span class="n">0.0</span>, math.pi / <span class="n">2.0</span>, <span class="n">0.0</span>),
-                )
+            z = z0 + t * (z1 - z0) + RUNG_Z_OFFSETS[i]
+            <span class="c"># Tenons stop inside the stile, so the rung rims never reach the</span>
+            <span class="c"># chamfered outer face. Rungs stay unbeveled: they are already</span>
+            <span class="c"># round, and beveling a cap rim spikes through that chamfer.</span>
+            add_cylinder(
+                bm,
+                (<span class="n">0.0</span>, <span class="n">0.0</span>, z),
+                rung_radius * RUNG_RADIUS_SCALE[i],
+                SPAN + <span class="n">2.0</span> * RUNG_TENON,
+                RUNG_SEGS,
+                WOOD_IDX,
+                euler=(<span class="n">0.0</span>, math.pi / <span class="n">2.0</span>, <span class="n">0.0</span>),
             )
 
         <span class="k">if</span> bevel_offset &gt; <span class="n">0.0</span>:
-            edges = list({e <span class="k">for</span> v <span class="k">in</span> wood_verts <span class="k">for</span> e <span class="k">in</span> v.link_edges <span class="k">if</span> v.is_valid})
+            edges = list(
+                {
+                    edge
+                    <span class="k">for</span> vertex <span class="k">in</span> stile_verts
+                    <span class="k">for</span> edge <span class="k">in</span> vertex.link_edges
+                    <span class="k">if</span> vertex.is_valid
+                }
+            )
             <span class="k">if</span> edges:
                 bmesh.ops.bevel(
                     bm,
@@ -519,24 +560,13 @@ <h2>Source</h2>
         before = set(bm.faces)
         <span class="k">for</span> sign <span class="k">in</span> (-<span class="n">1.0</span>, <span class="n">1.0</span>):
             hx = sign * half
-            add_box(bm, (hx, <span class="n">0.0</span>, <span class="n">0.028</span>), (STILE_W + <span class="n">0.018</span>, STILE_D + <span class="n">0.018</span>, <span class="n">0.056</span>), METAL_IDX)
-            add_box(
-                bm,
-                (hx, STILE_D / <span class="n">2.0</span> + <span class="n">0.010</span>, <span class="n">0.070</span>),
-                (STILE_W * <span class="n">0.70</span>, <span class="n">0.014</span>, <span class="n">0.090</span>),
-                METAL_IDX,
-            )
-            add_box(
-                bm,
-                (hx, -(STILE_D / <span class="n">2.0</span> + <span class="n">0.010</span>), <span class="n">0.070</span>),
-                (STILE_W * <span class="n">0.70</span>, <span class="n">0.014</span>, <span class="n">0.090</span>),
-                METAL_IDX,
-            )
-            add_box(
-                bm,
-                (hx, <span class="n">0.0</span>, STILE_H - <span class="n">0.055</span>),
-                (STILE_W + <span class="n">0.016</span>, STILE_D + <span class="n">0.016</span>, <span class="n">0.028</span>),
-                METAL_IDX,
+            metal_verts.extend(
+                add_box(
+                    bm,
+                    (hx, <span class="n">0.0</span>, STILE_H - TOP_CAP_H * <span class="n">0.30</span>),
+                    (STILE_W + <span class="n">0.010</span>, STILE_D + <span class="n">0.010</span>, TOP_CAP_H),
+                    METAL_IDX,
+                )
             )
         metal_faces.update(set(bm.faces) - before)
 
@@ -553,8 +583,52 @@ <h2>Source</h2>
             v.co.x -= cx
             v.co.y -= cy
             v.co.z -= zmin
-            <span class="k">if</span> v.co.z &lt; <span class="n">0.0</span>:
-                v.co.z = <span class="n">0.0</span>
+
+        before = set(bm.faces)
+        <span class="k">for</span> sign <span class="k">in</span> (-<span class="n">1.0</span>, <span class="n">1.0</span>):
+            bottom = rake @ Vector((sign * half, <span class="n">0.0</span>, <span class="n">0.0</span>))
+            bottom.x -= cx
+            bottom.y -= cy
+            bottom.z -= zmin
+            metal_verts.extend(
+                add_box(
+                    bm,
+                    (bottom.x, bottom.y, SHOE_H / <span class="n">2.0</span>),
+                    (SHOE_W, SHOE_D, SHOE_H),
+                    METAL_IDX,
+                )
+            )
+        metal_faces.update(set(bm.faces) - before)
+
+        <span class="k">if</span> bevel_offset &gt; <span class="n">0.0</span>:
+            metal_edges = list(
+                {
+                    edge
+                    <span class="k">for</span> vertex <span class="k">in</span> metal_verts
+                    <span class="k">for</span> edge <span class="k">in</span> vertex.link_edges
+                    <span class="k">if</span> vertex.is_valid
+                }
+            )
+            <span class="k">if</span> metal_edges:
+                <span class="c"># Bevel does not inherit material_index onto the faces it</span>
+                <span class="c"># creates, so claim them from the op&#x27;s own return rather than</span>
+                <span class="c"># from a pre-bevel face snapshot. Without this every chamfer</span>
+                <span class="c"># on a cap or shoe falls back to slot 0 and renders as wood.</span>
+                bevelled = bmesh.ops.bevel(
+                    bm,
+                    geom=metal_edges,
+                    offset=min(bevel_offset, <span class="n">0.002</span>),
+                    segments=bevel_segments,
+                    profile=<span class="n">0.5</span>,
+                    affect=<span class="s">&quot;EDGES&quot;</span>,
+                    clamp_overlap=<span class="k">True</span>,
+                )
+                metal_faces.update(bevelled.get(<span class="s">&quot;faces&quot;</span>) <span class="k">or</span> [])
+
+        ys = [v.co.y <span class="k">for</span> v <span class="k">in</span> bm.verts]
+        final_cy = <span class="n">0.5</span> * (min(ys) + max(ys))
+        <span class="k">for</span> v <span class="k">in</span> bm.verts:
+            v.co.y -= final_cy
 
         pack_uvs(bm)
         bmesh.ops.recalc_face_normals(bm, faces=list(bm.faces))
@@ -606,6 +680,146 @@ <h2>Source</h2>
     <span class="k">return</span> (min(xs), min(ys), min(zs), max(xs), max(ys), max(zs))
 
 
+<span class="k">def</span> face_area(me, poly):
+    vs = [me.vertices[i].co <span class="k">for</span> i <span class="k">in</span> poly.vertices]
+    <span class="k">if</span> len(vs) &lt; <span class="n">3</span>:
+        <span class="k">return</span> <span class="n">0.0</span>
+    v0 = vs[<span class="n">0</span>]
+    area = <span class="n">0.0</span>
+    <span class="k">for</span> i <span class="k">in</span> range(<span class="n">1</span>, len(vs) - <span class="n">1</span>):
+        area += (vs[i] - v0).cross(vs[i + <span class="n">1</span>] - v0).length * <span class="n">0.5</span>
+    <span class="k">return</span> area
+
+
+<span class="k">def</span> hygiene_audit(me):
+    <span class="c"># Combinatorics match examples/mesh-hygiene-audit.audit (copied, not imported).</span>
+    nv, ne, nf = len(me.vertices), len(me.edges), len(me.polygons)
+    ngons = sum(<span class="n">1</span> <span class="k">for</span> p <span class="k">in</span> me.polygons <span class="k">if</span> len(p.vertices) &gt; <span class="n">4</span>)
+    areas = [face_area(me, p) <span class="k">for</span> p <span class="k">in</span> me.polygons]
+    zero_area = sum(<span class="n">1</span> <span class="k">for</span> area <span class="k">in</span> areas <span class="k">if</span> area &lt;= AREA_EPS)
+    bm = bmesh.new()
+    <span class="k">try</span>:
+        bm.from_mesh(me)
+        bm.verts.ensure_lookup_table()
+        bm.edges.ensure_lookup_table()
+        loose_v = sum(<span class="n">1</span> <span class="k">for</span> v <span class="k">in</span> bm.verts <span class="k">if</span> len(v.link_edges) == <span class="n">0</span>)
+        loose_e = sum(<span class="n">1</span> <span class="k">for</span> e <span class="k">in</span> bm.edges <span class="k">if</span> len(e.link_faces) == <span class="n">0</span>)
+        nonman = sum(<span class="n">1</span> <span class="k">for</span> e <span class="k">in</span> bm.edges <span class="k">if</span> <span class="k">not</span> e.is_manifold)
+        ret = bmesh.ops.find_doubles(bm, verts=list(bm.verts), dist=DOUBLES_EPS)
+        doubles = len(ret.get(<span class="s">&quot;targetmap&quot;</span>) <span class="k">or</span> {})
+    <span class="k">finally</span>:
+        bm.free()
+    <span class="k">return</span> {
+        <span class="s">&quot;nv&quot;</span>: nv,
+        <span class="s">&quot;ne&quot;</span>: ne,
+        <span class="s">&quot;nf&quot;</span>: nf,
+        <span class="s">&quot;ngons&quot;</span>: ngons,
+        <span class="s">&quot;loose_v&quot;</span>: loose_v,
+        <span class="s">&quot;loose_e&quot;</span>: loose_e,
+        <span class="s">&quot;nonman&quot;</span>: nonman,
+        <span class="s">&quot;zero_area&quot;</span>: zero_area,
+        <span class="s">&quot;doubles&quot;</span>: doubles,
+        <span class="s">&quot;euler&quot;</span>: nv - ne + nf,
+    }
+
+
+<span class="k">def</span> mesh_components(me):
+    <span class="s">&quot;&quot;&quot;Per-part AABBs in the construction frame, un-raked so the stiles read
+    axis-aligned. The parts interpenetrate but share no vertices, so edge
+    connectivity separates them.&quot;&quot;&quot;</span>
+    neighbors = [[] <span class="k">for</span> _ <span class="k">in</span> range(len(me.vertices))]
+    <span class="k">for</span> edge <span class="k">in</span> me.edges:
+        a, b = edge.vertices
+        neighbors[a].append(b)
+        neighbors[b].append(a)
+    unrake = Euler((-RAKE, <span class="n">0.0</span>, <span class="n">0.0</span>)).to_matrix()
+    seen = [<span class="k">False</span>] * len(me.vertices)
+    parts = []
+    <span class="k">for</span> start <span class="k">in</span> range(len(me.vertices)):
+        <span class="k">if</span> seen[start]:
+            <span class="k">continue</span>
+        seen[start] = <span class="k">True</span>
+        stack = [start]
+        points = []
+        <span class="k">while</span> stack:
+            current = stack.pop()
+            points.append(unrake @ me.vertices[current].co)
+            <span class="k">for</span> nxt <span class="k">in</span> neighbors[current]:
+                <span class="k">if</span> <span class="k">not</span> seen[nxt]:
+                    seen[nxt] = <span class="k">True</span>
+                    stack.append(nxt)
+        lo = Vector(
+            (
+                min(p.x <span class="k">for</span> p <span class="k">in</span> points),
+                min(p.y <span class="k">for</span> p <span class="k">in</span> points),
+                min(p.z <span class="k">for</span> p <span class="k">in</span> points),
+            )
+        )
+        hi = Vector(
+            (
+                max(p.x <span class="k">for</span> p <span class="k">in</span> points),
+                max(p.y <span class="k">for</span> p <span class="k">in</span> points),
+                max(p.z <span class="k">for</span> p <span class="k">in</span> points),
+            )
+        )
+        parts.append((lo, hi))
+    <span class="k">return</span> parts
+
+
+<span class="k">def</span> joint_audit(me):
+    <span class="s">&quot;&quot;&quot;Worst-case rung-to-stile fit, recomputed from vertex positions.&quot;&quot;&quot;</span>
+    parts = mesh_components(me)
+    stiles = [p <span class="k">for</span> p <span class="k">in</span> parts <span class="k">if</span> (p[<span class="n">1</span>].z - p[<span class="n">0</span>].z) &gt; STILE_H * <span class="n">0.8</span>]
+    rungs = [p <span class="k">for</span> p <span class="k">in</span> parts <span class="k">if</span> (p[<span class="n">1</span>].x - p[<span class="n">0</span>].x) &gt; SPAN]
+    <span class="k">if</span> len(stiles) != <span class="n">2</span> <span class="k">or</span> len(rungs) != N_RUNGS:
+        <span class="k">return</span> {
+            <span class="s">&quot;parts&quot;</span>: len(parts),
+            <span class="s">&quot;stiles&quot;</span>: len(stiles),
+            <span class="s">&quot;rungs&quot;</span>: len(rungs),
+            <span class="s">&quot;clearance&quot;</span>: -<span class="n">1.0</span>,
+            <span class="s">&quot;engage&quot;</span>: -<span class="n">1.0</span>,
+            <span class="s">&quot;breakout&quot;</span>: -<span class="n">1.0</span>,
+        }
+    left = min(stiles, key=<span class="k">lambda</span> p: p[<span class="n">0</span>].x)
+    right = max(stiles, key=<span class="k">lambda</span> p: p[<span class="n">0</span>].x)
+    clearance = min(
+        min(
+            (stile[<span class="n">1</span>].y - stile[<span class="n">0</span>].y) - (rung[<span class="n">1</span>].y - rung[<span class="n">0</span>].y)
+            <span class="k">for</span> stile <span class="k">in</span> (left, right)
+        )
+        * <span class="n">0.5</span>
+        <span class="k">for</span> rung <span class="k">in</span> rungs
+    )
+    engage = min(
+        min(left[<span class="n">1</span>].x - rung[<span class="n">0</span>].x, rung[<span class="n">1</span>].x - right[<span class="n">0</span>].x) <span class="k">for</span> rung <span class="k">in</span> rungs
+    )
+    breakout = min(
+        min(rung[<span class="n">0</span>].x - left[<span class="n">0</span>].x, right[<span class="n">1</span>].x - rung[<span class="n">1</span>].x) <span class="k">for</span> rung <span class="k">in</span> rungs
+    )
+    <span class="k">return</span> {
+        <span class="s">&quot;parts&quot;</span>: len(parts),
+        <span class="s">&quot;stiles&quot;</span>: len(stiles),
+        <span class="s">&quot;rungs&quot;</span>: len(rungs),
+        <span class="s">&quot;clearance&quot;</span>: clearance,
+        <span class="s">&quot;engage&quot;</span>: engage,
+        <span class="s">&quot;breakout&quot;</span>: breakout,
+    }
+
+
+<span class="k">def</span> add_stray_vert(me):
+    <span class="c"># Falsification only: one unconnected vertex, placed inside the existing</span>
+    <span class="c"># bounds so the bbox budget still passes and the hygiene budget is the</span>
+    <span class="c"># gate that fires.</span>
+    bm = bmesh.new()
+    <span class="k">try</span>:
+        bm.from_mesh(me)
+        bm.verts.new((<span class="n">0.0</span>, <span class="n">0.0</span>, STILE_H / <span class="n">3.0</span>))
+        bm.to_mesh(me)
+        me.update()
+    <span class="k">finally</span>:
+        bm.free()
+
+
 <span class="k">def</span> uv_stats(mesh):
     uv = mesh.uv_layers.active
     <span class="k">if</span> uv <span class="k">is</span> <span class="k">None</span>:
@@ -723,10 +937,24 @@ <h2>Source</h2>
     )
 
 
-<span class="k">def</span> check(skip_decimate):
+<span class="k">def</span> check(skip_decimate, lift_z=<span class="k">False</span>, stray_vert=<span class="k">False</span>, fat_rungs=<span class="k">False</span>):
     bpy.ops.wm.read_factory_settings(use_empty=<span class="k">True</span>)
-    low = build_ladder_mesh(<span class="s">&quot;LadderLow&quot;</span>, bevel_offset=<span class="n">0.0025</span>, bevel_segments=<span class="n">2</span>)
-    high = build_ladder_mesh(<span class="s">&quot;LadderHigh&quot;</span>, bevel_offset=<span class="n">0.0025</span>, bevel_segments=<span class="n">4</span>)
+    <span class="c"># Falsification: a dowel as deep as the stile, which is what used to break</span>
+    <span class="c"># through the front and back chamfers.</span>
+    rung_radius = STILE_D / <span class="n">2.0</span> <span class="k">if</span> fat_rungs <span class="k">else</span> RUNG_R
+    low = build_ladder_mesh(
+        <span class="s">&quot;LadderLow&quot;</span>, bevel_offset=<span class="n">0.0025</span>, bevel_segments=<span class="n">2</span>, rung_radius=rung_radius
+    )
+    high = build_ladder_mesh(
+        <span class="s">&quot;LadderHigh&quot;</span>, bevel_offset=<span class="n">0.0025</span>, bevel_segments=<span class="n">4</span>, rung_radius=rung_radius
+    )
+    <span class="k">if</span> lift_z:
+        low.location.z += LIFT_Z
+    <span class="k">if</span> stray_vert:
+        add_stray_vert(low.data)
+    <span class="c"># world_bbox reads matrix_world, which is evaluated data. Without this the</span>
+    <span class="c"># cached matrix hides a moved object and the grounded budget cannot fail.</span>
+    bpy.context.view_layer.update()
     wood = principled(<span class="s">&quot;LadderWood&quot;</span>, (<span class="n">0.42</span>, <span class="n">0.24</span>, <span class="n">0.10</span>, <span class="n">1.0</span>), <span class="n">0.0</span>, <span class="n">0.55</span>)
     metal = principled(<span class="s">&quot;LadderMetal&quot;</span>, (<span class="n">0.48</span>, <span class="n">0.46</span>, <span class="n">0.42</span>, <span class="n">1.0</span>), <span class="n">1.0</span>, <span class="n">0.28</span>)
     assign_slots(low, wood, metal)
@@ -795,6 +1023,18 @@ <h2>Source</h2>
         <span class="s">f&quot;</span><span class="s">measured collider_tris=</span>{col_tris}<span class="s"> bake=</span>{bake_result}<span class="s"> </span><span class="s">&quot;</span>
         <span class="s">f&quot;</span><span class="s">bake_has_data=</span>{img.has_data}<span class="s"> export_bytes=</span>{export_size}<span class="s">&quot;</span>
     )
+    hyg = hygiene_audit(low.data)
+    print(
+        <span class="s">f&quot;</span><span class="s">measured hygiene loose_v=</span>{hyg[<span class="s">&#x27;loose_v&#x27;</span>]}<span class="s"> loose_e=</span>{hyg[<span class="s">&#x27;loose_e&#x27;</span>]}<span class="s"> </span><span class="s">&quot;</span>
+        <span class="s">f&quot;</span><span class="s">nonman=</span>{hyg[<span class="s">&#x27;nonman&#x27;</span>]}<span class="s"> zero_area=</span>{hyg[<span class="s">&#x27;zero_area&#x27;</span>]}<span class="s"> </span><span class="s">&quot;</span>
+        <span class="s">f&quot;</span><span class="s">doubles=</span>{hyg[<span class="s">&#x27;doubles&#x27;</span>]}<span class="s"> ngons=</span>{hyg[<span class="s">&#x27;ngons&#x27;</span>]}<span class="s"> euler=</span>{hyg[<span class="s">&#x27;euler&#x27;</span>]}<span class="s">&quot;</span>
+    )
+    joint = joint_audit(low.data)
+    print(
+        <span class="s">f&quot;</span><span class="s">measured joints parts=</span>{joint[<span class="s">&#x27;parts&#x27;</span>]}<span class="s"> stiles=</span>{joint[<span class="s">&#x27;stiles&#x27;</span>]}<span class="s"> </span><span class="s">&quot;</span>
+        <span class="s">f&quot;</span><span class="s">rungs=</span>{joint[<span class="s">&#x27;rungs&#x27;</span>]}<span class="s"> clearance=</span>{joint[<span class="s">&#x27;clearance&#x27;</span>]:<span class="s">.5f</span>}<span class="s"> </span><span class="s">&quot;</span>
+        <span class="s">f&quot;</span><span class="s">engage=</span>{joint[<span class="s">&#x27;engage&#x27;</span>]:<span class="s">.5f</span>}<span class="s"> breakout=</span>{joint[<span class="s">&#x27;breakout&#x27;</span>]:<span class="s">.5f</span>}<span class="s">&quot;</span>
+    )
 
     <span class="k">if</span> <span class="k">not</span> (BASE_TRIS_MIN &lt;= base_tris &lt;= BASE_TRIS_MAX):
         <span class="k">return</span> fail(
@@ -859,6 +1099,49 @@ <h2>Source</h2>
         ), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
     <span class="k">if</span> export_size &lt;= <span class="n">0</span>:
         <span class="k">return</span> fail(<span class="s">&quot;export file missing or empty&quot;</span>, <span class="n">13</span>), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
+    <span class="k">if</span> (
+        hyg[<span class="s">&quot;loose_v&quot;</span>]
+        <span class="k">or</span> hyg[<span class="s">&quot;loose_e&quot;</span>]
+        <span class="k">or</span> hyg[<span class="s">&quot;nonman&quot;</span>]
+        <span class="k">or</span> hyg[<span class="s">&quot;zero_area&quot;</span>]
+        <span class="k">or</span> hyg[<span class="s">&quot;doubles&quot;</span>]
+        <span class="k">or</span> hyg[<span class="s">&quot;ngons&quot;</span>]
+    ):
+        <span class="k">return</span> fail(
+            <span class="s">f&quot;</span><span class="s">hygiene loose_v=</span>{hyg[<span class="s">&#x27;loose_v&#x27;</span>]}<span class="s"> loose_e=</span>{hyg[<span class="s">&#x27;loose_e&#x27;</span>]}<span class="s"> </span><span class="s">&quot;</span>
+            <span class="s">f&quot;</span><span class="s">nonman=</span>{hyg[<span class="s">&#x27;nonman&#x27;</span>]}<span class="s"> zero_area=</span>{hyg[<span class="s">&#x27;zero_area&#x27;</span>]}<span class="s"> </span><span class="s">&quot;</span>
+            <span class="s">f&quot;</span><span class="s">doubles=</span>{hyg[<span class="s">&#x27;doubles&#x27;</span>]}<span class="s"> ngons=</span>{hyg[<span class="s">&#x27;ngons&#x27;</span>]}<span class="s">&quot;</span>,
+            <span class="n">15</span>,
+        ), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
+    <span class="k">if</span> abs(bb[<span class="n">2</span>]) &gt; ZMIN_EPS:
+        <span class="k">return</span> fail(
+            <span class="s">f&quot;</span><span class="s">zmin </span>{bb[<span class="n">2</span>]:<span class="s">.6f</span>}<span class="s"> not within </span>{ZMIN_EPS}<span class="s"> of 0 </span><span class="s">&quot;</span>
+            <span class="s">&quot;(--lift-z is the designed fail)&quot;</span>,
+            <span class="n">16</span>,
+        ), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
+    <span class="k">if</span> joint[<span class="s">&quot;parts&quot;</span>] != PART_COUNT:
+        <span class="k">return</span> fail(
+            <span class="s">f&quot;</span><span class="s">part count </span>{joint[<span class="s">&#x27;parts&#x27;</span>]}<span class="s"> != </span>{PART_COUNT}<span class="s"> </span><span class="s">&quot;</span>
+            <span class="s">f&quot;</span><span class="s">(stiles=</span>{joint[<span class="s">&#x27;stiles&#x27;</span>]}<span class="s"> rungs=</span>{joint[<span class="s">&#x27;rungs&#x27;</span>]}<span class="s">)</span><span class="s">&quot;</span>,
+            <span class="n">17</span>,
+        ), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
+    <span class="k">if</span> joint[<span class="s">&quot;clearance&quot;</span>] &lt; RUNG_DEPTH_CLEARANCE:
+        <span class="k">return</span> fail(
+            <span class="s">f&quot;</span><span class="s">rung-to-stile depth clearance </span>{joint[<span class="s">&#x27;clearance&#x27;</span>]:<span class="s">.5f</span>}<span class="s"> &lt; </span><span class="s">&quot;</span>
+            <span class="s">f&quot;</span>{RUNG_DEPTH_CLEARANCE}<span class="s"> (--fat-rungs is the designed fail)</span><span class="s">&quot;</span>,
+            <span class="n">17</span>,
+        ), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
+    <span class="k">if</span> joint[<span class="s">&quot;engage&quot;</span>] &lt; TENON_ENGAGE_MIN:
+        <span class="k">return</span> fail(
+            <span class="s">f&quot;</span><span class="s">tenon engagement </span>{joint[<span class="s">&#x27;engage&#x27;</span>]:<span class="s">.5f</span>}<span class="s"> &lt; </span>{TENON_ENGAGE_MIN}<span class="s">&quot;</span>,
+            <span class="n">17</span>,
+        ), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
+    <span class="k">if</span> joint[<span class="s">&quot;breakout&quot;</span>] &lt; TENON_BREAKOUT_MIN:
+        <span class="k">return</span> fail(
+            <span class="s">f&quot;</span><span class="s">tenon breakout margin </span>{joint[<span class="s">&#x27;breakout&#x27;</span>]:<span class="s">.5f</span>}<span class="s"> &lt; </span><span class="s">&quot;</span>
+            <span class="s">f&quot;</span>{TENON_BREAKOUT_MIN}<span class="s">&quot;</span>,
+            <span class="n">17</span>,
+        ), <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>, <span class="k">None</span>
     <span class="k">return</span> <span class="n">0</span>, low, high, wood, tex, collider
 
 
@@ -884,7 +1167,9 @@ <h2>Source</h2>
     floor_me = bpy.data.meshes.new(<span class="s">&quot;Floor&quot;</span>)
     bm = bmesh.new()
     <span class="k">try</span>:
-        bmesh.ops.create_grid(bm, x_segments=<span class="n">1</span>, y_segments=<span class="n">1</span>, size=<span class="n">14.0</span>)
+        <span class="c"># Oversized so no edge of the set can enter frame; the committed hero</span>
+        <span class="c"># used to show the wall&#x27;s left edge as a bright band in the corner.</span>
+        bmesh.ops.create_grid(bm, x_segments=<span class="n">1</span>, y_segments=<span class="n">1</span>, size=<span class="n">60.0</span>)
         bm.to_mesh(floor_me)
     <span class="k">finally</span>:
         bm.free()
@@ -976,9 +1261,29 @@ <h2>Source</h2>
         action=<span class="s">&quot;store_true&quot;</span>,
         help=<span class="s">&quot;falsification: skip the LOD DECIMATE stage&quot;</span>,
     )
+    p.add_argument(
+        <span class="s">&quot;--lift-z&quot;</span>,
+        action=<span class="s">&quot;store_true&quot;</span>,
+        help=<span class="s">&quot;falsification: lift the mesh so zmin fails the grounded budget&quot;</span>,
+    )
+    p.add_argument(
+        <span class="s">&quot;--stray-vert&quot;</span>,
+        action=<span class="s">&quot;store_true&quot;</span>,
+        help=<span class="s">&quot;falsification: add a loose vertex so the hygiene budget fails&quot;</span>,
+    )
+    p.add_argument(
+        <span class="s">&quot;--fat-rungs&quot;</span>,
+        action=<span class="s">&quot;store_true&quot;</span>,
+        help=<span class="s">&quot;falsification: dowels as deep as the stile, failing joint fit&quot;</span>,
+    )
     args = p.parse_args(argv)
 
-    code, low, _high, wood, tex, _col = check(args.skip_decimate)
+    code, low, _high, wood, tex, _col = check(
+        args.skip_decimate,
+        lift_z=args.lift_z,
+        stray_vert=args.stray_vert,
+        fat_rungs=args.fat_rungs,
+    )
     <span class="k">if</span> code:
         <span class="k">return</span> code
     <span class="k">if</span> args.output:
diff --git a/showcase/gallery.json b/showcase/gallery.json
index ef09b9c..5cda79b 100644
--- a/showcase/gallery.json
+++ b/showcase/gallery.json
@@ -296,8 +296,8 @@
     {
       "name": "wooden-ladder",
       "dir": "showcase/wooden-ladder",
-      "teaches": "A procedural timber ladder with raked stiles, six rungs, and iron shoes through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract.",
-      "witnessesFix": "Recomputed: 2184 tris, two materials with 1008 wood and 48 metal faces, UVs in 0..1 with zero AABB overlap, outer AABB 0.474×0.361×1.482 m, LOD ratios in band, convex collider 52 tris, non-empty glTF. --skip-decimate exits 9 on the LOD1 ratio budget.",
+      "teaches": "A procedural timber ladder with raked stiles, six dowel rungs tenoned into the stiles, and iron shoes and top caps through UVs, bake, LOD, collider, and Unity glTF, asserting recomputed budgets rather than an API contract.",
+      "witnessesFix": "Recomputed: 936 tris, two materials with 324 wood and 216 metal faces, UVs in 0..1 with zero AABB overlap, outer AABB 0.472×0.365×1.460 m, grounded at zmin 0, mesh hygiene all zero, 12 shells with every rung clearing the stile chamfer by 3.61 mm, convex collider 24 tris, non-empty glTF. Four falsifiers exit 9, 15, 16, and 17 on the LOD, hygiene, grounded, and joint-fit budgets.",
       "hero": "docs/gallery/assets/wooden-ladder-hero.webp",
       "preview": "showcase/wooden-ladder/preview.webp",
       "tags": [
diff --git a/showcase/wooden-ladder/README.md b/showcase/wooden-ladder/README.md
index 3eaa4f0..ae0f4be 100644
--- a/showcase/wooden-ladder/README.md
+++ b/showcase/wooden-ladder/README.md
@@ -1,9 +1,9 @@
 # Wooden ladder
 
 A showcase piece, not an example. Procedural timber ladder (raked
-stiles, six rungs, iron shoes and straps) then the shipped pipeline:
-unique-cell UVs, Cycles high-to-low normal bake, LOD chain, convex
-collider, Unity glTF export.
+stiles, six 26 mm dowel rungs tenoned into the stiles, iron shoes and
+top caps) then the shipped pipeline: unique-cell UVs, Cycles
+high-to-low normal bake, LOD chain, convex collider, Unity glTF export.
 
 It asserts **budget conformance** of the generated result. It does not
 witness an API contract. "It rendered without error" is not a check.
@@ -21,14 +21,34 @@ materials, UVs, evaluated LOD, collider, or export file.
 
 | Axis | Declared | Measured (4.5.11 / 5.1.2 / 5.2.1) |
 | --- | --- | --- |
-| Base triangles | 2100–2280 | 2184 / 2184 / 2184 |
+| Base triangles | 900–975 | 936 / 936 / 936 |
 | LOD1 ratio | 0.32–0.62 of base | 0.5000 / 0.5000 / 0.5000 |
-| LOD2 ratio | 0.10–0.35 of base | 0.2198 / 0.2198 / 0.2198 |
-| Materials | exactly 2 distinct, ≥24 wood, ≥24 metal | 2 slots, 1008 wood, 48 metal |
+| LOD2 ratio | 0.10–0.35 of base | 0.2179 / 0.2179 / 0.2179 |
+| Materials | exactly 2 distinct, ≥280 wood, ≥180 metal | 2 slots, 324 wood, 216 metal |
 | UVs | in `0..1`, AABB overlap ≤ 1e-5 | in range, overlap 0 |
-| Outer AABB | (0.474, 0.361, 1.482) m ± 0.01 | (0.4740, 0.3612, 1.4823), zmin 0 |
-| Collider tris | ≤ 120 | 52 |
-| Export | written, size > 0 | 158256 / 158256 / 158240 bytes |
+| Outer AABB | (0.472, 0.365, 1.460) m ± 0.01 | (0.4720, 0.3649, 1.4597) |
+| Grounded | `abs(zmin)` ≤ 1e-4 | 0.0000 |
+| Mesh hygiene | non-manifold, loose v/e, doubles at 1e-5, zero-area, n-gons all 0 | all 0 |
+| Parts | exactly 12 shells (2 stiles, 6 rungs, 2 caps, 2 shoes) | 12 (2 / 6) |
+| Rung depth clearance | ≥ 0.003 m inside the stile faces | 0.00361 |
+| Tenon engagement | ≥ 0.006 m past the stile inner face | 0.01200 |
+| Tenon breakout margin | ≥ 0.005 m short of the stile outer face | 0.04600 |
+| Collider tris | ≤ 120 | 24 |
+| Export | written, size > 0 | 75140 / 75140 / 75128 bytes |
+
+Base triangles fell from **2184 to 936** in the quality pass: four iron
+fittings per stile collapsed to one shoe and one top cap, and the
+redundant top block came out. No hidden-face removal was involved.
+
+The rung rims are capped and buried in the stile rather than left open.
+That costs 144 tris nobody sees, but an open rim is a non-manifold
+boundary and the hygiene budget forbids it.
+
+The joint budgets are measured per rung against each stile, from vertex
+positions in the un-raked construction frame, and the reported value is
+the worst case over all twelve rung ends. `clearance` is how far the
+widest dowel stays inside the stile's front and back faces; it must
+exceed the 2.5 mm chamfer or the dowel erupts through it as a spike.
 
 DECIMATE COLLAPSE triangle counts are **not** identical across series —
 the gate is a ratio band, not an exact count. On this mesh the three
@@ -37,18 +57,31 @@ binaries agreed on LOD ratios. Bake pixels are stochastic; the gate is
 uses no RNG. Export byte counts differ by 16 B on 5.2.1 (glTF
 serializer), not a gated axis.
 
-`--skip-decimate` skips the LOD DECIMATE stage so LOD1 ratio is 1.0 and
-exit 9 fires. That is the named budget the falsifier violates.
+Each falsifier violates exactly one named budget, and each was proven to
+fire on all three binaries:
+
+| Falsifier | Budget violated | Exit | Measured failure |
+| --- | --- | --- | --- |
+| `--skip-decimate` | LOD1 ratio band | 9 | ratio 1.0000 |
+| `--stray-vert` | Mesh hygiene, loose verts | 15 | `loose_v=1` |
+| `--lift-z` | Grounded zmin | 16 | zmin 0.050000 |
+| `--fat-rungs` | Rung depth clearance | 17 | clearance −0.00051 |
+
+`--fat-rungs` widens the dowels to the full 34 mm stile depth, which is
+the proportion this piece shipped with before the quality pass.
 
 ## Run
 
 ```bash
 blender --background --python wooden_ladder.py --
 blender --background --python wooden_ladder.py -- --skip-decimate
+blender --background --python wooden_ladder.py -- --stray-vert
+blender --background --python wooden_ladder.py -- --lift-z
+blender --background --python wooden_ladder.py -- --fat-rungs
 blender --background --python wooden_ladder.py -- --output ladder.png
 ```
 
-Smoke does not pass `--output` or `--skip-decimate`.
+Smoke passes no flags: no `--output`, no falsifier.
 
 ## Exit codes
 
@@ -72,3 +105,6 @@ File-local. `9` is a valid check code. `10` is reserved for
 | 12 | Bake did not finish or image has no data |
 | 13 | Export file missing or empty |
 | 14 | `--output` produced no file |
+| 15 | Mesh hygiene (`--stray-vert` lands here) |
+| 16 | World AABB min Z off the floor (`--lift-z` lands here) |
+| 17 | Part count or rung-to-stile joint fit (`--fat-rungs` lands here) |
diff --git a/showcase/wooden-ladder/preview.webp b/showcase/wooden-ladder/preview.webp
index cab7c7994b54e9f53e256d9fdc041a9b226a4f61..c758379d6208a537b1225a123384c9c2aec9f6f5 100644
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diff --git a/showcase/wooden-ladder/wooden_ladder.py b/showcase/wooden-ladder/wooden_ladder.py
index 1a6ff2b..ac3b1a1 100644
--- a/showcase/wooden-ladder/wooden_ladder.py
+++ b/showcase/wooden-ladder/wooden_ladder.py
@@ -5,8 +5,12 @@
 high-to-low normal bake, LOD chain, convex collider, Unity glTF export.
 
 Budgets are declared below and recomputed from the generated result.
-They are not API-contract witnesses. ``--skip-decimate`` skips the LOD
-DECIMATE stage so the LOD-ratio budget fails.
+They are not API-contract witnesses. Each falsifier violates exactly one
+named budget: ``--skip-decimate`` skips the LOD DECIMATE stage so the
+LOD-ratio budget fails, ``--lift-z`` moves the mesh off the floor so the
+grounded budget fails, ``--stray-vert`` adds one unconnected vertex so the
+mesh-hygiene budget fails, and ``--fat-rungs`` widens the dowels to the
+full stile depth so the rung-to-stile joint-fit budget fails.
 
 No RNG. Construction is closed-form. DECIMATE COLLAPSE triangle counts
 are not byte-identical across Blender versions — the LOD gate is a
@@ -14,6 +18,9 @@
 
     blender --background --python wooden_ladder.py --
     blender --background --python wooden_ladder.py -- --skip-decimate
+    blender --background --python wooden_ladder.py -- --lift-z
+    blender --background --python wooden_ladder.py -- --stray-vert
+    blender --background --python wooden_ladder.py -- --fat-rungs
     blender --background --python wooden_ladder.py -- --output ladder.png
 """
 import argparse
@@ -42,15 +49,37 @@
 STILE_D = 0.034
 SPAN = 0.34
 N_RUNGS = 6
-RUNG_R = 0.017
-RUNG_SEGS = 10
+# A 26 mm dowel in a 34 mm stile. Sized so the widest rung still clears the
+# stile's 2.5 mm chamfer by more than a millimetre; at 17 mm the dowel was as
+# deep as the stile and broke through the front and back chamfers as a spike.
+RUNG_R = 0.013
+RUNG_SEGS = 12
+RUNG_TENON = 0.012
+RUNG_RADIUS_SCALE = (0.98, 1.02, 0.99, 1.03, 0.97, 1.01)
+RUNG_Z_OFFSETS = (0.0, 0.0015, -0.0010, 0.0010, -0.0015, 0.0)
+TOP_CAP_H = 0.025
+SHOE_H = 0.065
+SHOE_W = 0.074
+SHOE_D = 0.070
 RAKE = math.radians(12.0)
 BBOX_TOL = 0.01
+# 2 stiles + 6 rungs + 2 top caps + 2 shoes, each a closed shell.
+PART_COUNT = 12
+# Measured joint contract. Clearance exceeds the 2.5 mm chamfer so the dowel
+# stays on the stile's flat face; engagement keeps the tenon seated; breakout
+# keeps it from reaching the outer face.
+RUNG_DEPTH_CLEARANCE = 0.003
+TENON_ENGAGE_MIN = 0.006
+TENON_BREAKOUT_MIN = 0.005
+ZMIN_EPS = 1e-4
+DOUBLES_EPS = 1e-5
+AREA_EPS = 1e-10
+LIFT_Z = 0.05
 # Fitted after locking geometry. Recomputed from bound_box.
-OUTER_SIZE = (0.474, 0.361, 1.482)
+OUTER_SIZE = (0.472, 0.365, 1.460)
 
-BASE_TRIS_MIN = 2100
-BASE_TRIS_MAX = 2280
+BASE_TRIS_MIN = 900
+BASE_TRIS_MAX = 975
 LOD1_RATIO_MIN = 0.32
 LOD1_RATIO_MAX = 0.62
 LOD2_RATIO_MIN = 0.10
@@ -63,8 +92,11 @@
 COLLIDER_TRIS_MAX = 120
 BAKE_RES = 256
 CAGE_EXTRUSION = 0.06
-METAL_FACES_MIN = 24
-WOOD_FACES_MIN = 24
+# The caps and shoes carry far more chamfer than body faces, so a floor above
+# their 24 unbevelled box faces is what catches a bevel whose new faces fell
+# back to the wood slot.
+METAL_FACES_MIN = 180
+WOOD_FACES_MIN = 280
 
 WOOD_IDX = 0
 METAL_IDX = 1
@@ -114,7 +146,7 @@ def add_cone(bm, loc, radius1, radius2, depth, segments, mat_idx, euler=(0.0, 0.
     geo = bmesh.ops.create_cone(
         bm,
         cap_ends=True,
-        cap_tris=False,
+        cap_tris=True,
         segments=segments,
         radius1=radius1,
         radius2=radius2,
@@ -178,14 +210,15 @@ def pack_uvs(bm, margin=0.08):
             )
 
 
-def build_ladder_mesh(name, bevel_offset, bevel_segments):
+def build_ladder_mesh(name, bevel_offset, bevel_segments, rung_radius=RUNG_R):
     bm = bmesh.new()
-    wood_verts = []
+    stile_verts = []
     metal_faces = set()
+    metal_verts = []
     try:
         half = SPAN / 2.0 + STILE_W / 2.0
         for sign in (-1.0, 1.0):
-            wood_verts.extend(
+            stile_verts.extend(
                 add_box(
                     bm,
                     (sign * half, 0.0, STILE_H / 2.0),
@@ -193,34 +226,34 @@ def build_ladder_mesh(name, bevel_offset, bevel_segments):
                     WOOD_IDX,
                 )
             )
-            wood_verts.extend(
-                add_box(
-                    bm,
-                    (sign * half, 0.0, STILE_H + 0.012),
-                    (STILE_W + 0.008, STILE_D + 0.008, 0.028),
-                    WOOD_IDX,
-                )
-            )
 
         z0 = 0.16
         z1 = STILE_H - 0.14
         for i in range(N_RUNGS):
             t = i / (N_RUNGS - 1)
-            z = z0 + t * (z1 - z0)
-            wood_verts.extend(
-                add_cylinder(
-                    bm,
-                    (0.0, 0.0, z),
-                    RUNG_R,
-                    SPAN + STILE_W * 0.55,
-                    RUNG_SEGS,
-                    WOOD_IDX,
-                    euler=(0.0, math.pi / 2.0, 0.0),
-                )
+            z = z0 + t * (z1 - z0) + RUNG_Z_OFFSETS[i]
+            # Tenons stop inside the stile, so the rung rims never reach the
+            # chamfered outer face. Rungs stay unbeveled: they are already
+            # round, and beveling a cap rim spikes through that chamfer.
+            add_cylinder(
+                bm,
+                (0.0, 0.0, z),
+                rung_radius * RUNG_RADIUS_SCALE[i],
+                SPAN + 2.0 * RUNG_TENON,
+                RUNG_SEGS,
+                WOOD_IDX,
+                euler=(0.0, math.pi / 2.0, 0.0),
             )
 
         if bevel_offset > 0.0:
-            edges = list({e for v in wood_verts for e in v.link_edges if v.is_valid})
+            edges = list(
+                {
+                    edge
+                    for vertex in stile_verts
+                    for edge in vertex.link_edges
+                    if vertex.is_valid
+                }
+            )
             if edges:
                 bmesh.ops.bevel(
                     bm,
@@ -235,24 +268,13 @@ def build_ladder_mesh(name, bevel_offset, bevel_segments):
         before = set(bm.faces)
         for sign in (-1.0, 1.0):
             hx = sign * half
-            add_box(bm, (hx, 0.0, 0.028), (STILE_W + 0.018, STILE_D + 0.018, 0.056), METAL_IDX)
-            add_box(
-                bm,
-                (hx, STILE_D / 2.0 + 0.010, 0.070),
-                (STILE_W * 0.70, 0.014, 0.090),
-                METAL_IDX,
-            )
-            add_box(
-                bm,
-                (hx, -(STILE_D / 2.0 + 0.010), 0.070),
-                (STILE_W * 0.70, 0.014, 0.090),
-                METAL_IDX,
-            )
-            add_box(
-                bm,
-                (hx, 0.0, STILE_H - 0.055),
-                (STILE_W + 0.016, STILE_D + 0.016, 0.028),
-                METAL_IDX,
+            metal_verts.extend(
+                add_box(
+                    bm,
+                    (hx, 0.0, STILE_H - TOP_CAP_H * 0.30),
+                    (STILE_W + 0.010, STILE_D + 0.010, TOP_CAP_H),
+                    METAL_IDX,
+                )
             )
         metal_faces.update(set(bm.faces) - before)
 
@@ -269,8 +291,52 @@ def build_ladder_mesh(name, bevel_offset, bevel_segments):
             v.co.x -= cx
             v.co.y -= cy
             v.co.z -= zmin
-            if v.co.z < 0.0:
-                v.co.z = 0.0
+
+        before = set(bm.faces)
+        for sign in (-1.0, 1.0):
+            bottom = rake @ Vector((sign * half, 0.0, 0.0))
+            bottom.x -= cx
+            bottom.y -= cy
+            bottom.z -= zmin
+            metal_verts.extend(
+                add_box(
+                    bm,
+                    (bottom.x, bottom.y, SHOE_H / 2.0),
+                    (SHOE_W, SHOE_D, SHOE_H),
+                    METAL_IDX,
+                )
+            )
+        metal_faces.update(set(bm.faces) - before)
+
+        if bevel_offset > 0.0:
+            metal_edges = list(
+                {
+                    edge
+                    for vertex in metal_verts
+                    for edge in vertex.link_edges
+                    if vertex.is_valid
+                }
+            )
+            if metal_edges:
+                # Bevel does not inherit material_index onto the faces it
+                # creates, so claim them from the op's own return rather than
+                # from a pre-bevel face snapshot. Without this every chamfer
+                # on a cap or shoe falls back to slot 0 and renders as wood.
+                bevelled = bmesh.ops.bevel(
+                    bm,
+                    geom=metal_edges,
+                    offset=min(bevel_offset, 0.002),
+                    segments=bevel_segments,
+                    profile=0.5,
+                    affect="EDGES",
+                    clamp_overlap=True,
+                )
+                metal_faces.update(bevelled.get("faces") or [])
+
+        ys = [v.co.y for v in bm.verts]
+        final_cy = 0.5 * (min(ys) + max(ys))
+        for v in bm.verts:
+            v.co.y -= final_cy
 
         pack_uvs(bm)
         bmesh.ops.recalc_face_normals(bm, faces=list(bm.faces))
@@ -322,6 +388,146 @@ def world_bbox(obj):
     return (min(xs), min(ys), min(zs), max(xs), max(ys), max(zs))
 
 
+def face_area(me, poly):
+    vs = [me.vertices[i].co for i in poly.vertices]
+    if len(vs) < 3:
+        return 0.0
+    v0 = vs[0]
+    area = 0.0
+    for i in range(1, len(vs) - 1):
+        area += (vs[i] - v0).cross(vs[i + 1] - v0).length * 0.5
+    return area
+
+
+def hygiene_audit(me):
+    # Combinatorics match examples/mesh-hygiene-audit.audit (copied, not imported).
+    nv, ne, nf = len(me.vertices), len(me.edges), len(me.polygons)
+    ngons = sum(1 for p in me.polygons if len(p.vertices) > 4)
+    areas = [face_area(me, p) for p in me.polygons]
+    zero_area = sum(1 for area in areas if area <= AREA_EPS)
+    bm = bmesh.new()
+    try:
+        bm.from_mesh(me)
+        bm.verts.ensure_lookup_table()
+        bm.edges.ensure_lookup_table()
+        loose_v = sum(1 for v in bm.verts if len(v.link_edges) == 0)
+        loose_e = sum(1 for e in bm.edges if len(e.link_faces) == 0)
+        nonman = sum(1 for e in bm.edges if not e.is_manifold)
+        ret = bmesh.ops.find_doubles(bm, verts=list(bm.verts), dist=DOUBLES_EPS)
+        doubles = len(ret.get("targetmap") or {})
+    finally:
+        bm.free()
+    return {
+        "nv": nv,
+        "ne": ne,
+        "nf": nf,
+        "ngons": ngons,
+        "loose_v": loose_v,
+        "loose_e": loose_e,
+        "nonman": nonman,
+        "zero_area": zero_area,
+        "doubles": doubles,
+        "euler": nv - ne + nf,
+    }
+
+
+def mesh_components(me):
+    """Per-part AABBs in the construction frame, un-raked so the stiles read
+    axis-aligned. The parts interpenetrate but share no vertices, so edge
+    connectivity separates them."""
+    neighbors = [[] for _ in range(len(me.vertices))]
+    for edge in me.edges:
+        a, b = edge.vertices
+        neighbors[a].append(b)
+        neighbors[b].append(a)
+    unrake = Euler((-RAKE, 0.0, 0.0)).to_matrix()
+    seen = [False] * len(me.vertices)
+    parts = []
+    for start in range(len(me.vertices)):
+        if seen[start]:
+            continue
+        seen[start] = True
+        stack = [start]
+        points = []
+        while stack:
+            current = stack.pop()
+            points.append(unrake @ me.vertices[current].co)
+            for nxt in neighbors[current]:
+                if not seen[nxt]:
+                    seen[nxt] = True
+                    stack.append(nxt)
+        lo = Vector(
+            (
+                min(p.x for p in points),
+                min(p.y for p in points),
+                min(p.z for p in points),
+            )
+        )
+        hi = Vector(
+            (
+                max(p.x for p in points),
+                max(p.y for p in points),
+                max(p.z for p in points),
+            )
+        )
+        parts.append((lo, hi))
+    return parts
+
+
+def joint_audit(me):
+    """Worst-case rung-to-stile fit, recomputed from vertex positions."""
+    parts = mesh_components(me)
+    stiles = [p for p in parts if (p[1].z - p[0].z) > STILE_H * 0.8]
+    rungs = [p for p in parts if (p[1].x - p[0].x) > SPAN]
+    if len(stiles) != 2 or len(rungs) != N_RUNGS:
+        return {
+            "parts": len(parts),
+            "stiles": len(stiles),
+            "rungs": len(rungs),
+            "clearance": -1.0,
+            "engage": -1.0,
+            "breakout": -1.0,
+        }
+    left = min(stiles, key=lambda p: p[0].x)
+    right = max(stiles, key=lambda p: p[0].x)
+    clearance = min(
+        min(
+            (stile[1].y - stile[0].y) - (rung[1].y - rung[0].y)
+            for stile in (left, right)
+        )
+        * 0.5
+        for rung in rungs
+    )
+    engage = min(
+        min(left[1].x - rung[0].x, rung[1].x - right[0].x) for rung in rungs
+    )
+    breakout = min(
+        min(rung[0].x - left[0].x, right[1].x - rung[1].x) for rung in rungs
+    )
+    return {
+        "parts": len(parts),
+        "stiles": len(stiles),
+        "rungs": len(rungs),
+        "clearance": clearance,
+        "engage": engage,
+        "breakout": breakout,
+    }
+
+
+def add_stray_vert(me):
+    # Falsification only: one unconnected vertex, placed inside the existing
+    # bounds so the bbox budget still passes and the hygiene budget is the
+    # gate that fires.
+    bm = bmesh.new()
+    try:
+        bm.from_mesh(me)
+        bm.verts.new((0.0, 0.0, STILE_H / 3.0))
+        bm.to_mesh(me)
+        me.update()
+    finally:
+        bm.free()
+
+
 def uv_stats(mesh):
     uv = mesh.uv_layers.active
     if uv is None:
@@ -439,10 +645,24 @@ def export_unity(path, objects):
     )
 
 
-def check(skip_decimate):
+def check(skip_decimate, lift_z=False, stray_vert=False, fat_rungs=False):
     bpy.ops.wm.read_factory_settings(use_empty=True)
-    low = build_ladder_mesh("LadderLow", bevel_offset=0.0025, bevel_segments=2)
-    high = build_ladder_mesh("LadderHigh", bevel_offset=0.0025, bevel_segments=4)
+    # Falsification: a dowel as deep as the stile, which is what used to break
+    # through the front and back chamfers.
+    rung_radius = STILE_D / 2.0 if fat_rungs else RUNG_R
+    low = build_ladder_mesh(
+        "LadderLow", bevel_offset=0.0025, bevel_segments=2, rung_radius=rung_radius
+    )
+    high = build_ladder_mesh(
+        "LadderHigh", bevel_offset=0.0025, bevel_segments=4, rung_radius=rung_radius
+    )
+    if lift_z:
+        low.location.z += LIFT_Z
+    if stray_vert:
+        add_stray_vert(low.data)
+    # world_bbox reads matrix_world, which is evaluated data. Without this the
+    # cached matrix hides a moved object and the grounded budget cannot fail.
+    bpy.context.view_layer.update()
     wood = principled("LadderWood", (0.42, 0.24, 0.10, 1.0), 0.0, 0.55)
     metal = principled("LadderMetal", (0.48, 0.46, 0.42, 1.0), 1.0, 0.28)
     assign_slots(low, wood, metal)
@@ -511,6 +731,18 @@ def check(skip_decimate):
         f"measured collider_tris={col_tris} bake={bake_result} "
         f"bake_has_data={img.has_data} export_bytes={export_size}"
     )
+    hyg = hygiene_audit(low.data)
+    print(
+        f"measured hygiene loose_v={hyg['loose_v']} loose_e={hyg['loose_e']} "
+        f"nonman={hyg['nonman']} zero_area={hyg['zero_area']} "
+        f"doubles={hyg['doubles']} ngons={hyg['ngons']} euler={hyg['euler']}"
+    )
+    joint = joint_audit(low.data)
+    print(
+        f"measured joints parts={joint['parts']} stiles={joint['stiles']} "
+        f"rungs={joint['rungs']} clearance={joint['clearance']:.5f} "
+        f"engage={joint['engage']:.5f} breakout={joint['breakout']:.5f}"
+    )
 
     if not (BASE_TRIS_MIN <= base_tris <= BASE_TRIS_MAX):
         return fail(
@@ -575,6 +807,49 @@ def check(skip_decimate):
         ), None, None, None, None, None
     if export_size <= 0:
         return fail("export file missing or empty", 13), None, None, None, None, None
+    if (
+        hyg["loose_v"]
+        or hyg["loose_e"]
+        or hyg["nonman"]
+        or hyg["zero_area"]
+        or hyg["doubles"]
+        or hyg["ngons"]
+    ):
+        return fail(
+            f"hygiene loose_v={hyg['loose_v']} loose_e={hyg['loose_e']} "
+            f"nonman={hyg['nonman']} zero_area={hyg['zero_area']} "
+            f"doubles={hyg['doubles']} ngons={hyg['ngons']}",
+            15,
+        ), None, None, None, None, None
+    if abs(bb[2]) > ZMIN_EPS:
+        return fail(
+            f"zmin {bb[2]:.6f} not within {ZMIN_EPS} of 0 "
+            "(--lift-z is the designed fail)",
+            16,
+        ), None, None, None, None, None
+    if joint["parts"] != PART_COUNT:
+        return fail(
+            f"part count {joint['parts']} != {PART_COUNT} "
+            f"(stiles={joint['stiles']} rungs={joint['rungs']})",
+            17,
+        ), None, None, None, None, None
+    if joint["clearance"] < RUNG_DEPTH_CLEARANCE:
+        return fail(
+            f"rung-to-stile depth clearance {joint['clearance']:.5f} < "
+            f"{RUNG_DEPTH_CLEARANCE} (--fat-rungs is the designed fail)",
+            17,
+        ), None, None, None, None, None
+    if joint["engage"] < TENON_ENGAGE_MIN:
+        return fail(
+            f"tenon engagement {joint['engage']:.5f} < {TENON_ENGAGE_MIN}",
+            17,
+        ), None, None, None, None, None
+    if joint["breakout"] < TENON_BREAKOUT_MIN:
+        return fail(
+            f"tenon breakout margin {joint['breakout']:.5f} < "
+            f"{TENON_BREAKOUT_MIN}",
+            17,
+        ), None, None, None, None, None
     return 0, low, high, wood, tex, collider
 
 
@@ -600,7 +875,9 @@ def render_still(low, wood, tex, path, engine):
     floor_me = bpy.data.meshes.new("Floor")
     bm = bmesh.new()
     try:
-        bmesh.ops.create_grid(bm, x_segments=1, y_segments=1, size=14.0)
+        # Oversized so no edge of the set can enter frame; the committed hero
+        # used to show the wall's left edge as a bright band in the corner.
+        bmesh.ops.create_grid(bm, x_segments=1, y_segments=1, size=60.0)
         bm.to_mesh(floor_me)
     finally:
         bm.free()
@@ -692,9 +969,29 @@ def main():
         action="store_true",
         help="falsification: skip the LOD DECIMATE stage",
     )
+    p.add_argument(
+        "--lift-z",
+        action="store_true",
+        help="falsification: lift the mesh so zmin fails the grounded budget",
+    )
+    p.add_argument(
+        "--stray-vert",
+        action="store_true",
+        help="falsification: add a loose vertex so the hygiene budget fails",
+    )
+    p.add_argument(
+        "--fat-rungs",
+        action="store_true",
+        help="falsification: dowels as deep as the stile, failing joint fit",
+    )
     args = p.parse_args(argv)
 
-    code, low, _high, wood, tex, _col = check(args.skip_decimate)
+    code, low, _high, wood, tex, _col = check(
+        args.skip_decimate,
+        lift_z=args.lift_z,
+        stray_vert=args.stray_vert,
+        fat_rungs=args.fat_rungs,
+    )
     if code:
         return code
     if args.output:

From d05ba66608695b3a801fe589f3d90ddd969bec6a Mon Sep 17 00:00:00 2001
From: TMHSDigital <154358121+TMHSDigital@users.noreply.github.com>
Date: Tue, 15 Sep 2026 23:26:00 -0400
Subject: [PATCH 2/2] docs: require joint-fit budgets and a falsifier per
 hygiene budget

A part exactly as thick as its host passes any "do the parts overlap"
check while erupting through the host's chamfer as a spike, which is how
the wooden ladder shipped. Name the three minima that catch it, and the
frame to measure them in, so the next piece inherits them instead of
rediscovering the class.

The hygiene budgets added in the last pass had no named falsifier, so
nothing proved they could fail. Name one per budget and require the exit
code be checked rather than merely non-zero.

Signed-off-by: TMHSDigital <154358121+TMHSDigital@users.noreply.github.com>
Co-authored-by: Cursor <cursoragent@cursor.com>
---
 showcase/README.md | 17 ++++++++++++++++-
 1 file changed, 16 insertions(+), 1 deletion(-)

diff --git a/showcase/README.md b/showcase/README.md
index c46a12f..fe34264 100644
--- a/showcase/README.md
+++ b/showcase/README.md
@@ -34,7 +34,11 @@ entry in `showcase/gallery.json`, and a rendered still.
 - **Falsifier** breaks one pipeline stage so a **named** budget fails and
   the piece exits its documented code. Prove default and falsifier on
   4.5.11, 5.1.2, and 5.2.1. `--skip-decimate` is the LOD-ratio
-  falsifier (exit 9). `--lift-z` is the grounded-zmin falsifier (exit 16).
+  falsifier (exit 9), `--stray-vert` the mesh-hygiene falsifier (exit
+  15), `--lift-z` the grounded-zmin falsifier (exit 16), and
+  `--fat-rungs` (or the piece's equivalent) the joint-fit falsifier
+  (exit 17). A budget with no falsifier witnesses nothing: prove each
+  one fails once, and check the exit code, not just non-zero.
 - **Hygiene budgets.** Copied combinatorics from
   `examples/mesh-hygiene-audit` (do not import the example). Every piece
   asserts on the generated mesh: non-manifold edges 0, loose verts 0,
@@ -43,6 +47,17 @@ entry in `showcase/gallery.json`, and a rendered still.
   characteristic 2 — that is a single-shell contract. Pairs of parts
   meant to touch assert a BVH surface gap below a named epsilon
   (vert-vert is the wrong metric for thin straps and collars).
+- **Joint-fit budgets.** Parts that interpenetrate on purpose — a tenon
+  in a mortise, a peg in a hub — assert how deep the overlap goes, not
+  just that it exists. Split the mesh into shells by edge connectivity,
+  assert the expected shell count, and for each joint assert three
+  named minima recomputed from vertex positions: the inserted part stays
+  clear of the host's chamfer, it seats far enough past the host's near
+  face, and it stops short of the host's far face. A part exactly as
+  thick as its host passes a "parts overlap" test while erupting through
+  the host's chamfer as a spike — that is the class this catches.
+  Measure in the construction frame (un-rotate by any rake) so a tilted
+  host does not inflate its own AABB.
 - **Material face floors.** Every declared material asserts a named
   minimum face count on the finished mesh, recomputed from
   `polygon.material_index`. This catches the slot-assignment wipe class: