snappyHexMesh type castellatedBufferLayer with face zones crash: All edges of face seem to have same neighbour

Summary

snappyHexMesh using buffer layer feature with baffle type face zones can cause a crash for complex geometry. Crash does not happen if no face zone is specified (if the lines faceZone walls_nonmanifold; and faceType baffle; are commented away in the attached example case), so I guess this issue is related to face zones.

The error message for crash is

--> FOAM FATAL ERROR: (openfoam-2412)
On face:25060 fc:(0.375396 -0.0623236 0.337415) vertices:4(26303 26304 26305 26306) points:4((0.375584 -0.0742326 0.351182) (0.374816 -0.0671053 0.332587) (0.375999 -0.0500982 0.323812) (0.375188 -0.0578133 0.342304)) edges:4(51375 51376 51377 51378) All edges of face seem to have same neighbour 327901 starting walking from edge (26303 26304)

    From Foam::labelPair Foam::addPatchCellLayer::getEdgeString(const Foam::indirectPrimitivePatch&, const Foam::labelListList&, const Foam::boolList&, Foam::label, Foam::label) const
    in file polyTopoChange/polyTopoChange/addPatchCellLayer.C at line 229.

Example case

bugcase4.zip

Relevant logs and/or images

SnappyHexMesh log file with stderr: log.snappy.txt

Environment information

• OpenFOAM version : 4fe3f55e-20250110 OPENFOAM=2412 version=v2412
• Operating system : ubuntu
• Hardware info : x64
• Compiler : gcc (Ubuntu 13.3.0-6ubuntu2~24.04) 13.3.0

changed the description

Looks like faceType internal; and faceType boundary; fail with same error message, too.

changed title from snappyHexMesh type castellatedBufferLayer face zone type baffle crash: All edges of face seem to have same neighbour to snappyHexMesh type castellatedBufferLayer with face zones crash: All edges of face seem to have same neighbour

changed the description

added community label