feat(FXC-5154) Warn gmsh min cylinder radii

CHANGELOG.md

@@ -13,6 +13,11 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 - Added `Grid.fine_mesh_info` property to identify and report locations where grid cell sizes are fine for understanding meshing hotspots.
 - Added visualization of finest grid regions in `Simulation.plot_grid()` with shaded regions highlighting areas of fine meshing.
 - Added autograd support for `Sphere`.
+- Added validation warning in `HeatChargeSimulation` for very small `Cylinder` radii to help users avoid meshing and numerical issues.
+
+### Breaking Changes
+- Added `structure_priority_mode` for `TerminalComponentModeler` and default to `"conductor"` to ensure metal structures override dielectrics regardless of structure order, preventing order-dependent results in RF simulations.
+- 1D lumped elements (with zero lateral extent) are no longer allowed. Use a small finite lateral extent (e.g., `1e-6`) instead.
 - Added `GaussianOverlapMonitor` and `AstigmaticGaussianOverlapMonitor` for decomposing electromagnetic fields onto Gaussian beam profiles.
 - Added `GaussianPort` and `AstigmaticGaussianPort` for S-matrix calculations using Gaussian beam sources and overlap monitors.
 - Added `symmetric_pseudo` option for `s_param_def` in `TerminalComponentModeler` which applies a scaling factor that ensures the S-matrix is symmetric in reciprocal systems.

tests/test_components/test_heat_charge.py

@@ -2832,3 +2832,72 @@ def test_heat_charge_simulation_plot():
         "for CHARGE simulations, resulting in at least 2 more visual elements "
         "than charge_sim.scene.plot()"
     )
+
+
+def test_cylinder_small_radius_warning():
+    """Test that warning is issued for very small cylinder radii in HeatChargeSimulation."""
+    solid = td.MultiPhysicsMedium(
+        heat=td.SolidSpec(conductivity=1, capacity=1),
+        name="solid",
+    )
+    background = td.MultiPhysicsMedium(
+        heat=td.FluidSpec(),
+        name="background",
+    )
+
+    # Test non-tapered cylinder with tiny radius
+    tiny_cylinder = td.Structure(
+        geometry=td.Cylinder(center=(0, 0, 0), radius=1e-8, length=1, axis=2),
+        medium=solid,
+        name="tiny",
+    )
+    with AssertLogLevel("WARNING", contains_str="radius"):
+        _ = td.HeatChargeSimulation(
+            center=(0, 0, 0),
+            size=(2, 2, 2),
+            medium=background,
+            structures=[tiny_cylinder],
+            grid_spec=td.UniformUnstructuredGrid(dl=0.1),
+            monitors=[td.TemperatureMonitor(size=(1, 1, 1), name="tmp")],
+        )
+
+    # Test transformed (translated) cylinder with tiny radius
+    tiny_cylinder_transformed = td.Structure(
+        geometry=td.Cylinder(center=(0, 0, 0), radius=1e-8, length=1, axis=2).translated(
+            x=0.1, y=0.0, z=0.0
+        ),
+        medium=solid,
+        name="tiny_transformed",
+    )
+    with AssertLogLevel("WARNING", contains_str="radius"):
+        _ = td.HeatChargeSimulation(
+            center=(0, 0, 0),
+            size=(2, 2, 2),
+            medium=background,
+            structures=[tiny_cylinder_transformed],
+            grid_spec=td.UniformUnstructuredGrid(dl=0.1),
+            monitors=[td.TemperatureMonitor(size=(1, 1, 1), name="tmp")],
+        )
+
+    # Test tapered cylinder with steep sidewall causing negative radius_top
+    tapered_cylinder = td.Structure(
+        geometry=td.Cylinder(
+            center=(0, 0, 0),
+            radius=0.1,
+            length=1,
+            axis=2,
+            sidewall_angle=np.pi / 3,  # 60 degrees - causes negative radius_top
+            reference_plane="bottom",
+        ),
+        medium=solid,
+        name="tapered",
+    )
+    with AssertLogLevel("WARNING", contains_str="radius_top"):
+        _ = td.HeatChargeSimulation(
+            center=(0, 0, 0),
+            size=(2, 2, 2),
+            medium=background,
+            structures=[tapered_cylinder],
+            grid_spec=td.UniformUnstructuredGrid(dl=0.1),
+            monitors=[td.TemperatureMonitor(size=(1, 1, 1), name="tmp")],
+        )

tidy3d/components/geometry/utils.py

@@ -249,7 +249,8 @@ def flatten_groups(
 def traverse_geometries(geometry: GeometryType) -> GeometryType:
     """Iterator over all geometries within the given geometry.
 
-    Iterates over groups and clip operations within the given geometry, yielding each one.
+    Iterates over groups, clip operations, and transformed geometries within the given geometry,
+    yielding each one.
 
     Parameters
     ----------
@@ -267,6 +268,8 @@ def traverse_geometries(geometry: GeometryType) -> GeometryType:
     elif isinstance(geometry, base.ClipOperation):
         yield from traverse_geometries(geometry.geometry_a)
         yield from traverse_geometries(geometry.geometry_b)
+    elif isinstance(geometry, base.Transformed):
+        yield from traverse_geometries(geometry.geometry)
     yield geometry
 
 

tidy3d/components/tcad/simulation/heat_charge.py

@@ -24,6 +24,8 @@
     StructureStructureInterface,
 )
 from tidy3d.components.geometry.base import Box
+from tidy3d.components.geometry.primitives import Cylinder
+from tidy3d.components.geometry.utils import traverse_geometries
 from tidy3d.components.material.tcad.charge import (
     ChargeConductorMedium,
     SemiconductorMedium,
@@ -127,6 +129,11 @@
 # define some limits for transient heat simulations
 TRANSIENT_HEAT_MAX_STEPS = 1000
 
+# OpenCASCADE minimum tolerance for cylinder radii
+OPENCASCADE_CYLINDER_RADIUS_TOL = 1e-6
+# Minimum radius as fraction of the larger radius (for tapered cylinders)
+MIN_CYLINDER_RADIUS_FRACTION = 0.01
+
 
 class TCADAnalysisTypes(str, Enum):
     """Enumeration of the types of simulations currently supported"""
@@ -363,6 +370,45 @@ def check_unsupported_geometries(cls, val):
                 )
         return val
 
+    @pd.validator("structures", always=True)
+    def _warn_small_cylinder_radius(cls, val):
+        """Warn if any Cylinder geometry has radius too small for meshing."""
+        for structure in val:
+            for geometry in traverse_geometries(structure.geometry):
+                if isinstance(geometry, Cylinder):
+                    r_bottom = geometry.radius_bottom
+                    r_top = geometry.radius_top
+                    is_tapered = not np.isclose(r_bottom, r_top)
+
+                    # Compute minimum allowed radius (matches backend heat_mesh.py logic)
+                    min_radius = max(
+                        OPENCASCADE_CYLINDER_RADIUS_TOL,
+                        MIN_CYLINDER_RADIUS_FRACTION * max(abs(r_bottom), abs(r_top)),
+                    )
+
+                    # Warn if radii are below minimum
+                    if is_tapered:
+                        if r_bottom < min_radius:
+                            log.warning(
+                                f"Cylinder 'radius_bottom' ({r_bottom:.3e}) is below the minimum "
+                                f"radius for meshing ({min_radius:.3e}). The sidewall angle may be "
+                                f"too steep. Will be clamped to minimum radius or mesh size, whichever is larger."
+                            )
+                        if r_top < min_radius:
+                            log.warning(
+                                f"Cylinder 'radius_top' ({r_top:.3e}) is below the minimum "
+                                f"radius for meshing ({min_radius:.3e}). The sidewall angle may be "
+                                f"too steep. Will be clamped to minimum radius or mesh size, whichever is larger."
+                            )
+                    else:
+                        if r_bottom < min_radius:
+                            log.warning(
+                                f"Cylinder 'radius' ({r_bottom:.3e}) is below the minimum "
+                                f"radius for meshing ({min_radius:.3e}). "
+                                f"Will be clamped to minimum radius or mesh size, whichever is larger."
+                            )
+        return val
+
     @staticmethod
     def _check_cross_solids(objs: tuple[Box, ...], values: dict) -> tuple[int, ...]:
         """Given model dictionary ``values``, check whether objects in list ``objs`` cross