guidelines_final.json

{
  "guideline_id": "D001",
  "category": "DFM",
  "topic": "Wall Thickness",

  "evaluation_criteria": [
    "Verify nominal wall thickness follows recommended range for process (injection molding: 1.0–3.0 mm; die casting: 2.0–4.0 mm; machining: ≥1.0 mm).",
    "Verify thickness transitions do not exceed a 30–50% sudden change to avoid sink/warp.",
    "Verify ribs and bosses follow wall-thickness ratio rules (ribs ≤ 0.6 × nominal wall).",
    "Verify uniformity across adjacent regions (variation ≤ ±10%).",
    "Verify long unsupported walls meet stiffness requirement given thickness and height."
  ],

  "user_questions": [
    "What is the process for this part? (injection_molding, die_casting, machining)",
    "What is the nominal wall thickness in the primary regions (mm)?",
    "What is the maximum wall-thickness variation between adjacent areas (mm)?",
    "What is the rib or boss thickness relative to the nominal wall (mm)?",
    "What is the maximum unsupported wall height (mm)?"
  ],

  "expected_answers": [
    "Injection molding requires 1.0–3.0 mm; die casting 2.0–4.0 mm; machining ≥1.0 mm.",
    "Nominal wall thickness must be within the allowed range for the chosen process.",
    "Thickness variation must be ≤ ±10% of nominal wall thickness.",
    "Rib/boss thickness must be ≤ 0.6 × nominal wall thickness.",
    "Unsupported wall must satisfy stiffness rule: thickness ≥ (height / 20)."
  ],

  "pass_fail_logic": {
    "process_wall_range_check": "FAIL if nominal_wall not within allowed_range_for_process.",
    "thickness_uniformity_check": "FAIL if variation > (0.1 × nominal_wall).",
    "rib_boss_ratio_check": "FAIL if rib_or_boss_thickness > (0.6 × nominal_wall).",
    "transition_change_check": "FAIL if sudden_thickness_change > 0.5 × nominal_wall.",
    "stiffness_check": "FAIL if nominal_wall < (unsupported_height / 20)."
  },

  "image_features_needed": [
    "Extract wall regions and compute thickness.",
    "Identify ribs and bosses and measure relative thickness.",
    "Detect wall transitions between adjacent surfaces.",
    "Segment unsupported wall spans and measure height/length.",
    "Detect process-related geometry (ejection features signify molding)."
  ]
}

{
  "guideline_id": "D002",
  "category": "DFM",
  "topic": "Draft Angle",

  "evaluation_criteria": [
    "Verify minimum draft angle meets process requirements (injection molding: interior ≥1°, exterior ≥0.5°; die casting: ≥2°; sheet metal: ≥0° unless formed).",
    "Verify deep features (depth/thickness > 4×) include additional draft (add +0.5° to +1°).",
    "Verify textured surfaces include texture-compensation draft (add +1° per 0.025 mm texture depth).",
    "Verify no negative draft exists unless explicitly required, as it indicates an undercut.",
    "Verify draft direction aligns consistently with the parting line."
  ],

  "user_questions": [
    "What manufacturing process is used? (injection_molding, die_casting, sheet_metal, machining)",
    "What is the measured draft angle on the primary vertical interior walls (°)?",
    "What is the measured draft angle on exterior vertical walls (°)?",
    "What is the depth of the feature with the smallest draft angle (mm)?",
    "Is the surface textured? If yes, provide texture depth (mm)."
  ],

  "expected_answers": [
    "Injection molding requires: interior ≥1°, exterior ≥0.5°; die casting requires ≥2°; sheet metal requires ≥0° unless formed.",
    "Interior draft must meet or exceed the required minimum for the chosen process.",
    "Exterior draft must meet or exceed the required minimum for the chosen process.",
    "Deep features must add +0.5° to +1° of draft when depth/thickness > 4×.",
    "Textured surfaces must add +1° of draft per 0.025 mm texture depth."
  ],

  "pass_fail_logic": {
    "interior_draft_check": "FAIL if process='injection_molding' AND interior_draft < 1.0.",
    "exterior_draft_check": "FAIL if process='injection_molding' AND exterior_draft < 0.5.",
    "die_cast_draft_check": "FAIL if process='die_casting' AND (interior_draft < 2.0 OR exterior_draft < 2.0).",
    "deep_feature_check": "FAIL if (feature_depth/nominal_wall > 4) AND draft < (base_required_draft + 0.5).",
    "texture_compensation_check": "FAIL if draft < (base_required_draft + texture_depth/0.025)."
  },

  "image_features_needed": [
    "Detect vertical faces aligned with pull direction.",
    "Compute draft angle relative to parting line.",
    "Identify interior vs exterior surfaces.",
    "Measure feature depth vs thickness to detect deep cores.",
    "Detect textured regions and estimate texture depth if visible."
  ]
}

{
  "guideline_id": "D003",
  "category": "DFM",
  "topic": "Fillet Radius",

  "evaluation_criteria": [
    "Verify internal fillets meet minimum radius requirements for process (injection molding ≥ 0.5 × wall thickness; die casting ≥ 1.0 mm; machining ≥ tool radius).",
    "Verify external fillets follow recommended minimum (≥ 0.25 × wall thickness).",
    "Verify no sharp internal corners exist (sharp corners cause stress concentration and flow hesitation).",
    "Verify intersecting rib/fillet blends follow recommended geometry (rib-root fillet ≥ 0.25 × rib thickness).",
    "Verify fillet transitions are smooth and do not violate mold release or tool path constraints."
  ],

  "user_questions": [
    "What is the manufacturing process? (injection_molding, die_casting, machining)",
    "What is the wall thickness near the fillet location (mm)?",
    "What is the internal fillet radius (mm)?",
    "What is the external fillet radius (mm)?",
    "What is the fillet radius at rib roots (mm)?"
  ],

  "expected_answers": [
    "Injection molding internal fillet radius must be ≥ 0.5 × wall thickness.",
    "External fillet radius must be ≥ 0.25 × wall thickness.",
    "Machining fillet radius must be ≥ 1× tool radius used for internal corners.",
    "Die casting fillet radius must be ≥ 1.0 mm for all internal corners.",
    "Rib-root fillet radius must be ≥ 0.25 × rib thickness."
  ],

  "pass_fail_logic": {
    "internal_fillet_check": "FAIL if process='injection_molding' AND internal_radius < (0.5 × wall).",
    "external_fillet_check": "FAIL if external_radius < (0.25 × wall).",
    "machining_tool_check": "FAIL if process='machining' AND internal_radius < tool_radius.",
    "die_cast_fillet_check": "FAIL if process='die_casting' AND internal_radius < 1.0.",
    "rib_root_check": "FAIL if rib_root_radius < (0.25 × rib_thickness)."
  },

  "image_features_needed": [
    "Detect internal and external corners.",
    "Extract fillet curvature and measure radius using contour curvature.",
    "Identify ribs and measure rib-root fillet radius.",
    "Segment regions by wall thickness to compute required radius.",
    "Detect sharp corners and classify as non-fillet geometry."
  ]
}

{
  "guideline_id": "D004",
  "category": "DFM",
  "topic": "Rib Design",

  "evaluation_criteria": [
    "Verify rib thickness does not exceed 0.5 × adjacent wall thickness (to avoid sink marks in molding).",
    "Verify rib height is ≤ 3 × rib thickness (to avoid weak/slender ribs).",
    "Verify rib draft angle ≥ 0.5° per side (injection molding) to allow clean ejection.",
    "Verify rib-root fillet radius ≥ 0.25 × rib thickness.",
    "Verify spacing between ribs ≥ 2 × rib thickness (to maintain uniform flow and cooling)."
  ],

  "user_questions": [
    "What is the adjacent wall thickness where the rib is attached (mm)?",
    "What is the rib thickness (mm)?",
    "What is the rib height (mm)?",
    "What is the draft angle on the rib side walls (degrees)?",
    "What is the fillet radius at the rib root (mm)?"
  ],

  "expected_answers": [
    "Rib thickness must be ≤ 0.5 × wall thickness for injection molding.",
    "Rib height must be ≤ 3 × rib thickness.",
    "Draft angle must be ≥ 0.5° per side for ribs.",
    "Rib-root fillet radius must be ≥ 0.25 × rib thickness.",
    "Rib spacing must be ≥ 2 × rib thickness."
  ],

  "pass_fail_logic": {
    "rib_thickness_check": "FAIL if rib_thickness > (0.5 × wall_thickness).",
    "rib_height_check": "FAIL if rib_height > (3 × rib_thickness).",
    "rib_draft_check": "FAIL if draft_angle < 0.5.",
    "rib_root_fillet_check": "FAIL if fillet_radius < (0.25 × rib_thickness).",
    "rib_spacing_check": "FAIL if spacing < (2 × rib_thickness)."
  },

  "image_features_needed": [
    "Detect rib geometry (thin vertical wall-like features).",
    "Measure rib thickness and height from side profiles.",
    "Identify root fillets and measure radius via curvature extraction.",
    "Detect rib spacing by identifying repetitive thin features.",
    "Detect draft angle by analyzing rib wall taper relative to mold pull direction."
  ]
}

{
  "guideline_id": "D005",
  "category": "DFM",
  "topic": "Boss Design",

  "evaluation_criteria": [
    "Verify outer boss diameter is between 2.0 × and 2.5 × the screw/pin diameter (industry standard for molded bosses).",
    "Verify boss wall thickness is ≤ 0.6 × the nominal wall thickness to prevent sink marks.",
    "Verify boss height is ≤ 3 × the outer boss diameter to prevent buckling.",
    "Verify draft angle on boss walls is ≥ 0.5° for clean ejection.",
    "Verify base fillet radius ≥ 0.25 × boss wall thickness for stress reduction."
  ],

  "user_questions": [
    "What is the screw or pin diameter intended for the boss (mm)?",
    "What is the outer boss diameter (mm)?",
    "What is the nominal part wall thickness (mm)?",
    "What is the boss height (mm)?",
    "What is the draft angle on the boss outer wall (degrees)?",
    "What is the fillet radius at the boss base (mm)?"
  ],

  "expected_answers": [
    "Outer boss diameter must be between 2.0 × and 2.5 × the screw/pin diameter.",
    "Boss wall thickness must be ≤ 0.6 × nominal wall thickness.",
    "Boss height must be ≤ 3 × outer boss diameter.",
    "Draft angle must be ≥ 0.5° for molded bosses.",
    "Boss base fillet radius must be ≥ 0.25 × boss wall thickness."
  ],

  "pass_fail_logic": {
    "outer_diameter_check": "FAIL if outer_diameter < (2.0 × screw_diam) OR outer_diameter > (2.5 × screw_diam).",
    "wall_thickness_check": "FAIL if boss_wall_thickness > (0.6 × nominal_wall_thickness).",
    "boss_height_check": "FAIL if boss_height > (3 × outer_diameter).",
    "draft_angle_check": "FAIL if draft_angle < 0.5.",
    "fillet_radius_check": "FAIL if fillet_radius < (0.25 × boss_wall_thickness)."
  },

  "image_features_needed": [
    "Detect cylindrical features (bosses) in the model.",
    "Measure boss outer diameter and internal core diameter using circular feature extraction.",
    "Measure boss wall thickness via diameter difference.",
    "Determine boss height from vertical extrusion length.",
    "Detect and measure draft angle by analyzing taper of cylindrical walls.",
    "Measure fillet radius at boss base using curvature analysis."
  ]
}

{
  "guideline_id": "D006",
  "category": "DFM",
  "topic": "Material Shrinkage Compensation",

  "evaluation_criteria": [
    "Verify selected material shrink rate matches the manufacturing process (injection molding, die casting, blow molding).",
    "Verify dimensional compensation added in the CAD model equals material shrink rate × nominal dimension.",
    "Verify shrink direction is aligned with mold flow and part geometry.",
    "Verify thick-to-thin transitions are uniform to prevent differential shrink.",
    "Verify ribs, bosses, and reinforcing features meet shrink-sensitive design rules (uniform wall thickness, proper fillets, supported geometry)."
  ],

  "user_questions": [
    "What is the material used (e.g., ABS, Nylon 6/6, PP, PBT, HDPE, Aluminum A380)?",
    "What is the material shrink rate (%) recommended by the manufacturer?",
    "What is the nominal dimension requiring shrink compensation (mm)?",
    "Is the shrink direction aligned with the mold flow direction? (yes/no)",
    "Does the part contain thick-to-thin transitions? If yes, provide the thickest and thinnest wall values (mm)."
  ],

  "expected_answers": [
    "Shrink rate must match the process: Injection molding typical ranges: ABS 0.4–0.7%, Nylon 6/6 1.0–2.0%, PP 1.5–2.5%, PBT 1.2–2.0%, HDPE 1.5–3.0%; Die casting aluminum A380: 0.6%.",
    "CAD dimensional compensation must equal: final_dimension = nominal_dimension × (1 + shrink_rate).",
    "Shrink direction must match mold flow direction defined in the manufacturing plan.",
    "Thick-to-thin wall transitions must maintain a ratio ≤ 1.5:1 to prevent differential shrink.",
    "Ribs, bosses, and similar features must follow shrink-safe rules: rib thickness ≤ 0.6 × wall, boss thickness ≤ 0.6 × wall, fillet radii > 0.25 × wall."
  ],

  "pass_fail_logic": {
    "material_shrink_rate_check": "FAIL if shrink_rate not in material_shrink_table[material].",
    "dimensional_compensation_check": "FAIL if compensated_dimension != nominal_dimension × (1 + shrink_rate).",
    "shrink_direction_check": "FAIL if shrink_direction != mold_flow_direction.",
    "wall_ratio_check": "FAIL if (thick_wall / thin_wall) > 1.5.",
    "feature_shrink_safety_check": "FAIL if ribs or bosses violate thickness or fillet rules."
  },

  "image_features_needed": [
    "Measure nominal dimensions to check shrink-compensated geometry.",
    "Detect thick and thin wall regions from sectional analysis.",
    "Identify ribs, bosses, gussets and classify feature types.",
    "Measure wall thickness distribution to detect shrink-risk areas.",
    "Extract mold-flow direction cues (gate orientation, flow channels) when visible."
  ]
}

{
  "guideline_id": "D007",
  "category": "DFM",
  "topic": "Tool Access & Manufacturability",

  "evaluation_criteria": [
    "Verify all machining or molding tool paths have at least the minimum required approach clearance.",
    "Verify no features require undercut tooling unless explicitly planned (side-actions, lifters, collapsible cores).",
    "Verify minimum cutter diameter or mold pin diameter can physically access the feature.",
    "Verify screw, bolt, or fastener access zones have adequate tool clearance (driver length, diameter).",
    "Verify no enclosed geometry prevents ejection, extraction, or machining tool withdrawal."
  ],

  "user_questions": [
    "What is the smallest tool (cutter, drill, or mold pin) that will be used to create the feature? Provide diameter in mm.",
    "What is the minimum approach clearance available around the feature (mm)?",
    "Does this geometry require undercuts? If yes, specify type: side-action, lifter, collapsible core, manual insert.",
    "What fastener or assembly tool needs access to this region? Provide driver type (Phillips, Torx, Hex) and required clearance (mm).",
    "Is the feature enclosed or partially enclosed such that tool or ejector withdrawal may be obstructed? (yes/no)"
  ],

  "expected_answers": [
    "Feature must allow a tool larger than or equal to the minimum cutter/pin diameter: milling ≥ 2 mm, drilling ≥ 1 mm, mold pins ≥ 0.8 mm.",
    "Approach clearance must be ≥ tool_diameter × 1.5 for safe entry (e.g., 2 mm tool → 3 mm clearance).",
    "If an undercut exists, valid methods include: side-action, lifter, collapsible core; otherwise geometry must be redesigned.",
    "Fastener tools require: Phillips/Torx drivers ≥ 40 mm length clearance and ≥ 1.5 × driver diameter radial clearance.",
    "Enclosed geometry must allow withdrawal angle ≥ 2° or have an ejection strategy (pins, sleeves, lifters)."
  ],

  "pass_fail_logic": {
    "tool_diameter_access_check": "FAIL if feature_width < minimum_tool_diameter.",
    "approach_clearance_check": "FAIL if approach_clearance < (tool_diameter × 1.5).",
    "undercut_check": "FAIL if undercut_present AND undercut_solution NOT IN ['side-action','lifter','collapsible core','manual insert'].",
    "fastener_access_check": "FAIL if driver_clearance < (1.5 × driver_diameter) OR axial_clearance < 40 mm.",
    "withdrawal_obstruction_check": "FAIL if enclosed_geometry == true AND withdrawal_angle < 2° AND no_ejector_strategy == true."
  },

  "image_features_needed": [
    "Identify narrow channels, pockets, or recesses affecting tool access.",
    "Measure minimum feature width for cutter or pin entry.",
    "Detect potential undercut geometry from shadow or curvature patterns.",
    "Identify driver/tool approach paths to fastener features.",
    "Detect enclosed or partially enclosed volumes limiting tool withdrawal."
  ]
}

{
  "guideline_id": "D008",
  "category": "DFM",
  "topic": "Undercut Avoidance & Parting Line Design",

  "evaluation_criteria": [
    "Verify part geometry can be released from the mold without requiring undercuts unless intentionally designed.",
    "Verify all faces are manufacturable with a two-plate mold unless additional actions are explicitly planned.",
    "Verify parting line placement results in manufacturable draft on all vertical faces.",
    "Verify no geometry traps steel (internal pockets with no pull direction).",
    "Verify manual inserts, side-actions, or lifters are only used when unavoidable and are located with proper clearance."
  ],

  "user_questions": [
    "Does the part contain any recessed or hooked geometry that blocks straight-pull release? (yes/no)",
    "What is the draft angle on vertical walls adjacent to the suspected undercut region (degrees)?",
    "Is there a required undercut? If yes, specify the type: side-action, lifter, collapsible core, manual insert.",
    "What is the planned parting line direction and location? Provide the vector or description.",
    "Do any internal pockets or cavities lack a clear pull direction? (yes/no)"
  ],

  "expected_answers": [
    "Straight-pull manufacturability requires **0 undercuts** for a standard 2-plate mold.",
    "Adjacent vertical walls must have ≥ **1° draft (minimum)**; recommended 2–3° for most plastics.",
    "If an undercut exists, acceptable solutions: ['side-action','lifter','collapsible core','manual insert']; unlisted solutions = NOT acceptable.",
    "Parting line must allow every face to pull in a single direction with required draft.",
    "Internal pockets must have a pull direction OR be opened via a side-action; pockets with **no pull direction** violate manufacturability."
  ],

  "pass_fail_logic": {
    "undercut_presence_check": "FAIL if undercut == true AND undercut_solution NOT IN ['side-action','lifter','collapsible core','manual insert'].",
    "draft_angle_check": "FAIL if draft_angle < 1.",
    "parting_line_check": "FAIL if any face cannot be drafted along chosen parting line.",
    "steel_trap_check": "FAIL if steel_trap_detected == true.",
    "internal_pocket_check": "FAIL if internal_pocket_without_pull == true."
  },

  "image_features_needed": [
    "Detect hooked or recessed geometry indicating potential undercuts.",
    "Identify parting line candidates based on geometry silhouette.",
    "Measure draft angles by comparing wall direction to mold pull axis.",
    "Detect steel traps by identifying fully enclosed wall contours.",
    "Isolate internal cavities and determine if they have visible pull direction."
  ]
}

{
  "guideline_id": "D009",
  "category": "DFM",
  "topic": "Minimum Feature Size & Manufacturable Geometry",

  "evaluation_criteria": [
    "Verify all features meet the minimum manufacturable thickness or diameter for the intended process.",
    "Verify small slots, holes, ribs, and text features do not fall below tooling or machining limits.",
    "Verify depth-to-width ratios for cavities, pockets, or slots are within process limits.",
    "Verify fillet radii at small features meet minimum radius requirements to avoid stress or tooling breakage.",
    "Verify sharp corners or micro-features are replaced with manufacturing-appropriate radii or draft."
  ],

  "user_questions": [
    "What is the smallest wall thickness or feature width in the part (mm)?",
    "What is the smallest hole or pin diameter used (mm)?",
    "What is the deepest pocket or cavity depth and its minimum width (depth and width in mm)?",
    "What is the minimum fillet radius used in small interior corners (mm)?",
    "Does any geometry include sharp corners, embossed/engraved text, or micro-details? If yes, specify feature size (mm)."
  ],

  "expected_answers": [
    "Minimum wall thickness must meet process requirements: Injection molding: ABS ≥ 1.2 mm, Nylon ≥ 0.8 mm, PP ≥ 1.0 mm, PC ≥ 1.0 mm; Machining: ≥ 0.5 mm; Die casting: ≥ 1.0–1.5 mm.",
    "Minimum hole diameter must be ≥ tooling limits: molded pin ≥ 0.8 mm, drilled hole ≥ 1.0 mm, machined endmill ≥ 2 mm typical.",
    "Depth-to-width ratio must be ≤ 3:1 for milling and ≤ 2:1 for molding; deeper features require draft or special tooling.",
    "Minimum fillet radius must be ≥ 0.25 mm in interior corners to avoid tool breakage or molded stress concentration.",
    "Sharp corners and text features must follow minimum size rules: text stroke ≥ 0.4 mm (molded), engraving depth ≥ 0.2 mm, no zero-radius corners."
  ],

  "pass_fail_logic": {
    "minimum_feature_size_check": "FAIL if smallest_feature < min_required_for_process.",
    "hole_diameter_check": "FAIL if hole_diameter < min_tool_diameter.",
    "aspect_ratio_check": "FAIL if (depth / width) > max_allowed_aspect_ratio_for_process.",
    "fillet_radius_check": "FAIL if fillet_radius < 0.25 mm.",
    "sharp_features_check": "FAIL if sharp_corner_detected AND radius == 0 AND no justification provided."
  },

  "image_features_needed": [
    "Detect the smallest visible features (thin walls, slots, ribs, text).",
    "Measure feature width and thickness using image-based dimension extraction.",
    "Identify small holes or pin-sized features and measure diameters.",
    "Detect deep cavities or pockets requiring aspect ratio evaluation.",
    "Detect sharp corners or insufficient radii in high-stress or micro-detail areas."
  ]
}

{
  "guideline_id": "D010",
  "category": "DFM",
  "topic": "Assembly Direction & Self-Locating Features",

  "evaluation_criteria": [
    "Verify the assembly direction is linear (single-axis) and does not require rotation, twisting, or multi-axis insertion.",
    "Verify alignment and self-locating features (tabs, chamfers, bosses) support repeatable assembly.",
    "Verify insertion clearance fits standard assembly tolerances (typically 0.1–0.3 mm per side for plastics).",
    "Verify no geometry creates jamming, interference, or binding during linear insertion.",
    "Verify fastener, snap-fit, or press-fit elements are accessible along the same assembly axis."
  ],

  "user_questions": [
    "What is the intended assembly direction for this part relative to its mating component? (Provide axis such as +Z, -X, etc.)",
    "What is the clearance between mating features during insertion (mm)?",
    "Does the part include self-locating features such as chamfers, tapered bosses, or alignment tabs? If yes, describe them.",
    "Are there any points in the assembly where insertion force significantly increases or binding might occur? (yes/no)",
    "Are fasteners, snaps, or press-fit features aligned with the main assembly direction? (yes/no)"
  ],

  "expected_answers": [
    "Valid assembly directions include any single linear axis: ['+X','-X','+Y','-Y','+Z','-Z'].",
    "Insertion clearance must be ≥ 0.1 mm (tight fit), 0.2–0.3 mm (standard fit), or >0.3 mm (loose fit).",
    "Self-locating features must include at least one of: chamfer ≥ 0.5 mm, lead-in angle ≥ 10°, tapered boss with 1–2° draft.",
    "Binding locations must be eliminated; acceptable answer: 'No binding points identified'.",
    "Fasteners or snaps must be accessible from the assembly direction; otherwise redesign is required."
  ],

  "pass_fail_logic": {
    "assembly_axis_check": "FAIL if assembly_direction NOT IN ['+X','-X','+Y','-Y','+Z','-Z'].",
    "insertion_clearance_check": "FAIL if clearance < 0.1 mm.",
    "self_locating_feature_check": "FAIL if no self_locating_features_present.",
    "binding_check": "FAIL if binding_detected == true.",
    "fastener_alignment_check": "FAIL if fasteners_or_snaps_not_accessible_from_assembly_direction == true."
  },

  "image_features_needed": [
    "Identify assembly mating faces and highlight insertion axis.",
    "Measure clearance gaps between mating surfaces and features.",
    "Detect chamfers, tapers, alignment tabs, and bosses used for self-location.",
    "Identify potential binding points such as misaligned walls or angled surfaces.",
    "Detect orientation and accessibility of fasteners or snap-fit features."
  ]
}

{
  "guideline_id": "G011",
  "category": "GDT",
  "topic": "True Position Tolerance",

  "evaluation_criteria": [
    "Verify the true position tolerance (diameter zone) is appropriate for the hole/pin size and functional requirement.",
    "Verify the datums referenced in the position callout exist and are stable, orthogonal, and fully constrained.",
    "Verify hole center location deviation does not exceed allowed tolerance zone.",
    "Verify hole orientation is aligned with the datum axis when required.",
    "Verify pattern-of-holes share consistent datum reference and equalized tolerance distribution."
  ],

  "user_questions": [
    "What is the hole diameter (mm)?",
    "What is the specified true position tolerance (mm or mm at MMC)?",
    "What are the referenced datums in the callout (e.g., A|B|C)?",
    "What is the measured deviation of the hole center from nominal in X and Y (mm)?",
    "Is this hole part of a hole pattern? If yes, how many holes and what spacing tolerance is required?"
  ],

  "expected_answers": [
    "True position tolerance must follow typical ranges: small holes (≤5 mm): 0.05–0.15 mm; medium (5–12 mm): 0.1–0.25 mm; large (>12 mm): 0.2–0.5 mm.",
    "Position tolerance at MMC increases allowable deviation by the bonus tolerance: tol = specified_tol + (MMC - actual_size).",
    "Datums must include: A (primary planar surface), B (secondary orthogonal surface), C (third orthogonal surface).",
    "Hole center deviation must satisfy: sqrt(dx² + dy²) ≤ tolerance_diameter / 2.",
    "Hole patterns must maintain equal spacing with spacing tolerance ≤ 0.1–0.3 mm depending on functional requirement."
  ],

  "pass_fail_logic": {
    "tolerance_range_check": "FAIL if position_tolerance < min_allowed_for_size OR > max_allowed_for_size.",
    "datum_validity_check": "FAIL if datums_missing OR datums_non_orthogonal OR datums_unstable.",
    "center_location_check": "FAIL if sqrt(dx*dx + dy*dy) > (tolerance_zone_diameter / 2).",
    "orientation_check": "FAIL if required_orientation AND orientation_error > limit.",
    "pattern_consistency_check": "FAIL if hole_spacing_error > spacing_tolerance."
  },

  "image_features_needed": [
    "Detect hole centers using edge or centroid analysis.",
    "Measure deviation between nominal and actual center positions.",
    "Identify datum planes and axes visible in the drawing or model.",
    "Measure hole diameter and verify MMC/LMC conditions.",
    "Detect hole patterns and evaluate uniform spacing and alignment."
  ]
}

{
  "guideline_id": "G012",
  "category": "GDT",
  "topic": "Flatness",

  "evaluation_criteria": [
    "Verify the flatness tolerance is appropriate for the surface size and functional requirement.",
    "Verify the measured surface variation (peak-to-valley) does not exceed the flatness tolerance.",
    "Verify no warping, bowing, or twisting exceeds acceptable deformation levels.",
    "Verify machining, molding, or casting process can realistically produce the specified flatness.",
    "Verify the surface does not rely on external datums; flatness must be self-contained (datum-free tolerance)."
  ],

  "user_questions": [
    "What is the flatness tolerance specified for this surface (mm)?",
    "What is the measured peak-to-valley deviation across the surface (mm)?",
    "What is the approximate surface size (length × width in mm)?",
    "What is the material and manufacturing process for this part?",
    "Does the surface show any visible warping, twisting, or bowing? (yes/no)"
  ],

  "expected_answers": [
    "Flatness tolerance should follow typical limits: small surfaces (<50 mm): 0.02–0.05 mm; medium (50–150 mm): 0.05–0.15 mm; large (>150 mm): 0.1–0.3 mm.",
    "Measured surface deviation must satisfy: peak_to_valley ≤ flatness_tolerance.",
    "Larger surfaces require looser flatness: long plates >200 mm generally ≥ 0.1 mm.",
    "Process limits: machining can achieve 0.01–0.05 mm; die casting typically 0.1–0.3 mm; molding 0.1–0.5 mm depending on geometry.",
    "Flatness is free-state: no datums should be referenced in the flatness callout."
  ],

  "pass_fail_logic": {
    "tolerance_feasibility_check": "FAIL if specified_flatness < minimum_process_capability.",
    "deviation_check": "FAIL if measured_peak_to_valley > flatness_tolerance.",
    "warping_check": "FAIL if warping_detected AND warping_amount > flatness_tolerance.",
    "surface_size_reasonableness_check": "FAIL if surface_size > 200 mm AND flatness_tolerance < 0.05 mm (unrealistic).",
    "datum_reference_check": "FAIL if flatness_callout_incorrectly_references_datum == true."
  },

  "image_features_needed": [
    "Detect high and low points on the surface using shading or gradient mapping.",
    "Measure effective surface curvature or deviation.",
    "Identify signs of bowing or twisting from silhouette or edge contour.",
    "Estimate size of the evaluated surface from image scale cues.",
    "Detect datum references on drawings to ensure flatness is datum-free."
  ]
}

{
  "guideline_id": "G013",
  "category": "GDT",
  "topic": "Parallelism",

  "evaluation_criteria": [
    "Verify the referenced datum plane or axis is valid, stable, and orthogonal to other datums.",
    "Verify the surface or axis being evaluated stays within the parallelism tolerance zone relative to the datum.",
    "Verify parallelism tolerance is proportional to feature size and functional requirement.",
    "Verify the manufacturing process can achieve the specified parallelism at the chosen tolerance.",
    "Verify parallel surfaces do not show twist, taper, bow, or angular deviation exceeding tolerance."
  ],

  "user_questions": [
    "What is the parallelism tolerance specified (mm or degrees)?",
    "What datum (A/B/C) is referenced for the parallelism requirement?",
    "What is the measured angular deviation between the evaluated surface and its datum (degrees)?",
    "What is the measured peak-to-valley separation between the two surfaces (mm)?",
    "What is the manufacturing process used (machining, grinding, molding, casting)?"
  ],

  "expected_answers": [
    "Parallelism tolerance ranges: precision machining: 0.01–0.05 mm; standard machining: 0.05–0.1 mm; molded parts: 0.1–0.3 mm; cast parts: 0.2–0.5 mm.",
    "A valid datum must be planar (e.g., A) or cylindrical (e.g., axis B) and must be stable and fully constrained.",
    "Angular deviation must be ≤ 0.1° for precision fits, ≤ 0.3° for general fits, ≤ 1° for molded features.",
    "Peak-to-valley variation must be ≤ the parallelism tolerance zone.",
    "Process capability: grinding: 0.005 mm, machining: 0.02–0.1 mm, molding: 0.1–0.3 mm, casting: 0.2–0.5 mm."
  ],

  "pass_fail_logic": {
    "datum_validity_check": "FAIL if datum_invalid OR datum_not_flat OR datum_not_stable.",
    "angular_deviation_check": "FAIL if angular_deviation > allowed_angular_limit.",
    "zone_variation_check": "FAIL if measured_PV > parallelism_tolerance.",
    "process_capability_check": "FAIL if parallelism_tolerance < minimum_process_capability.",
    "twist_or_bow_check": "FAIL if taper, bow, or twist detected beyond tolerance."
  },

  "image_features_needed": [
    "Identify datum plane or axis from geometry or drawing.",
    "Detect angular deviation between surfaces using edge direction analysis.",
    "Measure surface separation or PV variation using contour mapping.",
    "Identify twist or taper through silhouette comparison.",
    "Infer process-related defects (warp, bend) from shading gradients or curvature."
  ]
}

{
  "guideline_id": "G014",
  "category": "GDT",
  "topic": "Perpendicularity",

  "evaluation_criteria": [
    "Verify the referenced datum (plane or axis) is valid, orthogonal, and stable.",
    "Verify the evaluated surface or axis stays within the perpendicularity tolerance zone relative to the datum.",
    "Verify the perpendicularity tolerance is appropriate for the functional requirement (press fits, bearings, alignment surfaces).",
    "Verify measured angular deviation does not exceed allowable limits for the manufacturing process.",
    "Verify no bow, twist, or taper causes out-of-square conditions exceeding tolerance."
  ],

  "user_questions": [
    "What is the perpendicularity tolerance specified for this feature (mm or degrees)?",
    "Which datum is referenced for the perpendicularity requirement (A/B/C)?",
    "What is the measured angular deviation from 90° (degrees)?",
    "What is the maximum measured deviation between the evaluated feature and the datum (mm)?",
    "What is the manufacturing process for the feature (machining, grinding, molding, casting)?"
  ],

  "expected_answers": [
    "Typical perpendicularity tolerance ranges: precision machining: 0.01–0.05 mm; standard machining: 0.05–0.1 mm; molding: 0.1–0.3 mm; casting: 0.2–0.6 mm.",
    "Valid datums: planar A, planar B, or cylindrical axis C; must be fully constrained and orthogonal where required.",
    "Measured angular deviation must be ≤ 0.1° for precision fits, ≤ 0.3° for standard fits, ≤ 1° for molded/cast surfaces.",
    "Linear deviation at the measured height must be ≤ the perpendicularity tolerance zone.",
    "Twist, bow, or out-of-square distortion must be ≤ tolerance or part fails functional alignment."
  ],

  "pass_fail_logic": {
    "datum_validity_check": "FAIL if datum does not exist, is unstable, or is not orthogonal to required reference datums.",
    "angular_deviation_check": "FAIL if angular_deviation > allowed_process_limit.",
    "tolerance_zone_check": "FAIL if linear_deviation > perpendicularity_tolerance.",
    "process_capability_check": "FAIL if tolerance < minimum_capability_for_process.",
    "warp_or_twist_check": "FAIL if twist/bow/taper exceeds perpendicularity tolerance."
  },

  "image_features_needed": [
    "Detect datum plane or axis from drawing or geometry.",
    "Measure angle between evaluated surface and datum using edge-orientation extraction.",
    "Measure max deviation across surface height for perpendicularity zone verification.",
    "Detect twist, bow, or taper using silhouette curvature.",
    "Identify machining or molding features that might cause angular error."
  ]
}

{
  "guideline_id": "G015",
  "category": "GDT",
  "topic": "Concentricity",

  "evaluation_criteria": [
    "Verify the datum axis is defined correctly and based on a stable cylindrical or planar feature.",
    "Verify the derived median points of the evaluated cylinder remain within the concentricity tolerance zone.",
    "Verify the concentricity tolerance is appropriate for the mating requirement (bearing fit, shaft fit, alignment pins).",
    "Verify diameter deviation, ovality, and surface imperfections do not distort the derived axis.",
    "Verify coaxial features share the same datum reference to ensure functional alignment."
  ],

  "user_questions": [
    "What is the specified concentricity tolerance for this feature (mm)?",
    "Which datum axis is referenced in the concentricity callout (A/B/C)?",
    "What is the measured radial deviation of the evaluated axis relative to the datum (mm)?",
    "What is the diameter of the cylinder being evaluated (mm)?",
    "Is this feature intended to mate with another cylindrical component (shaft, bearing, dowel pin)? (yes/no)"
  ],

  "expected_answers": [
    "Typical concentricity tolerances: high-precision bearing fits: 0.01–0.03 mm; standard alignment features: 0.05–0.1 mm; molded/cast cylindrical features: 0.1–0.3 mm.",
    "Valid datum axis must come from a cylindrical feature with acceptable roundness (≤0.05 mm for precision).",
    "Radial deviation must satisfy: deviation ≤ concentricity_tolerance / 2.",
    "Cylinder diameter must be stable and consistent; ovality should be ≤ 0.3% of nominal diameter.",
    "If mating, concentricity must be within the functional requirement of the paired part (e.g., shaft runout limits)."
  ],

  "pass_fail_logic": {
    "datum_axis_validity_check": "FAIL if datum axis is unstable, oval, or derived from a distorted surface.",
    "radial_deviation_check": "FAIL if radial_deviation > (concentricity_tolerance / 2).",
    "ovality_check": "FAIL if ovality > (0.003 × nominal_diameter).",
    "process_feasibility_check": "FAIL if concentricity_tolerance < minimum_process_capability.",
    "mating_requirement_check": "FAIL if concentricity exceeds functional requirement for a mating part."
  },

  "image_features_needed": [
    "Detect cylindrical features and estimate cylinder axis from silhouette or shading gradients.",
    "Extract centerline deviation by sampling median points of cylinder sections.",
    "Measure diameter consistency and detect ovality.",
    "Identify referenced datum cylinder from drawing or geometry.",
    "Detect mating features (holes, shafts) that impose coaxial requirements."
  ]
}

{
  "guideline_id": "G016",
  "category": "GDT",
  "topic": "Circularity",

  "evaluation_criteria": [
    "Verify the evaluated cross-sections of the cylindrical or round feature fall within the circularity tolerance band.",
    "Verify the radial variation (max–min radius) does not exceed the specified circularity tolerance.",
    "Verify the manufacturing process can realistically meet the circularity requirement for the selected material.",
    "Verify circularity variation is not caused by ovality, lobing, tool chatter, or shrink-related distortion.",
    "Verify all required cross-sections along the feature length meet the circularity requirement (not only mid-plane)."
  ],

  "user_questions": [
    "What is the circularity tolerance specified for this feature (mm)?",
    "What is the measured maximum radius and minimum radius across a cross-section (mm)?",
    "What is the nominal diameter of the cylindrical feature (mm)?",
    "What manufacturing process was used (turning, grinding, molding, casting, extrusion)?",
    "Does the feature show signs of lobing or non-roundness (e.g., 2-lobe, 3-lobe patterns)? (yes/no)"
  ],

  "expected_answers": [
    "Typical circularity tolerances: precision turned/grinded surfaces: 0.005–0.02 mm; standard machining: 0.02–0.05 mm; molded parts: 0.05–0.15 mm; cast parts: 0.1–0.3 mm.",
    "Circularity band requirement: (max_radius - min_radius) ≤ circularity_tolerance.",
    "Nominal diameter tolerance interaction: circularity must be < 25% of the size tolerance for high-precision fits.",
    "Process capability: grinding ~0.005 mm, precision turning ~0.01 mm, molding ~0.05 mm+, casting ~0.1–0.3 mm.",
    "Lobed patterns indicate tool vibration or mold distortion; if lobing exists, circularity is typically out of tolerance."
  ],

  "pass_fail_logic": {
    "radius_variation_check": "FAIL if (max_radius - min_radius) > circularity_tolerance.",
    "process_capability_check": "FAIL if specified_circularity < minimum_possible_for_process.",
    "ovality_check": "FAIL if ovality > circularity_tolerance.",
    "lobing_check": "FAIL if lobing_detected AND lobing_amplitude > circularity_tolerance.",
    "section_consistency_check": "FAIL if any cross-section violates circularity tolerance."
  },

  "image_features_needed": [
    "Detect circular cross-sections from edges or silhouette curvature.",
    "Measure radial variation across sampled points around the circle.",
    "Identify lobing patterns (e.g., 3-lobe, 4-lobe) common in machining or molding.",
    "Measure diameter consistency to detect ovality vs. circularity deviation.",
    "Infer process-related patterns (tool chatter, shrink distortion) from surface texture or geometry."
  ]
}

{
  "guideline_id": "G017",
  "category": "GDT",
  "topic": "Cylindricity",

  "evaluation_criteria": [
    "Verify all cross-sections of the cylinder maintain roundness within the cylindricity tolerance zone.",
    "Verify the cylinder’s generatrix (surface line along its length) does not deviate beyond tolerance, ensuring no taper or barrel shape.",
    "Verify the cylinder's axis remains straight and free from bending, bowing, or twisting deviations.",
    "Verify surface imperfections such as ovality, lobing, or tool-chatter do not exceed the tolerance zone.",
    "Verify the manufacturing process and material choice can realistically achieve the cylindricity requirement."
  ],

  "user_questions": [
    "What is the cylindricity tolerance specified for this feature (mm)?",
    "What is the maximum radial variation measured along the cylinder at any cross-section (mm)?",
    "What is the maximum straightness deviation of the cylinder’s axis over its full length (mm)?",
    "What is the nominal diameter and total cylinder length (mm)?",
    "What manufacturing process was used (turning, grinding, molding, casting)?"
  ],

  "expected_answers": [
    "Typical cylindricity ranges: precision grinding: 0.005–0.02 mm; precision turning: 0.01–0.05 mm; standard machining: 0.05–0.1 mm; molding: 0.05–0.2 mm; casting: 0.1–0.4 mm.",
    "Radial variation in any cross-section must satisfy: (max_radius - min_radius) ≤ cylindricity_tolerance.",
    "Axis straightness deviation must be ≤ cylindricity_tolerance (to avoid taper, bow, or barrel shapes).",
    "Length-to-diameter ratio considerations: long thin cylinders (L/D > 10) may require looser tolerance or grinding.",
    "Process capability: grinding ≈ 0.005 mm; high-precision turning ≈ 0.01 mm; molding/casting significantly higher."
  ],

  "pass_fail_logic": {
    "cross_section_variation_check": "FAIL if radial_variation > cylindricity_tolerance.",
    "axis_straightness_check": "FAIL if axis_deviation > cylindricity_tolerance.",
    "taper_or_barrel_check": "FAIL if measured_diameter_change_along_length > cylindricity_tolerance.",
    "process_capability_check": "FAIL if cylindricity_tolerance < minimum_process_capability.",
    "lobing_or_ovality_check": "FAIL if lobing_amplitude > cylindricity_tolerance OR ovality > cylindricity_tolerance."
  },

  "image_features_needed": [
    "Extract cylindrical surface using edge/curvature segmentation.",
    "Measure diameter consistency across multiple cross-sections along the cylinder length.",
    "Estimate cylinder axis deviation by comparing sampled points along its generatrix.",
    "Detect taper, bow, barrel, or hourglass shapes through silhouette curvature.",
    "Identify lobing (2-lobe, 3-lobe, 4-lobe patterns) or molded distortions using roundness profiles."
  ]
}

{
  "guideline_id": "G018",
  "category": "GDT",
  "topic": "Runout",

  "evaluation_criteria": [
    "Verify the datum axis used for runout measurement is stable, straight, and properly established.",
    "Verify circular runout is measured by rotating the part and ensuring surface variation stays within tolerance.",
    "Verify total runout considers full surface variation (radial + axial) along the entire length of the feature.",
    "Verify runout tolerance is appropriate for functional requirements (rotating shafts, bearings, gears).",
    "Verify geometry defects such as wobble, tilt, bend, or taper do not exceed the allowed tolerance zone."
  ],

  "user_questions": [
    "Is the callout specifying circular runout or total runout?",
    "What is the runout tolerance specified (mm)?",
    "What datum axis is referenced for the runout measurement (A/B/C)?",
    "What is the maximum radial deviation measured during rotation (mm)?",
    "What is the maximum axial deviation of the feature along its length (mm)?"
  ],

  "expected_answers": [
    "Circular runout typical ranges: precision rotating shafts: 0.005–0.02 mm; standard machined shafts: 0.02–0.05 mm; molded/cast rotating parts: 0.05–0.15 mm.",
    "Total runout typical ranges: grinding: 0.005–0.01 mm; precision turning: 0.01–0.03 mm; standard machining: 0.03–0.08 mm.",
    "Radial deviation must satisfy: radial_runout ≤ runout_tolerance.",
    "Axial deviation must satisfy (for total runout): axial_runout ≤ runout_tolerance.",
    "Datum axis must come from a stable cylindrical reference with roundness typically < 0.05 mm."
  ],

  "pass_fail_logic": {
    "datum_axis_validity_check": "FAIL if datum axis is unstable, non-round, or misaligned.",
    "radial_runout_check": "FAIL if radial_runout > runout_tolerance.",
    "axial_runout_check": "FAIL if total_runout_callout AND axial_runout > runout_tolerance.",
    "surface_profile_check": "FAIL if taper, wobble, or bow generate deviation beyond tolerance.",
    "process_capability_check": "FAIL if runout_tolerance < minimum_process_capability."
  },

  "image_features_needed": [
    "Identify cylindrical datum features for axis extraction.",
    "Measure radial movement of the surface profile during simulated rotation analysis.",
    "Measure axial deviation by comparing slices along the cylindrical height.",
    "Detect wobble or tilt through curvature/edge deviation patterns.",
    "Identify taper or bow shapes based on silhouette geometry."
  ]
}


{
  "guideline_id": "G019",
  "category": "GDT",
  "topic": "Profile Tolerance",

  "evaluation_criteria": [
    "Verify the profile tolerance zone width is appropriate for the functional requirement of the feature.",
    "Verify the measured deviation between the actual geometry and nominal CAD profile stays within tolerance.",
    "Verify referenced datums (if any) fully constrain location and orientation for surface profile control.",
    "Verify both inward and outward deviation are controlled symmetrically unless unilateral profile is specified.",
    "Verify complex surfaces (freeform, aerodynamic, ergonomic) maintain continuous curvature and no abrupt transitions beyond tolerance."
  ],

  "user_questions": [
    "Is the profile callout specifying profile of a line or profile of a surface?",
    "What is the specified profile tolerance zone width (mm)?",
    "What datums (if any) are referenced in the profile callout?",
    "What is the maximum measured deviation from the nominal CAD profile (mm)?",
    "Is the profile unilateral or bilateral? (If unilateral, specify + or – direction.)"
  ],

  "expected_answers": [
    "Typical profile tolerance ranges: precision machined surfaces: 0.02–0.1 mm; molded surfaces: 0.1–0.3 mm; cast surfaces: 0.3–1.0 mm; freeform aesthetic surfaces: 0.1–0.5 mm depending on class A requirements.",
    "Profile deviation must satisfy: deviation ≤ (profile_tolerance / 2) for bilateral zones.",
    "Datum references: A for primary plane, B for secondary orientation, C for tertiary constraint.",
    "Deviation peaks must not exceed tolerance even in high curvature regions.",
    "Unilateral profile must satisfy: deviation ≤ +tolerance OR ≤ –tolerance depending on direction."
  ],

  "pass_fail_logic": {
    "profile_zone_width_check": "FAIL if profile_tolerance < minimum_feasible_for_process.",
    "deviation_check": "FAIL if any measured_deviation > (profile_tolerance / 2) for bilateral profiles.",
    "datum_constraint_check": "FAIL if referenced_datums_needed AND datums_missing OR unstable.",
    "unilateral_profile_check": "FAIL if unilateral_profile AND deviation exceeds allowed side.",
    "curvature_continuity_check": "FAIL if abrupt curvature change exceeds tolerance."
  },

  "image_features_needed": [
    "Extract boundary curves (for line profile) or surface patches (for surface profile).",
    "Compare the detected geometry to nominal CAD silhouette or expected ideal shape.",
    "Measure the maximum deviation between actual and nominal geometry.",
    "Identify curvature continuity issues, ripples, or abrupt transitions.",
    "Detect datum references on the drawing or implied datum alignment from geometry."
  ]
}


{
  "guideline_id": "G020",
  "category": "GDT",
  "topic": "Datum Structure",

  "evaluation_criteria": [
    "Verify primary datum constrains 3 degrees of freedom (DOF) with a stable, planar surface.",
    "Verify secondary datum constrains 2 DOF perpendicular to primary datum.",
    "Verify tertiary datum constrains final DOF, fully locking rotational/translation ambiguity.",
    "Verify datum features chosen on the drawing correspond to functionally significant surfaces or features.",
    "Verify datum references in feature control frames match the actual manufacturing and inspection setup."
  ],

  "user_questions": [
    "What is the primary datum feature (A)?",
    "What is the secondary datum feature (B)?",
    "What is the tertiary datum feature (C)?",
    "Are the datums planar, cylindrical, or irregular functional surfaces?",
    "Do the referenced datums correctly stabilize all 6 DOF for inspection?"
  ],

  "expected_answers": [
    "Primary datum must be a large, stable surface that establishes orientation—commonly a major mounting face.",
    "Secondary datum typically locks rotation and translation orthogonal to datum A.",
    "Tertiary datum removes final rotational ambiguity—often an edge, pin, or hole.",
    "Cylindrical datums require axis extraction; planar datums require best-fit plane alignment.",
    "A valid datum scheme must constrain all 6 DOF: 3 translational + 3 rotational."
  ],

  "pass_fail_logic": {
    "primary_datum_check": "FAIL if primary datum lacks stability or does not constrain 3 DOF.",
    "secondary_datum_check": "FAIL if secondary datum does not constrain 2 DOF perpendicular to primary.",
    "tertiary_datum_check": "FAIL if tertiary datum fails to constrain final DOF.",
    "functional_relevance_check": "FAIL if datum surfaces are not functionally meaningful.",
    "inspection_setup_check": "FAIL if datum references in FCF cannot be practically fixtured for inspection."
  },

  "image_features_needed": [
    "Detect datum feature symbols (A, B, C).",
    "Identify planar, cylindrical, or complex surfaces associated with each datum.",
    "Extract axes, center planes, or best-fit surfaces from geometry.",
    "Evaluate fixture orientation needed to constrain all DOF.",
    "Verify consistency between geometry, datum tags, and FCF requirements."
  ]
}