Refactored Solid.extrude_until, moved split to Shape, fixed misc typing problems

docs/assets/ttt/ttt-ppp0109.py

@@ -47,9 +47,10 @@ with BuildPart() as ppp109:
         split(bisect_by=Plane.YZ)
     extrude(amount=6)
     f = ppp109.faces().filter_by(Axis((0, 0, 0), (-1, 0, 1)))[0]
-    # extrude(f, until=Until.NEXT) # throws a warning
-    extrude(f, amount=10)
-    fillet(ppp109.edge(Select.NEW), 16)
+    extrude(f, until=Until.NEXT)
+    fillet(ppp109.edges().filter_by(Axis.Y).sort_by(Axis.Z)[2], 16)
+    # extrude(f, amount=10)
+    # fillet(ppp109.edges(Select.NEW), 16)
 
 
 show(ppp109)
@@ -59,4 +60,4 @@ want_mass = 307.23
 tolerance = 1
 delta = abs(got_mass - want_mass)
 print(f"Mass: {got_mass:0.2f} g")
-assert delta < tolerance, f'{got_mass=}, {want_mass=}, {delta=}, {tolerance=}'
+assert delta < tolerance, f"{got_mass=}, {want_mass=}, {delta=}, {tolerance=}"

src/build123d/operations_part.py

@@ -223,8 +223,8 @@ def extrude(
 
                 new_solids.append(
                     Solid.extrude_until(
-                        section=face,
-                        target_object=target_object,
+                        face,
+                        target=target_object,
                         direction=plane.z_dir * direction,
                         until=until,
                     )

src/build123d/topology/one_d.py

@@ -233,11 +233,11 @@ from .shape_core import (
     shapetype,
     topods_dim,
     unwrap_topods_compound,
+    _topods_bool_op,
 )
 from .utils import (
     _extrude_topods_shape,
     _make_topods_face_from_wires,
-    _topods_bool_op,
     isclose_b,
 )
 from .zero_d import Vertex, topo_explore_common_vertex
@@ -1377,144 +1377,6 @@ class Mixin1D(Shape[TOPODS]):
 
         return (visible_edges, hidden_edges)
 
-    @overload
-    def split(
-        self, tool: TrimmingTool, keep: Literal[Keep.TOP, Keep.BOTTOM]
-    ) -> Self | list[Self] | None:
-        """split and keep inside or outside"""
-
-    @overload
-    def split(self, tool: TrimmingTool, keep: Literal[Keep.ALL]) -> list[Self]:
-        """split and return the unordered pieces"""
-
-    @overload
-    def split(self, tool: TrimmingTool, keep: Literal[Keep.BOTH]) -> tuple[
-        Self | list[Self] | None,
-        Self | list[Self] | None,
-    ]:
-        """split and keep inside and outside"""
-
-    @overload
-    def split(self, tool: TrimmingTool) -> Self | list[Self] | None:
-        """split and keep inside (default)"""
-
-    def split(self, tool: TrimmingTool, keep: Keep = Keep.TOP):
-        """split
-
-        Split this shape by the provided plane or face.
-
-        Args:
-            surface (Plane | Face): surface to segment shape
-            keep (Keep, optional): which object(s) to save. Defaults to Keep.TOP.
-
-        Returns:
-            Shape: result of split
-        Returns:
-            Self | list[Self] | None,
-            Tuple[Self | list[Self] | None]: The result of the split operation.
-
-            - **Keep.TOP**: Returns the top as a `Self` or `list[Self]`, or `None`
-              if no top is found.
-            - **Keep.BOTTOM**: Returns the bottom as a `Self` or `list[Self]`, or `None`
-              if no bottom is found.
-            - **Keep.BOTH**: Returns a tuple `(inside, outside)` where each element is
-              either a `Self` or `list[Self]`, or `None` if no corresponding part is found.
-        """
-        if self._wrapped is None or not tool:
-            raise ValueError("Can't split an empty edge/wire/tool")
-
-        shape_list = TopTools_ListOfShape()
-        shape_list.Append(self.wrapped)
-
-        # Define the splitting tool
-        trim_tool = (
-            BRepBuilderAPI_MakeFace(tool.wrapped).Face()  # gp_Pln to Face
-            if isinstance(tool, Plane)
-            else tool.wrapped
-        )
-        tool_list = TopTools_ListOfShape()
-        tool_list.Append(trim_tool)
-
-        # Create the splitter algorithm
-        splitter = BRepAlgoAPI_Splitter()
-
-        # Set the shape to be split and the splitting tool (plane face)
-        splitter.SetArguments(shape_list)
-        splitter.SetTools(tool_list)
-
-        # Perform the splitting operation
-        splitter.Build()
-
-        split_result = downcast(splitter.Shape())
-        # Remove unnecessary TopoDS_Compound around single shape
-        if isinstance(split_result, TopoDS_Compound):
-            split_result = unwrap_topods_compound(split_result, True)
-
-        # For speed the user may just want all the objects which they
-        # can sort more efficiently then the generic algorithm below
-        if keep == Keep.ALL:
-            return ShapeList(
-                self.__class__.cast(part)
-                for part in get_top_level_topods_shapes(split_result)
-            )
-
-        if not isinstance(tool, Plane):
-            # Get a TopoDS_Face to work with from the tool
-            if isinstance(trim_tool, TopoDS_Shell):
-                face_explorer = TopExp_Explorer(trim_tool, ta.TopAbs_FACE)
-                tool_face = TopoDS.Face_s(face_explorer.Current())
-            else:
-                tool_face = trim_tool
-
-            # Create a reference point off the +ve side of the tool
-            surface_gppnt = gp_Pnt()
-            surface_normal = gp_Vec()
-            u_min, u_max, v_min, v_max = BRepTools.UVBounds_s(tool_face)
-            BRepGProp_Face(tool_face).Normal(
-                (u_min + u_max) / 2, (v_min + v_max) / 2, surface_gppnt, surface_normal
-            )
-            normalized_surface_normal = Vector(
-                surface_normal.X(), surface_normal.Y(), surface_normal.Z()
-            ).normalized()
-            surface_point = Vector(surface_gppnt)
-            ref_point = surface_point + normalized_surface_normal
-
-            # Create a HalfSpace - Solidish object to determine top/bottom
-            # Note: BRepPrimAPI_MakeHalfSpace takes either a TopoDS_Shell or TopoDS_Face but the
-            # mypy expects only a TopoDS_Shell here
-            half_space_maker = BRepPrimAPI_MakeHalfSpace(trim_tool, ref_point.to_pnt())
-            # type: ignore
-            tool_solid = half_space_maker.Solid()
-
-        tops: list[Shape] = []
-        bottoms: list[Shape] = []
-        properties = GProp_GProps()
-        for part in get_top_level_topods_shapes(split_result):
-            sub_shape = self.__class__.cast(part)
-            if isinstance(tool, Plane):
-                is_up = tool.to_local_coords(sub_shape).center().Z >= 0
-            else:
-                # Intersect self and the thickened tool
-                is_up_obj = _topods_bool_op(
-                    (part,), (tool_solid,), BRepAlgoAPI_Common()
-                )
-                # Check for valid intersections
-                BRepGProp.LinearProperties_s(is_up_obj, properties)
-                # Mass represents the total length for linear properties
-                is_up = properties.Mass() >= TOLERANCE
-            (tops if is_up else bottoms).append(sub_shape)
-
-        top = None if not tops else tops[0] if len(tops) == 1 else tops
-        bottom = None if not bottoms else bottoms[0] if len(bottoms) == 1 else bottoms
-
-        if keep == Keep.BOTH:
-            return (top, bottom)
-        if keep == Keep.TOP:
-            return top
-        if keep == Keep.BOTTOM:
-            return bottom
-        return None
-
     def start_point(self) -> Vector:
         """The start point of this edge
 

src/build123d/topology/shape_core.py

@@ -100,6 +100,7 @@ from OCP.BRepFeat import BRepFeat_SplitShape
 from OCP.BRepGProp import BRepGProp, BRepGProp_Face
 from OCP.BRepIntCurveSurface import BRepIntCurveSurface_Inter
 from OCP.BRepMesh import BRepMesh_IncrementalMesh
+from OCP.BRepPrimAPI import BRepPrimAPI_MakeHalfSpace
 from OCP.BRepTools import BRepTools
 from OCP.gce import gce_MakeLin
 from OCP.Geom import Geom_Line
@@ -196,7 +197,7 @@ class Shape(NodeMixin, Generic[TOPODS]):
         ta.TopAbs_COMPSOLID: "CompSolid",
     }
 
-    shape_properties_LUT = {
+    shape_properties_LUT: dict[TopAbs_ShapeEnum:function] = {
         ta.TopAbs_VERTEX: None,
         ta.TopAbs_EDGE: BRepGProp.LinearProperties_s,
         ta.TopAbs_WIRE: BRepGProp.LinearProperties_s,
@@ -1786,6 +1787,144 @@ class Shape(NodeMixin, Generic[TOPODS]):
         """solids - all the solids in this Shape"""
         return ShapeList()
 
+    @overload
+    def split(
+        self, tool: TrimmingTool, keep: Literal[Keep.TOP, Keep.BOTTOM]
+    ) -> Self | list[Self] | None:
+        """split and keep inside or outside"""
+
+    @overload
+    def split(self, tool: TrimmingTool, keep: Literal[Keep.ALL]) -> list[Self]:
+        """split and return the unordered pieces"""
+
+    @overload
+    def split(self, tool: TrimmingTool, keep: Literal[Keep.BOTH]) -> tuple[
+        Self | list[Self] | None,
+        Self | list[Self] | None,
+    ]:
+        """split and keep inside and outside"""
+
+    @overload
+    def split(self, tool: TrimmingTool) -> Self | list[Self] | None:
+        """split and keep inside (default)"""
+
+    def split(self, tool: TrimmingTool, keep: Keep = Keep.TOP):
+        """split
+
+        Split this shape by the provided plane or face.
+
+        Args:
+            surface (Plane | Face): surface to segment shape
+            keep (Keep, optional): which object(s) to save. Defaults to Keep.TOP.
+
+        Returns:
+            Shape: result of split
+        Returns:
+            Self | list[Self] | None,
+            Tuple[Self | list[Self] | None]: The result of the split operation.
+
+            - **Keep.TOP**: Returns the top as a `Self` or `list[Self]`, or `None`
+              if no top is found.
+            - **Keep.BOTTOM**: Returns the bottom as a `Self` or `list[Self]`, or `None`
+              if no bottom is found.
+            - **Keep.BOTH**: Returns a tuple `(inside, outside)` where each element is
+              either a `Self` or `list[Self]`, or `None` if no corresponding part is found.
+        """
+        if self._wrapped is None or not tool:
+            raise ValueError("Can't split an empty edge/wire/tool")
+
+        shape_list = TopTools_ListOfShape()
+        shape_list.Append(self.wrapped)
+
+        # Define the splitting tool
+        trim_tool = (
+            BRepBuilderAPI_MakeFace(tool.wrapped).Face()  # gp_Pln to Face
+            if isinstance(tool, Plane)
+            else tool.wrapped
+        )
+        tool_list = TopTools_ListOfShape()
+        tool_list.Append(trim_tool)
+
+        # Create the splitter algorithm
+        splitter = BRepAlgoAPI_Splitter()
+
+        # Set the shape to be split and the splitting tool (plane face)
+        splitter.SetArguments(shape_list)
+        splitter.SetTools(tool_list)
+
+        # Perform the splitting operation
+        splitter.Build()
+
+        split_result = downcast(splitter.Shape())
+        # Remove unnecessary TopoDS_Compound around single shape
+        if isinstance(split_result, TopoDS_Compound):
+            split_result = unwrap_topods_compound(split_result, True)
+
+        # For speed the user may just want all the objects which they
+        # can sort more efficiently then the generic algorithm below
+        if keep == Keep.ALL:
+            return ShapeList(
+                self.__class__.cast(part)
+                for part in get_top_level_topods_shapes(split_result)
+            )
+
+        if not isinstance(tool, Plane):
+            # Get a TopoDS_Face to work with from the tool
+            if isinstance(trim_tool, TopoDS_Shell):
+                face_explorer = TopExp_Explorer(trim_tool, ta.TopAbs_FACE)
+                tool_face = TopoDS.Face_s(face_explorer.Current())
+            else:
+                tool_face = trim_tool
+
+            # Create a reference point off the +ve side of the tool
+            surface_gppnt = gp_Pnt()
+            surface_normal = gp_Vec()
+            u_min, u_max, v_min, v_max = BRepTools.UVBounds_s(tool_face)
+            BRepGProp_Face(tool_face).Normal(
+                (u_min + u_max) / 2, (v_min + v_max) / 2, surface_gppnt, surface_normal
+            )
+            normalized_surface_normal = Vector(
+                surface_normal.X(), surface_normal.Y(), surface_normal.Z()
+            ).normalized()
+            surface_point = Vector(surface_gppnt)
+            ref_point = surface_point + normalized_surface_normal
+
+            # Create a HalfSpace - Solidish object to determine top/bottom
+            # Note: BRepPrimAPI_MakeHalfSpace takes either a TopoDS_Shell or TopoDS_Face but the
+            # mypy expects only a TopoDS_Shell here
+            half_space_maker = BRepPrimAPI_MakeHalfSpace(trim_tool, ref_point.to_pnt())
+            # type: ignore
+            tool_solid = half_space_maker.Solid()
+
+        tops: list[Shape] = []
+        bottoms: list[Shape] = []
+        properties = GProp_GProps()
+        for part in get_top_level_topods_shapes(split_result):
+            sub_shape = self.__class__.cast(part)
+            if isinstance(tool, Plane):
+                is_up = tool.to_local_coords(sub_shape).center().Z >= 0
+            else:
+                # Intersect self and the thickened tool
+                is_up_obj = _topods_bool_op(
+                    (part,), (tool_solid,), BRepAlgoAPI_Common()
+                )
+                # Check for valid intersections
+                BRepGProp.LinearProperties_s(is_up_obj, properties)
+                # Mass represents the total length for linear properties
+                is_up = properties.Mass() >= TOLERANCE
+            (tops if is_up else bottoms).append(sub_shape)
+
+        top = None if not tops else tops[0] if len(tops) == 1 else tops
+        bottom = None if not bottoms else bottoms[0] if len(bottoms) == 1 else bottoms
+
+        if keep == Keep.BOTH:
+            return (top, bottom)
+        if keep == Keep.TOP:
+            return top
+        if keep == Keep.BOTTOM:
+            return bottom
+        return None
+
     @overload
     def split_by_perimeter(
         self, perimeter: Edge | Wire, keep: Literal[Keep.INSIDE, Keep.OUTSIDE]
@@ -3011,6 +3150,45 @@ def _sew_topods_faces(faces: Iterable[TopoDS_Face]) -> TopoDS_Shape:
     return downcast(shell_builder.SewedShape())
 
 
+def _topods_bool_op(
+    args: Iterable[TopoDS_Shape],
+    tools: Iterable[TopoDS_Shape],
+    operation: BRepAlgoAPI_BooleanOperation | BRepAlgoAPI_Splitter,
+) -> TopoDS_Shape:
+    """Generic boolean operation for TopoDS_Shapes
+
+    Args:
+        args: Iterable[TopoDS_Shape]:
+        tools: Iterable[TopoDS_Shape]:
+        operation: BRepAlgoAPI_BooleanOperation | BRepAlgoAPI_Splitter:
+
+    Returns: TopoDS_Shape
+
+    """
+    args = list(args)
+    tools = list(tools)
+    arg = TopTools_ListOfShape()
+    for obj in args:
+        arg.Append(obj)
+
+    tool = TopTools_ListOfShape()
+    for obj in tools:
+        tool.Append(obj)
+
+    operation.SetArguments(arg)
+    operation.SetTools(tool)
+
+    operation.SetRunParallel(True)
+    operation.Build()
+
+    result = downcast(operation.Shape())
+    # Remove unnecessary TopoDS_Compound around single shape
+    if isinstance(result, TopoDS_Compound):
+        result = unwrap_topods_compound(result, True)
+
+    return result
+
+
 def _topods_entities(shape: TopoDS_Shape, topo_type: Shapes) -> list[TopoDS_Shape]:
     """Return the TopoDS_Shapes of topo_type from this TopoDS_Shape"""
     out = {}  # using dict to prevent duplicates

src/build123d/topology/three_d.py

@@ -54,11 +54,10 @@ license:
 
 from __future__ import annotations
 
-import platform
-import warnings
 from collections.abc import Iterable, Sequence
 from math import radians, cos, tan
-from typing import TYPE_CHECKING
+from typing import TYPE_CHECKING, Literal, overload
+from typing import cast as tcast
 from typing_extensions import Self
 
 import OCP.TopAbs as ta
@@ -86,13 +85,20 @@ from OCP.GProp import GProp_GProps
 from OCP.GeomAbs import GeomAbs_Intersection, GeomAbs_JoinType
 from OCP.LocOpe import LocOpe_DPrism
 from OCP.ShapeFix import ShapeFix_Solid
-from OCP.Standard import Standard_Failure
+from OCP.Standard import Standard_Failure, Standard_TypeMismatch
 from OCP.StdFail import StdFail_NotDone
-from OCP.TopExp import TopExp
+from OCP.TopExp import TopExp, TopExp_Explorer
 from OCP.TopTools import TopTools_IndexedDataMapOfShapeListOfShape, TopTools_ListOfShape
-from OCP.TopoDS import TopoDS, TopoDS_Face, TopoDS_Shape, TopoDS_Solid, TopoDS_Wire
+from OCP.TopoDS import (
+    TopoDS,
+    TopoDS_Face,
+    TopoDS_Shape,
+    TopoDS_Shell,
+    TopoDS_Solid,
+    TopoDS_Wire,
+)
 from OCP.gp import gp_Ax2, gp_Pnt
-from build123d.build_enums import CenterOf, GeomType, Kind, Transition, Until
+from build123d.build_enums import CenterOf, GeomType, Keep, Kind, Transition, Until
 from build123d.geometry import (
     DEG2RAD,
     TOLERANCE,
@@ -107,7 +113,19 @@ from build123d.geometry import (
 )
 
 from .one_d import Edge, Wire, Mixin1D
-from .shape_core import TOPODS, Shape, ShapeList, Joint, downcast, shapetype
+from .shape_core import (
+    TOPODS,
+    Shape,
+    ShapeList,
+    Joint,
+    TrimmingTool,
+    downcast,
+    shapetype,
+    _sew_topods_faces,
+    get_top_level_topods_shapes,
+    unwrap_topods_compound,
+)
+
 from .two_d import sort_wires_by_build_order, Mixin2D, Face, Shell
 from .utils import (
     _extrude_topods_shape,
@@ -126,7 +144,6 @@ class Mixin3D(Shape[TOPODS]):
     """Additional methods to add to 3D Shape classes"""
 
     project_to_viewport = Mixin1D.project_to_viewport
-    split = Mixin1D.split
     find_intersection_points = Mixin2D.find_intersection_points
 
     vertices = Mixin1D.vertices
@@ -507,7 +524,9 @@ class Mixin3D(Shape[TOPODS]):
             for obj in common_set:
                 match (obj, target):
                     case (_, Vertex() | Edge() | Wire() | Face() | Shell() | Solid()):
-                        operation = BRepAlgoAPI_Section()
+                        operation: BRepAlgoAPI_Section | BRepAlgoAPI_Common = (
+                            BRepAlgoAPI_Section()
+                        )
                         result = bool_op((obj,), (target,), operation)
                         if (
                             not isinstance(obj, Edge | Wire)
@@ -610,8 +629,10 @@ class Mixin3D(Shape[TOPODS]):
             try:
                 new_shape = self.__class__(fillet_builder.Shape())
                 if not new_shape.is_valid:
-                    raise fillet_exception
-            except fillet_exception:
+                    # raise fillet_exception
+                    raise Standard_Failure
+            # except fillet_exception:
+            except (Standard_Failure, StdFail_NotDone):
                 return __max_fillet(window_min, window_mid, current_iteration + 1)
 
             # These numbers work, are they close enough? - if not try larger window
@@ -630,10 +651,10 @@ class Mixin3D(Shape[TOPODS]):
 
         # Unfortunately, MacOS doesn't support the StdFail_NotDone exception so platform
         # specific exceptions are required.
-        if platform.system() == "Darwin":
-            fillet_exception = Standard_Failure
-        else:
-            fillet_exception = StdFail_NotDone
+        # if platform.system() == "Darwin":
+        #     fillet_exception = Standard_Failure
+        # else:
+        #     fillet_exception = StdFail_NotDone
 
         max_radius = __max_fillet(0.0, 2 * self.bounding_box().diagonal, 0)
 
@@ -892,7 +913,17 @@ class Solid(Mixin3D[TopoDS_Solid]):
         inner_comp = _make_topods_compound_from_shapes(inner_solids)
 
         # subtract from the outer solid
-        return Solid(BRepAlgoAPI_Cut(outer_solid, inner_comp).Shape())
+        difference = BRepAlgoAPI_Cut(outer_solid, inner_comp).Shape()
+
+        # convert to a TopoDS_Solid - might be wrapped in a TopoDS_Compound
+        try:
+            result = TopoDS.Solid_s(difference)
+        except Standard_TypeMismatch:
+            result = TopoDS.Solid_s(
+                unwrap_topods_compound(TopoDS.Compound_s(difference), True)
+            )
+
+        return Solid(result)
 
     @classmethod
     def extrude_taper(
@@ -933,7 +964,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
                 direction.length / cos(radians(taper)),
                 radians(taper),
             )
-            new_solid = Solid(prism_builder.Shape())
+            new_solid = Solid(TopoDS.Solid_s(prism_builder.Shape()))
         else:
             # Determine the offset to get the taper
             offset_amt = -direction.length * tan(radians(taper))
@@ -972,110 +1003,116 @@ class Solid(Mixin3D[TopoDS_Solid]):
     @classmethod
     def extrude_until(
         cls,
-        section: Face,
-        target_object: Compound | Solid,
+        profile: Face,
+        target: Compound | Solid,
         direction: VectorLike,
         until: Until = Until.NEXT,
-    ) -> Compound | Solid:
+    ) -> Solid:
         """extrude_until
 
-        Extrude section in provided direction until it encounters either the
-        NEXT or LAST surface of target_object. Note that the bounding surface
-        must be larger than the extruded face where they contact.
+        Extrude `profile` in the provided `direction` until it encounters a
+        bounding surface on the `target`. The termination surface is chosen
+        according to the `until` option:
+
+            * ``Until.NEXT`` — Extrude forward until the first intersecting surface.
+            * ``Until.LAST`` — Extrude forward through all intersections, stopping at
+            the farthest surface.
+            * ``Until.PREVIOUS`` — Reverse the extrusion direction and stop at the
+            first intersecting surface behind the profile.
+            * ``Until.FIRST`` — Reverse the direction and stop at the farthest
+            surface behind the profile.
+
+        When ``Until.PREVIOUS`` or ``Until.FIRST`` are used, the extrusion
+        direction is automatically inverted before execution.
+
+        Note:
+            The bounding surface on the target must be large enough to
+            completely cover the extruded profile at the contact region.
+            Partial overlaps may yield open or invalid solids.
 
         Args:
-            section (Face): Face to extrude
-            target_object (Union[Compound, Solid]): object to limit extrusion
-            direction (VectorLike): extrusion direction
-            until (Until, optional): surface to limit extrusion. Defaults to Until.NEXT.
+            profile (Face): The face to extrude.
+            target (Union[Compound, Solid]): The object that limits the extrusion.
+            direction (VectorLike): Extrusion direction.
+            until (Until, optional): Surface selection mode controlling which
+                intersection to stop at. Defaults to ``Until.NEXT``.
 
         Raises:
-            ValueError: provided face does not intersect target_object
+            ValueError: If the provided profile does not intersect the target.
 
         Returns:
-            Union[Compound, Solid]: extruded Face
+            Solid: The extruded and limited solid.
         """
         direction = Vector(direction)
         if until in [Until.PREVIOUS, Until.FIRST]:
             direction *= -1
             until = Until.NEXT if until == Until.PREVIOUS else Until.LAST
 
-        max_dimension = find_max_dimension([section, target_object])
-        clipping_direction = (
-            direction * max_dimension
-            if until == Until.NEXT
-            else -direction * max_dimension
-        )
-        direction_axis = Axis(section.center(), clipping_direction)
-        # Create a linear extrusion to start
-        extrusion = Solid.extrude(section, direction * max_dimension)
+        # 1: Create extrusion of length the maximum distance between profile and target
+        max_dimension = find_max_dimension([profile, target])
+        extrusion = Solid.extrude(profile, direction * max_dimension)
 
-        # Project section onto the shape to generate faces that will clip the extrusion
-        # and exclude the planar faces normal to the direction of extrusion and these
-        # will have no volume when extruded
-        faces = []
-        for face in section.project_to_shape(target_object, direction):
-            if isinstance(face, Face):
-                faces.append(face)
+        # 2: Intersect the extrusion with the target to find the target's modified faces
+        intersect_op = BRepAlgoAPI_Common(target.wrapped, extrusion.wrapped)
+        intersect_op.Build()
+        intersection = intersect_op.Shape()
+        face_exp = TopExp_Explorer(intersection, ta.TopAbs_FACE)
+        if not face_exp.More():
+            raise ValueError("No intersection: extrusion does not contact target")
+
+        # Find the faces from the intersection that originated on the target
+        history = intersect_op.History()
+        modified_target_faces = []
+        face_explorer = TopExp_Explorer(target.wrapped, ta.TopAbs_FACE)
+        while face_explorer.More():
+            target_face = TopoDS.Face_s(face_explorer.Current())
+            modified_los: TopTools_ListOfShape = history.Modified(target_face)
+            while not modified_los.IsEmpty():
+                modified_face = TopoDS.Face_s(modified_los.First())
+                modified_los.RemoveFirst()
+                modified_target_faces.append(modified_face)
+            face_explorer.Next()
+
+        # 3: Sew the resulting faces into shells - one for each surface the extrusion
+        #    passes through and sort by distance from the profile
+        sewed_shape = _sew_topods_faces(modified_target_faces)
+
+        # From the sewed shape extract the shells and single faces
+        top_level_shapes = get_top_level_topods_shapes(sewed_shape)
+        modified_target_surfaces: ShapeList[Face | Shell] = ShapeList()
+
+        # For each of the top level Shells and Faces
+        for top_level_shape in top_level_shapes:
+            if isinstance(top_level_shape, TopoDS_Face):
+                modified_target_surfaces.append(Face(top_level_shape))
+            elif isinstance(top_level_shape, TopoDS_Shell):
+                modified_target_surfaces.append(Shell(top_level_shape))
             else:
-                faces += face.faces()
+                raise RuntimeError(f"Invalid sewn shape {type(top_level_shape)}")
 
-        clip_faces = [
-            f
-            for f in faces
-            if not (f.is_planar and f.normal_at().dot(direction) == 0.0)
+        modified_target_surfaces = modified_target_surfaces.sort_by(
+            lambda s: s.distance_to(profile)
+        )
+        limit = modified_target_surfaces[
+            0 if until in [Until.NEXT, Until.PREVIOUS] else -1
         ]
-        if not clip_faces:
-            raise ValueError("provided face does not intersect target_object")
-
-        # Create the objects that will clip the linear extrusion
-        clipping_objects = [
-            Solid.extrude(f, clipping_direction).fix() for f in clip_faces
-        ]
-        clipping_objects = [o for o in clipping_objects if o.volume > 1e-9]
-
-        if until == Until.NEXT:
-            trimmed_extrusion = extrusion.cut(target_object)
-            if isinstance(trimmed_extrusion, ShapeList):
-                closest_extrusion = trimmed_extrusion.sort_by(direction_axis)[0]
-            else:
-                closest_extrusion = trimmed_extrusion
-            for clipping_object in clipping_objects:
-                # It's possible for clipping faces to self intersect when they are extruded
-                # thus they could be non manifold which results failed boolean operations
-                #  - so skip these objects
-                try:
-                    extrusion_shapes = closest_extrusion.cut(clipping_object)
-                except Exception:
-                    warnings.warn(
-                        "clipping error - extrusion may be incorrect",
-                        stacklevel=2,
+        keep: Literal[Keep.TOP, Keep.BOTTOM] = (
+            Keep.TOP if until in [Until.NEXT, Until.PREVIOUS] else Keep.BOTTOM
         )
-        else:
-            base_part = extrusion.intersect(target_object)
-            if isinstance(base_part, ShapeList):
-                extrusion_parts = base_part
-            elif base_part is None:
-                extrusion_parts = ShapeList()
-            else:
-                extrusion_parts = ShapeList([base_part])
-            for clipping_object in clipping_objects:
-                try:
-                    clipped_extrusion = extrusion.intersect(clipping_object)
-                    if clipped_extrusion is not None:
-                        extrusion_parts.append(
-                            clipped_extrusion.solids().sort_by(direction_axis)[0]
-                        )
-                except Exception:
-                    warnings.warn(
-                        "clipping error - extrusion may be incorrect",
-                        stacklevel=2,
-                    )
-            extrusion_shapes = Solid.fuse(*extrusion_parts)
 
-        result = extrusion_shapes.solids().sort_by(direction_axis)[0]
+        # 4: Split the extrusion by the appropriate shell
+        clipped_extrusion = extrusion.split(limit, keep=keep)
 
-        return result
+        # 5: Return the appropriate type
+        if clipped_extrusion is None:
+            raise RuntimeError("Extrusion is None")  # None isn't an option here
+        elif isinstance(clipped_extrusion, Solid):
+            return clipped_extrusion
+        else:
+            #  isinstance(clipped_extrusion, list):
+            return ShapeList(clipped_extrusion).sort_by(
+                Axis(profile.center(), direction)
+            )[0]
 
     @classmethod
     def from_bounding_box(cls, bbox: BoundBox | OrientedBoundBox) -> Solid:
@@ -1106,6 +1143,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
             Solid: Box
         """
         return cls(
+            TopoDS.Solid_s(
                 BRepPrimAPI_MakeBox(
                     plane.to_gp_ax2(),
                     length,
@@ -1113,6 +1151,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
                     height,
                 ).Shape()
             )
+        )
 
     @classmethod
     def make_cone(
@@ -1138,6 +1177,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
             Solid: Full or partial cone
         """
         return cls(
+            TopoDS.Solid_s(
                 BRepPrimAPI_MakeCone(
                     plane.to_gp_ax2(),
                     base_radius,
@@ -1146,6 +1186,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
                     angle * DEG2RAD,
                 ).Shape()
             )
+        )
 
     @classmethod
     def make_cylinder(
@@ -1169,6 +1210,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
             Solid: Full or partial cylinder
         """
         return cls(
+            TopoDS.Solid_s(
                 BRepPrimAPI_MakeCylinder(
                     plane.to_gp_ax2(),
                     radius,
@@ -1176,6 +1218,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
                     angle * DEG2RAD,
                 ).Shape()
             )
+        )
 
     @classmethod
     def make_loft(cls, objs: Iterable[Vertex | Wire], ruled: bool = False) -> Solid:
@@ -1195,7 +1238,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
         Returns:
             Solid: Lofted object
         """
-        return cls(_make_loft(objs, True, ruled))
+        return cls(TopoDS.Solid_s(_make_loft(objs, True, ruled)))
 
     @classmethod
     def make_sphere(
@@ -1221,6 +1264,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
             Solid: sphere
         """
         return cls(
+            TopoDS.Solid_s(
                 BRepPrimAPI_MakeSphere(
                     plane.to_gp_ax2(),
                     radius,
@@ -1229,6 +1273,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
                     angle3 * DEG2RAD,
                 ).Shape()
             )
+        )
 
     @classmethod
     def make_torus(
@@ -1255,6 +1300,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
             Solid: Full or partial torus
         """
         return cls(
+            TopoDS.Solid_s(
                 BRepPrimAPI_MakeTorus(
                     plane.to_gp_ax2(),
                     major_radius,
@@ -1264,6 +1310,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
                     major_angle * DEG2RAD,
                 ).Shape()
             )
+        )
 
     @classmethod
     def make_wedge(
@@ -1293,6 +1340,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
             Solid: wedge
         """
         return cls(
+            TopoDS.Solid_s(
                 BRepPrimAPI_MakeWedge(
                     plane.to_gp_ax2(),
                     delta_x,
@@ -1304,6 +1352,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
                     max_z,
                 ).Solid()
             )
+        )
 
     @classmethod
     def revolve(
@@ -1340,7 +1389,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
             True,
         )
 
-        return cls(revol_builder.Shape())
+        return cls(TopoDS.Solid_s(revol_builder.Shape()))
 
     @classmethod
     def sweep(
@@ -1488,7 +1537,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
         if make_solid:
             builder.MakeSolid()
 
-        return cls(builder.Shape())
+        return cls(TopoDS.Solid_s(builder.Shape()))
 
     @classmethod
     def thicken(
@@ -1544,7 +1593,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
         )
         offset_builder.MakeOffsetShape()
         try:
-            result = Solid(offset_builder.Shape())
+            result = Solid(TopoDS.Solid_s(offset_builder.Shape()))
         except StdFail_NotDone as err:
             raise RuntimeError("Error applying thicken to given surface") from err
 
@@ -1591,7 +1640,7 @@ class Solid(Mixin3D[TopoDS_Solid]):
 
         try:
             draft_angle_builder.Build()
-            result = Solid(draft_angle_builder.Shape())
+            result = Solid(TopoDS.Solid_s(draft_angle_builder.Shape()))
         except StdFail_NotDone as err:
             raise DraftAngleError(
                 "Draft build failed on the given solid.",

src/build123d/topology/two_d.py

@@ -145,6 +145,7 @@ from .shape_core import (
     ShapeList,
     SkipClean,
     _sew_topods_faces,
+    _topods_bool_op,
     _topods_entities,
     _topods_face_normal_at,
     downcast,
@@ -155,7 +156,6 @@ from .utils import (
     _extrude_topods_shape,
     _make_loft,
     _make_topods_face_from_wires,
-    _topods_bool_op,
     find_max_dimension,
 )
 from .zero_d import Vertex
@@ -171,7 +171,6 @@ class Mixin2D(ABC, Shape[TOPODS]):
     """Additional methods to add to Face and Shell class"""
 
     project_to_viewport = Mixin1D.project_to_viewport
-    split = Mixin1D.split
 
     vertices = Mixin1D.vertices
     vertex = Mixin1D.vertex

src/build123d/topology/utils.py

@@ -24,7 +24,6 @@ Key Features:
   - `_make_topods_face_from_wires`: Generates planar faces with optional holes.
 
 - **Boolean Operations**:
-  - `_topods_bool_op`: Generic Boolean operations for TopoDS_Shapes.
   - `new_edges`: Identifies newly created edges from combined shapes.
 
 - **Enhanced Math**:
@@ -282,45 +281,6 @@ def _make_topods_face_from_wires(
     return TopoDS.Face_s(sf_f.Result())
 
 
-def _topods_bool_op(
-    args: Iterable[TopoDS_Shape],
-    tools: Iterable[TopoDS_Shape],
-    operation: BRepAlgoAPI_BooleanOperation | BRepAlgoAPI_Splitter,
-) -> TopoDS_Shape:
-    """Generic boolean operation for TopoDS_Shapes
-
-    Args:
-        args: Iterable[TopoDS_Shape]:
-        tools: Iterable[TopoDS_Shape]:
-        operation: BRepAlgoAPI_BooleanOperation | BRepAlgoAPI_Splitter:
-
-    Returns: TopoDS_Shape
-
-    """
-    args = list(args)
-    tools = list(tools)
-    arg = TopTools_ListOfShape()
-    for obj in args:
-        arg.Append(obj)
-
-    tool = TopTools_ListOfShape()
-    for obj in tools:
-        tool.Append(obj)
-
-    operation.SetArguments(arg)
-    operation.SetTools(tool)
-
-    operation.SetRunParallel(True)
-    operation.Build()
-
-    result = downcast(operation.Shape())
-    # Remove unnecessary TopoDS_Compound around single shape
-    if isinstance(result, TopoDS_Compound):
-        result = unwrap_topods_compound(result, True)
-
-    return result
-
-
 def delta(shapes_one: Iterable[Shape], shapes_two: Iterable[Shape]) -> list[Shape]:
     """Compare the OCCT objects of each list and return the differences"""
     shapes_one = list(shapes_one)

src/build123d/topology/zero_d.py

@@ -68,8 +68,8 @@ from OCP.TopExp import TopExp_Explorer
 from OCP.TopoDS import TopoDS, TopoDS_Shape, TopoDS_Vertex, TopoDS_Edge
 from OCP.gp import gp_Pnt
 from build123d.geometry import Matrix, Vector, VectorLike, Location, Axis, Plane
-
-from .shape_core import Shape, ShapeList, downcast, shapetype
+from build123d.build_enums import Keep
+from .shape_core import Shape, ShapeList, TrimmingTool, downcast, shapetype
 
 
 if TYPE_CHECKING:  # pragma: no cover
@@ -161,7 +161,7 @@ class Vertex(Shape[TopoDS_Vertex]):
 
         shape_type = shapetype(obj)
         # NB downcast is needed to handle TopoDS_Shape types
-        return constructor_lut[shape_type](downcast(obj))
+        return constructor_lut[shape_type](TopoDS.Vertex_s(obj))
 
     @classmethod
     def extrude(cls, obj: Shape, direction: VectorLike) -> Vertex:
@@ -312,6 +312,10 @@ class Vertex(Shape[TopoDS_Vertex]):
         """The center of a vertex is itself!"""
         return Vector(self)
 
+    def split(self, tool: TrimmingTool, keep: Keep = Keep.TOP):
+        """split - not implemented"""
+        raise NotImplementedError("Vertices cannot be split.")
+
     def to_tuple(self) -> tuple[float, float, float]:
         """Return vertex as three tuple of floats"""
         warnings.warn(

tests/test_build_part.py

@@ -330,6 +330,60 @@ class TestExtrude(unittest.TestCase):
             extrude(until=Until.NEXT)
         self.assertAlmostEqual(test.part.volume, 10**3 - 8**3 + 1**2 * 8, 5)
 
+    def test_extrude_until2(self):
+        target = Box(10, 5, 5) - Pos(X=2.5) * Cylinder(0.5, 5)
+        pln = Plane((7, 0, 7), z_dir=(-1, 0, -1))
+        profile = (pln * Circle(1)).face()
+        extrusion = extrude(profile, dir=pln.z_dir, until=Until.NEXT, target=target)
+        self.assertLess(extrusion.bounding_box().min.Z, 2.5)
+
+    def test_extrude_until3(self):
+        with BuildPart() as p:
+            with BuildSketch(Plane.XZ):
+                Rectangle(8, 8, align=Align.MIN)
+                with Locations((1, 1)):
+                    Rectangle(7, 7, align=Align.MIN, mode=Mode.SUBTRACT)
+            extrude(amount=2, both=True)
+            with BuildSketch(
+                Plane((-2, 0, -2), x_dir=(0, 1, 0), z_dir=(1, 0, 1))
+            ) as profile:
+                Rectangle(4, 1)
+            extrude(until=Until.NEXT)
+
+        self.assertAlmostEqual(p.part.volume, 72.313, 2)
+
+    def test_extrude_until_errors(self):
+        with self.assertRaises(ValueError):
+            extrude(
+                Rectangle(1, 1),
+                until=Until.NEXT,
+                dir=(0, 0, 1),
+                target=Pos(Z=-10) * Box(1, 1, 1),
+            )
+
+    def test_extrude_until_invalid_sewn_shape(self):
+        profile = Face.make_rect(1, 1)
+        target = Box(2, 2, 2)
+        direction = Vector(0, 0, 1)
+
+        bad_shape = Box(1, 1, 1).wrapped  # not a Face or Shell → forces RuntimeError
+
+        with patch(
+            "build123d.topology.three_d.get_top_level_topods_shapes",
+            return_value=[bad_shape],
+        ):
+            with self.assertRaises(RuntimeError):
+                extrude(profile, dir=direction, until=Until.NEXT, target=target)
+
+    def test_extrude_until_invalid_split(self):
+        profile = Face.make_rect(1, 1)
+        target = Box(2, 2, 2)
+        direction = Vector(0, 0, 1)
+
+        with patch("build123d.topology.three_d.Solid.split", return_value=None):
+            with self.assertRaises(RuntimeError):
+                extrude(profile, dir=direction, until=Until.NEXT, target=target)
+
     def test_extrude_face(self):
         with BuildPart(Plane.XZ) as box:
             with BuildSketch(Plane.XZ, mode=Mode.PRIVATE) as square: