Connect infill segments and adjust spacing and flow rate to fill the area completely without leaving gaps. #89

lib/Slic3r/Extruder.pm

@@ -117,6 +117,7 @@ sub extrude {
         * (($Slic3r::nozzle_diameter**2) / ($Slic3r::filament_diameter ** 2))
         * $Slic3r::flow_speed_ratio 
         * $self->flow_ratio
+        * ($path->flow_ratio || 1)
         * $Slic3r::extrusion_multiplier
         * $path->depth_layers;
     

lib/Slic3r/ExtrusionPath.pm

@@ -7,6 +7,9 @@ extends 'Slic3r::Polyline';
 # expressed in layers
 has 'depth_layers' => (is => 'ro', default => sub {1});
 
+# multiplier for the flow rate
+has 'flow_ratio' => (is => 'rw');
+
 # perimeter/fill/solid-fill/bridge/skirt
 has 'role'         => (is => 'ro', required => 1);
 

lib/Slic3r/ExtrusionPath/Collection.pm

@@ -18,7 +18,7 @@ sub add {
 
 sub endpoints {
     my $self = shift;
-    return map $_->endpoints, @{$self->paths};
+    return [ map $_->endpoints, @{$self->paths} ];
 }
 
 sub shortest_path {
@@ -30,7 +30,7 @@ sub shortest_path {
     CYCLE: while (@{$self->paths}) {
         # find nearest point
         $start_at = $start_near
-            ? Slic3r::Point->new(Slic3r::Geometry::nearest_point($start_near, [ $self->endpoints ]))
+            ? Slic3r::Point->new(Slic3r::Geometry::nearest_point($start_near, $self->endpoints))
             : $self->endpoints->[0];
         
         # loop through paths to find the one that starts or ends at the point found

lib/Slic3r/Fill.pm

@@ -60,6 +60,7 @@ sub make_fill {
                 $union = diff_ex(
                     [ map @$_, @$union ],
                     [ map $_->p, @surfaces_with_bridge_angle ],
+                    1,
                 );
             }
             
@@ -67,6 +68,7 @@ sub make_fill {
             $union = diff_ex(
                 [ map @$_, @$union ],
                 [ map $_->p, @surfaces ],
+                1,
             );
             
             push @surfaces, map Slic3r::Surface->cast_from_expolygon($_,
@@ -103,6 +105,7 @@ sub make_fill {
             density     => $density,
             flow_width  => $flow_width,
         );
+        my $params = shift @paths;
         
         # save into layer
         push @{ $layer->fills }, Slic3r::ExtrusionPath::Collection->new(
@@ -111,10 +114,11 @@ sub make_fill {
                     [ @$_ ],
                     role => ($is_bridge ? 'bridge' : $is_solid ? 'solid-fill' : 'fill'),
                     depth_layers => $surface->depth_layers,
+                    flow_ratio   => $params->{flow_ratio},
                 ), @paths,
             ],
         );
-        $layer->fills->[-1]->cleanup;
+        ###$layer->fills->[-1]->cleanup;
     }
 }
 

lib/Slic3r/Fill/PlanePath.pm

@@ -63,7 +63,7 @@ sub fill_surface {
     # paths must be rotated back
     $self->rotate_points_back(\@paths, $rotate_vector);
     
-    return @paths;
+    return {}, @paths;
 }
 
 1;

lib/Slic3r/Fill/Rectilinear.pm

@@ -3,7 +3,7 @@ use Moo;
 
 extends 'Slic3r::Fill::Base';
 
-use Slic3r::Geometry qw(X1 Y1 X2 Y2 A B X);
+use Slic3r::Geometry qw(X1 Y1 X2 Y2 A B X Y scale epsilon);
 use XXX;
 
 sub fill_surface {
@@ -16,28 +16,61 @@ sub fill_surface {
     $self->rotate_points($expolygon, $rotate_vector);
     
     my $bounding_box = [ $expolygon->bounding_box ];
-    my $flow_width_res = $params{flow_width} / $Slic3r::resolution;
+    $bounding_box->[X1] += scale 0.1;
-    my $distance_between_lines = $flow_width_res / $params{density};
+    $bounding_box->[X2] -= scale 0.1;
+    
+    my $min_spacing = scale $params{flow_width};
+    my $distance_between_lines = $min_spacing / $params{density};
+    my $line_oscillation = $distance_between_lines - $min_spacing;
+    
+    my $number_of_lines = int(($bounding_box->[X2] - $bounding_box->[X1]) / $distance_between_lines) + 1;
+    my $extra_space = ($bounding_box->[X2] - $bounding_box->[X1]) % $distance_between_lines;
+    $distance_between_lines += $extra_space / ($number_of_lines - 1) if $number_of_lines > 1;
+    my $flow_ratio = $distance_between_lines / ($min_spacing / $params{density});
     
     my @paths = ();
     my $x = $bounding_box->[X1];
     my $is_line_pattern = $self->isa('Slic3r::Fill::Line');
-    my $i = 0;
+    for (my $i = 0; $i < $number_of_lines; $i++) {
-    while ($x < $bounding_box->[X2]) {
         my $vertical_line = [ [$x, $bounding_box->[Y2]], [$x, $bounding_box->[Y1]] ];
         if ($is_line_pattern && $i % 2) {
-            $vertical_line->[A][X] -= ($distance_between_lines - $flow_width_res);
+            $vertical_line->[A][X] -= $line_oscillation;
-            $vertical_line->[B][X] += ($distance_between_lines - $flow_width_res);
+            $vertical_line->[B][X] += $line_oscillation;
         }
         push @paths, @{ $expolygon->clip_line($vertical_line) };
-        $x += int($distance_between_lines);
+        $x += $distance_between_lines;
-        $i++;
+    }
+    
+    # connect lines
+    {
+        my $collection = Slic3r::ExtrusionPath::Collection->new(
+            paths => [ map Slic3r::ExtrusionPath->cast([ @$_ ], role => 'bogus'), @paths ],
+        );
+        @paths = ();
+        
+        my $can_connect = $is_line_pattern
+            ? sub { $_[X] <= (abs((($_[2][Y] - $bounding_box->[Y1])*(2 * $line_oscillation)/($bounding_box->[Y2] - $bounding_box->[Y1])) - $line_oscillation) + $distance_between_lines) && $_[Y] <= $distance_between_lines * 5 }
+            : sub { ($_[X] <= $distance_between_lines) && ($_[Y] <= $distance_between_lines * 5) };
+        
+        foreach my $path ($collection->shortest_path) {
+            if (@paths) {
+                my @distance = map abs($paths[-1][-1][$_] - $path->points->[0][$_]), (X,Y);
+                
+                # TODO: we should also check that both points are on a fill_boundary to avoid 
+                # connecting paths on the boundaries of internal regions
+                if ($can_connect->(@distance, $paths[-1][-1])) {
+                    push @{$paths[-1]}, @{$path->points};
+                    next;
+                }
+            }
+            push @paths, [@{$path->points}];
+        }
     }
     
     # paths must be rotated back
     $self->rotate_points_back(\@paths, $rotate_vector);
     
-    return @paths;
+    return { flow_ratio => $flow_ratio }, @paths;
 }
 
 1;

lib/Slic3r/Print.pm

@@ -272,6 +272,7 @@ sub discover_horizontal_shells {
                 my $new_internal_solid = intersection_ex(
                     $surfaces_p,
                     [ map $_->p, grep $_->surface_type =~ /internal/, @neighbor_surfaces ],
+                    undef, 1,
                 );
                 next if !@$new_internal_solid;