fix: Route IfcAlignment creation through align_api.create()

Addresses Rick Brice's PR review feedback on #7785.

Root cause: the AddElement dialog was manually stitching together
IfcAlignment layout containers and calling create_representation(),
bypassing the validated construction sequence in align_api.create().
This left IfcGradientCurve.BaseCurve potentially None and skipped
zero-length segment and stationing referent setup.

Changes:
- root/operator.py: alignment templates now call align_api.create()
  directly (HORIZONTAL, GRADIENT, CANT) or _create_polyline_representation
  (POLYLINE_2D/3D), then manually link the result to the Blender object via
  tool.Ifc.link + tool.Collector.assign. The old generic core.assign_class
  path is retained for all non-alignment templates unchanged.
- tool/alignment.py: remove create_representation_structure() — superseded
  by the operator changes above.
- create_representation.py: revert the if layout_nest: guard; with
  align_api.create() as the entry point the zero-length segment always
  exists before create_representation is called.
- add_zero_length_segment.py: revert the BaseCurve None guard; the root
  cause (gradient curve created without a base curve) no longer occurs.
- alignment/operator.py: guard _create_geometric_representation call so it
  only runs when no curve representation exists yet; auto-invoke
  create_alignment_by_pi after PI picker finishes if >=2 PIs are defined.
- util/file.py: fix StopIteration on short IFC template files
  (next(ifc_file) → next(ifc_file, None) with break).

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

src/bonsai/bonsai/bim/module/alignment/operator.py

@@ -583,6 +583,10 @@ class CIVIL_OT_pick_pi_from_viewport(bpy.types.Operator, PolylineOperator, tool.
         recalculate_pi_geometry(props)
         rebuild_display_rows(props)
 
+        # If invoked from alignment creation flow, auto-create IFC segments
+        if props.active_alignment_id != 0 and len(props.pis) >= 2:
+            bpy.ops.civil.create_alignment_by_pi()
+
 
 class CIVIL_OT_recalculate_pis(Operator, tool.Ifc.Operator):
     """Recalculate PI geometry and update IFC/visualization"""
@@ -738,7 +742,8 @@ class CIVIL_OT_create_alignment_by_pi(Operator, tool.Ifc.Operator):
         segments = ifcopenshell.api.alignment.get_layout_segments(h_layout)
         has_real_segments = bool([s for s in segments if not tool.Alignment.is_zero_length_segment(s)])
 
-        ifcopenshell.api.alignment._create_geometric_representation(tool.Ifc.get(), existing_alignment)
+        if not ifcopenshell.api.alignment.get_curve(existing_alignment):
+            ifcopenshell.api.alignment._create_geometric_representation(tool.Ifc.get(), existing_alignment)
 
         if not has_real_segments:
             # Use existing alignment - add segments to it

src/bonsai/bonsai/bim/module/root/operator.py

@@ -540,47 +540,86 @@ class AddElement(bpy.types.Operator, tool.Ifc.Operator):
             if ifc_context:
                 ifc_context = tool.Ifc.get().by_id(ifc_context)
 
-        if representation_template in (
-            "EMPTY",
+        alignment_templates = {
             "ALIGNMENT_HORIZONTAL",
             "ALIGNMENT_GRADIENT",
             "ALIGNMENT_CANT",
             "ALIGNMENT_POLYLINE_3D",
             "ALIGNMENT_POLYLINE_2D",
-            "LAYERSET_AXIS2",
-            "LAYERSET_AXIS3",
-            "PROFILESET",
-        ) or representation_template.startswith("FLOW_SEGMENT_"):
-            mesh = None
-        elif representation_template == "OBJ" and not props.representation_obj:
-            mesh = None
+        }
+
+        if representation_template in alignment_templates:
+            import ifcopenshell.api.alignment as align_api
+            from ifcopenshell.api.alignment._create_polyline_representation import (
+                _create_polyline_representation,
+            )
+
+            ifc_file = tool.Ifc.get()
+            alignment_name = props.name or "Unnamed"
+
+            if representation_template == "ALIGNMENT_HORIZONTAL":
+                element = align_api.create(ifc_file, alignment_name, include_vertical=False, include_cant=False)
+            elif representation_template == "ALIGNMENT_GRADIENT":
+                element = align_api.create(ifc_file, alignment_name, include_vertical=True, include_cant=False)
+            elif representation_template == "ALIGNMENT_CANT":
+                element = align_api.create(ifc_file, alignment_name, include_vertical=True, include_cant=True)
+            elif representation_template == "ALIGNMENT_POLYLINE_3D":
+                element = ifc_file.createIfcAlignment(GlobalId=ifcopenshell.guid.new(), Name=alignment_name)
+                pts = [
+                    ifc_file.createIfcCartesianPoint(Coordinates=(0.0, 0.0, 0.0)),
+                    ifc_file.createIfcCartesianPoint(Coordinates=(1.0, 0.0, 0.0)),
+                ]
+                _create_polyline_representation(ifc_file, element, pts)
+                project = ifc_file.by_type("IfcProject")
+                if project:
+                    ifcopenshell.api.aggregate.assign_object(ifc_file, products=[element], relating_object=project[0])
+            elif representation_template == "ALIGNMENT_POLYLINE_2D":
+                element = ifc_file.createIfcAlignment(GlobalId=ifcopenshell.guid.new(), Name=alignment_name)
+                pts = [
+                    ifc_file.createIfcCartesianPoint(Coordinates=(0.0, 0.0)),
+                    ifc_file.createIfcCartesianPoint(Coordinates=(1.0, 0.0)),
+                ]
+                _create_polyline_representation(ifc_file, element, pts)
+                project = ifc_file.by_type("IfcProject")
+                if project:
+                    ifcopenshell.api.aggregate.assign_object(ifc_file, products=[element], relating_object=project[0])
+
+            element.Description = props.description or None
+            obj = bpy.data.objects.new(props.ifc_class[3:], None)
+            obj.name = alignment_name
+            obj.location = bpy.context.scene.cursor.location
+            tool.Root.set_object_name(obj, element)
+            tool.Ifc.link(element, obj)
+            tool.Collector.assign(obj)
         else:
-            mesh = bpy.data.meshes.new("Mesh")
+            if representation_template in (
+                "EMPTY",
+                "LAYERSET_AXIS2",
+                "LAYERSET_AXIS3",
+                "PROFILESET",
+            ) or representation_template.startswith("FLOW_SEGMENT_"):
+                mesh = None
+            elif representation_template == "OBJ" and not props.representation_obj:
+                mesh = None
+            else:
+                mesh = bpy.data.meshes.new("Mesh")
 
-        obj = bpy.data.objects.new(props.ifc_class[3:], mesh)
-        obj.name = props.name or "Unnamed"
-        obj.location = bpy.context.scene.cursor.location
-        element = core.assign_class(
-            tool.Ifc,
-            tool.Collector,
-            tool.Root,
-            obj=obj,
-            ifc_class=props.ifc_class,
-            predefined_type=predefined_type,
-            should_add_representation=False,
-        )
-        element.Description = props.description or None
+            obj = bpy.data.objects.new(props.ifc_class[3:], mesh)
+            obj.name = props.name or "Unnamed"
+            obj.location = bpy.context.scene.cursor.location
+            element = core.assign_class(
+                tool.Ifc,
+                tool.Collector,
+                tool.Root,
+                obj=obj,
+                ifc_class=props.ifc_class,
+                predefined_type=predefined_type,
+                should_add_representation=False,
+            )
+            element.Description = props.description or None
 
-        if representation_template == "EMPTY":
+        if representation_template == "EMPTY" or representation_template in alignment_templates:
             pass
-        elif representation_template in (
-            "ALIGNMENT_HORIZONTAL",
-            "ALIGNMENT_GRADIENT",
-            "ALIGNMENT_CANT",
-            "ALIGNMENT_POLYLINE_3D",
-            "ALIGNMENT_POLYLINE_2D",
-        ):
-            tool.Alignment.create_representation_structure(element, representation_template)
         elif not ifc_context:
             pass
         elif representation_template == "OBJ" and props.representation_obj:
@@ -849,6 +888,13 @@ class AddElement(bpy.types.Operator, tool.Ifc.Operator):
         bonsai.core.geometry.edit_object_placement(tool.Ifc, tool.Geometry, tool.Surveyor, obj=obj)
         tool.Blender.set_active_object(obj)
 
+        # After alignment creation, auto-invoke PI picker for layout-based templates
+        if props.ifc_class == "IfcAlignment" and representation_template.startswith("ALIGNMENT_") and representation_template not in ("ALIGNMENT_POLYLINE_2D", "ALIGNMENT_POLYLINE_3D"):
+            civil_props = context.scene.CivilAlignmentProperties
+            civil_props.active_alignment_id = element.id()
+            civil_props.active_alignment_name = element.Name or "Unnamed"
+            bpy.ops.civil.pick_pi_from_viewport("INVOKE_DEFAULT")
+
     def draw(self, context):
         props = tool.Root.get_root_props()
         self.layout.use_property_split = True

src/bonsai/bonsai/tool/alignment.py

@@ -388,68 +388,6 @@ class Alignment:
         ifc_file = tool.Ifc.get()
         align_api.layout_horizontal_alignment_by_pi_method(ifc_file, layout, hpoints, radii)
 
-    @classmethod
-    def create_representation_structure(cls, alignment: "ifcopenshell.entity_instance", template: str) -> None:
-        """Create semantic layout containers and geometric representation for an IfcAlignment.
-
-        Called from the AddElement operator when the user selects a representation type
-        for a newly-created IfcAlignment.  For layout-based templates (HORIZONTAL, GRADIENT,
-        CANT), the appropriate IfcAlignmentHorizontal / Vertical / Cant entities are nested to
-        the alignment and ifcopenshell.api.alignment.create_representation is invoked to build
-        the matching geometric curves.  For polyline templates, an IfcPolyLine with two
-        placeholder origin points is created directly.
-
-        Layout containers are IFC entities only — no Blender objects are created for them.
-
-        Args:
-            alignment: The IfcAlignment entity that was just created by AddElement.
-            template:  One of ALIGNMENT_HORIZONTAL, ALIGNMENT_GRADIENT, ALIGNMENT_CANT,
-                       ALIGNMENT_POLYLINE_3D, or ALIGNMENT_POLYLINE_2D.
-        """
-        import ifcopenshell.api.alignment as align_api
-        import ifcopenshell.api.nest
-        import ifcopenshell.guid
-        from ifcopenshell.api.alignment._create_polyline_representation import (
-            _create_polyline_representation,
-        )
-
-        ifc_file = tool.Ifc.get()
-
-        if template == "ALIGNMENT_HORIZONTAL":
-            h_layout = ifc_file.createIfcAlignmentHorizontal(GlobalId=ifcopenshell.guid.new())
-            ifcopenshell.api.nest.assign_object(ifc_file, related_objects=[h_layout], relating_object=alignment)
-            align_api.create_representation(ifc_file, alignment)
-
-        elif template == "ALIGNMENT_GRADIENT":
-            h_layout = ifc_file.createIfcAlignmentHorizontal(GlobalId=ifcopenshell.guid.new())
-            ifcopenshell.api.nest.assign_object(ifc_file, related_objects=[h_layout], relating_object=alignment)
-            v_layout = ifc_file.createIfcAlignmentVertical(GlobalId=ifcopenshell.guid.new())
-            ifcopenshell.api.nest.assign_object(ifc_file, related_objects=[v_layout], relating_object=alignment)
-            align_api.create_representation(ifc_file, alignment)
-
-        elif template == "ALIGNMENT_CANT":
-            h_layout = ifc_file.createIfcAlignmentHorizontal(GlobalId=ifcopenshell.guid.new())
-            ifcopenshell.api.nest.assign_object(ifc_file, related_objects=[h_layout], relating_object=alignment)
-            v_layout = ifc_file.createIfcAlignmentVertical(GlobalId=ifcopenshell.guid.new())
-            ifcopenshell.api.nest.assign_object(ifc_file, related_objects=[v_layout], relating_object=alignment)
-            c_layout = ifc_file.createIfcAlignmentCant(GlobalId=ifcopenshell.guid.new())
-            ifcopenshell.api.nest.assign_object(ifc_file, related_objects=[c_layout], relating_object=alignment)
-            align_api.create_representation(ifc_file, alignment)
-
-        elif template == "ALIGNMENT_POLYLINE_3D":
-            pts = [
-                ifc_file.createIfcCartesianPoint(Coordinates=(0.0, 0.0, 0.0)),
-                ifc_file.createIfcCartesianPoint(Coordinates=(1.0, 0.0, 0.0)),
-            ]
-            _create_polyline_representation(ifc_file, alignment, pts)
-
-        elif template == "ALIGNMENT_POLYLINE_2D":
-            pts = [
-                ifc_file.createIfcCartesianPoint(Coordinates=(0.0, 0.0)),
-                ifc_file.createIfcCartesianPoint(Coordinates=(1.0, 0.0)),
-            ]
-            _create_polyline_representation(ifc_file, alignment, pts)
-
     # =========================================================================
     # Zero-Length Segment Utilities
     # =========================================================================
@@ -634,6 +572,8 @@ class Alignment:
                 obj = bpy.data.objects.new(tool.Loader.get_name(curve_segment), mesh)
                 tool.Ifc.link(curve_segment, obj)
                 tool.Collector.assign(obj)
+                if parent_obj:
+                    obj.parent = parent_obj
         return obj
 
     @classmethod

src/ifcopenshell-python/ifcopenshell/api/alignment/add_zero_length_segment.py

@@ -123,8 +123,7 @@ def add_zero_length_segment(file: ifcopenshell.file, layout: entity_instance, in
         if layout.is_a("IfcSegmentedReferenceCurve"):
             ifcopenshell.api.alignment.add_zero_length_segment(file, layout.BaseCurve)
         elif layout.is_a("IfcGradientCurve"):
-            if layout.BaseCurve is not None:
-                ifcopenshell.api.alignment.add_zero_length_segment(file, layout.BaseCurve)
+            ifcopenshell.api.alignment.add_zero_length_segment(file, layout.BaseCurve)
 
     else:
         zero_length_curve_segment = None

src/ifcopenshell-python/ifcopenshell/api/alignment/create_representation.py

@@ -52,6 +52,5 @@ def create_representation(
     for layout in layouts:
         curve = ifcopenshell.api.alignment.get_layout_curve(layout)
         layout_nest = ifcopenshell.api.alignment.get_alignment_segment_nest(layout)
-        if layout_nest:  # None when no segments exist yet (by design of get_alignment_segment_nest)
-            for segment in layout_nest.RelatedObjects:
-                _add_segment_to_curve(file, segment, curve)
+        for segment in layout_nest.RelatedObjects:
+            _add_segment_to_curve(file, segment, curve)

src/ifcopenshell-python/ifcopenshell/util/file.py

@@ -91,7 +91,9 @@ class IfcHeaderExtractor:
         data = HeaderMetadata()
         max_lines_to_parse = 50
         for _ in range(max_lines_to_parse):
-            line = next(ifc_file)
+            line = next(ifc_file, None)
+            if line is None:
+                break
             if isinstance(line, bytes):
                 line = line.decode("utf-8")
             if line.startswith("FILE_DESCRIPTION"):