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Fix anchoring over sparse infill bug causing overextrusion when stacking thick bridges onto each other

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This commit is contained in:
PavelMikus 2023-03-16 14:25:36 +01:00
parent 765719d424
commit 8ed8adfd3d
1 changed files with 56 additions and 34 deletions
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90
src/libslic3r/PrintObject.cpp
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@ -1627,7 +1627,7 @@ void PrintObject::bridge_over_infill()
contains_only_lightning = false; contains_only_lightning = false;
} }
Polygons fill_polys = to_polygons(region->fill_expolygons()); Polygons fill_polys = to_polygons(region->fill_expolygons());
unsupported_area = union_(unsupported_area, expand(fill_polys, spacing)); unsupported_area.insert(unsupported_area.end(), fill_polys.begin(), fill_polys.end());
for (const Surface &surface : region->fill_surfaces()) { for (const Surface &surface : region->fill_surfaces()) {
if (surface.surface_type != stInternal || region->region().config().fill_density.value == 100) { if (surface.surface_type != stInternal || region->region().config().fill_density.value == 100) {
Polygons p = to_polygons(surface.expolygon); Polygons p = to_polygons(surface.expolygon);
@ -1635,9 +1635,10 @@ void PrintObject::bridge_over_infill()
} }
} }
} }
unsupported_area = closing(unsupported_area, SCALED_EPSILON);
lower_layer_solids = expand(lower_layer_solids, 4 * spacing); lower_layer_solids = expand(lower_layer_solids, 4 * spacing);
unsupported_area = shrink(unsupported_area, 5 * spacing); unsupported_area = shrink(unsupported_area, 4 * spacing);
unsupported_area = diff(unsupported_area, lower_layer_solids); unsupported_area = diff(unsupported_area, lower_layer_solids);
for (const LayerRegion *region : layer->regions()) { for (const LayerRegion *region : layer->regions()) {
@ -1647,18 +1648,25 @@ void PrintObject::bridge_over_infill()
bool partially_supported = area(unsupported) < area(to_polygons(s->expolygon)) - EPSILON; bool partially_supported = area(unsupported) < area(to_polygons(s->expolygon)) - EPSILON;
if (!unsupported.empty() && (!partially_supported || area(unsupported) > 5 * 5 * spacing * spacing)) { if (!unsupported.empty() && (!partially_supported || area(unsupported) > 5 * 5 * spacing * spacing)) {
Polygons worth_bridging = intersection(to_polygons(s->expolygon), expand(unsupported, 5 * spacing)); Polygons worth_bridging = intersection(to_polygons(s->expolygon), expand(unsupported, 5 * spacing));
for (Polygon p : diff(to_polygons(s->expolygon), worth_bridging)) { for (const Polygon& p : diff(to_polygons(s->expolygon), expand(worth_bridging, spacing))) {
if (p.area() < region->flow(frSolidInfill, true).scaled_spacing() * scale_(12.0)) { auto area = p.area();
if (area < spacing * scale_(12.0) && area > spacing * spacing) {
worth_bridging.push_back(p); worth_bridging.push_back(p);
} }
} }
worth_bridging = intersection(closing(worth_bridging, 3 * region->flow(frSolidInfill, true).scaled_spacing()), s->expolygon); worth_bridging = intersection(closing(worth_bridging, 2 * spacing), s->expolygon);
candidate_surfaces.push_back(CandidateSurface(s, lidx, worth_bridging, region, 0, contains_only_lightning)); candidate_surfaces.push_back(CandidateSurface(s, lidx, worth_bridging, region, 0, contains_only_lightning));
#ifdef DEBUG_BRIDGE_OVER_INFILL #ifdef DEBUG_BRIDGE_OVER_INFILL
debug_draw(std::to_string(lidx) + "_candidate_surface_" + std::to_string(area(s->expolygon)), debug_draw(std::to_string(lidx) + "_candidate_surface_" + std::to_string(area(s->expolygon)),
to_lines(region->layer()->lslices), to_lines(s->expolygon), to_lines(worth_bridging), to_lines(region->layer()->lslices), to_lines(s->expolygon), to_lines(worth_bridging),
to_lines(unsupported_area)); to_lines(unsupported_area));
#endif
#ifdef DEBUG_BRIDGE_OVER_INFILL
debug_draw(std::to_string(lidx) + "_candidate_processing_" + std::to_string(area(s->expolygon)),
to_lines(unsupported), to_lines(intersection(to_polygons(s->expolygon), expand(unsupported, 5 * spacing))),
to_lines(diff(to_polygons(s->expolygon), expand(worth_bridging, spacing))),
to_lines(unsupported_area));
#endif #endif
} }
} }
@ -1765,9 +1773,9 @@ void PrintObject::bridge_over_infill()
// LAMBDA to gather areas with sparse infill deep enough that we can fit thick bridges there. // LAMBDA to gather areas with sparse infill deep enough that we can fit thick bridges there.
auto gather_areas_w_depth = [target_flow_height_factor](const PrintObject *po, int lidx, float target_flow_height) { auto gather_areas_w_depth = [target_flow_height_factor](const PrintObject *po, int lidx, float target_flow_height) {
// Gather lower layers sparse infill areas, to depth defined by used bridge flow // Gather layers sparse infill areas, to depth defined by used bridge flow
Polygons lower_layers_sparse_infill{}; ExPolygons layers_sparse_infill{};
Polygons not_sparse_infill{}; ExPolygons not_sparse_infill{};
double bottom_z = po->get_layer(lidx)->print_z - target_flow_height * target_flow_height_factor - EPSILON; double bottom_z = po->get_layer(lidx)->print_z - target_flow_height * target_flow_height_factor - EPSILON;
for (int i = int(lidx) - 1; i >= 0; --i) { for (int i = int(lidx) - 1; i >= 0; --i) {
// Stop iterating if layer is lower than bottom_z. // Stop iterating if layer is lower than bottom_z.
@ -1778,19 +1786,19 @@ void PrintObject::bridge_over_infill()
for (const LayerRegion *region : layer->regions()) { for (const LayerRegion *region : layer->regions()) {
bool has_low_density = region->region().config().fill_density.value < 100; bool has_low_density = region->region().config().fill_density.value < 100;
for (const Surface &surface : region->fill_surfaces()) { for (const Surface &surface : region->fill_surfaces()) {
if (surface.surface_type == stInternal && has_low_density) { if ((surface.surface_type == stInternal && has_low_density) || surface.surface_type == stInternalVoid ) {
Polygons p = to_polygons(surface.expolygon); layers_sparse_infill.push_back(surface.expolygon);
lower_layers_sparse_infill.insert(lower_layers_sparse_infill.end(), p.begin(), p.end());
} else { } else {
Polygons p = to_polygons(surface.expolygon); not_sparse_infill.push_back(surface.expolygon);
not_sparse_infill.insert(not_sparse_infill.end(), p.begin(), p.end());
} }
} }
} }
lower_layers_sparse_infill = union_(lower_layers_sparse_infill);
} }
lower_layers_sparse_infill = closing(lower_layers_sparse_infill, SCALED_EPSILON); layers_sparse_infill = union_ex(layers_sparse_infill);
return diff(lower_layers_sparse_infill, not_sparse_infill); layers_sparse_infill = closing_ex(layers_sparse_infill, SCALED_EPSILON);
not_sparse_infill = union_ex(not_sparse_infill);
not_sparse_infill = closing_ex(not_sparse_infill, SCALED_EPSILON);
return diff(layers_sparse_infill, not_sparse_infill);
}; };
// LAMBDA do determine optimal bridging angle // LAMBDA do determine optimal bridging angle
@ -1927,7 +1935,7 @@ void PrintObject::bridge_over_infill()
}); });
if (maybe_below_anchor != anchors_intersections.rend()) { if (maybe_below_anchor != anchors_intersections.rend()) {
section.a = maybe_below_anchor->first; section.a = maybe_below_anchor->first;
section.a.y() -= bridging_flow.scaled_width() * (0.5 + 1.0); section.a.y() -= bridging_flow.scaled_width() * (0.5 + 0.5);
} }
auto maybe_upper_anchor = std::upper_bound(anchors_intersections.begin(), anchors_intersections.end(), section.b, auto maybe_upper_anchor = std::upper_bound(anchors_intersections.begin(), anchors_intersections.end(), section.b,
@ -1936,7 +1944,7 @@ void PrintObject::bridge_over_infill()
}); });
if (maybe_upper_anchor != anchors_intersections.end()) { if (maybe_upper_anchor != anchors_intersections.end()) {
section.b = maybe_upper_anchor->first; section.b = maybe_upper_anchor->first;
section.b.y() += bridging_flow.scaled_width() * (0.5 + 1.0); section.b.y() += bridging_flow.scaled_width() * (0.5 + 0.5);
} }
} }
@ -2059,6 +2067,7 @@ void PrintObject::bridge_over_infill()
}); });
// Gather deep infill areas, where thick bridges fit // Gather deep infill areas, where thick bridges fit
coordf_t spacing = surfaces_by_layer[lidx].front().region->flow(frSolidInfill, true).scaled_spacing();
coordf_t target_flow_height = surfaces_by_layer[lidx].front().region->flow(frSolidInfill, true).height() * target_flow_height_factor; coordf_t target_flow_height = surfaces_by_layer[lidx].front().region->flow(frSolidInfill, true).height() * target_flow_height_factor;
Polygons deep_infill_area = gather_areas_w_depth(po, lidx, target_flow_height); Polygons deep_infill_area = gather_areas_w_depth(po, lidx, target_flow_height);
@ -2079,6 +2088,8 @@ void PrintObject::bridge_over_infill()
} }
} }
deep_infill_area = expand(deep_infill_area, spacing);
// Now gather expansion polygons - internal infill on current layer, from which we can cut off anchors // Now gather expansion polygons - internal infill on current layer, from which we can cut off anchors
Polygons expansion_area; Polygons expansion_area;
Polygons total_fill_area; Polygons total_fill_area;
@ -2088,30 +2099,42 @@ void PrintObject::bridge_over_infill()
Polygons fill_polys = to_polygons(region->fill_expolygons()); Polygons fill_polys = to_polygons(region->fill_expolygons());
total_fill_area.insert(total_fill_area.end(), fill_polys.begin(), fill_polys.end()); total_fill_area.insert(total_fill_area.end(), fill_polys.begin(), fill_polys.end());
} }
total_fill_area = closing(total_fill_area, SCALED_EPSILON); total_fill_area = closing(total_fill_area, SCALED_EPSILON);
expansion_area = closing(expansion_area, SCALED_EPSILON); expansion_area = closing(expansion_area, SCALED_EPSILON);
expansion_area = intersection(expansion_area, deep_infill_area); expansion_area = intersection(expansion_area, deep_infill_area);
Polylines anchors = intersection_pl(infill_lines[lidx - 1], expansion_area); Polylines anchors = intersection_pl(infill_lines[lidx - 1], expansion_area);
#ifdef DEBUG_BRIDGE_OVER_INFILL
debug_draw(std::to_string(lidx) + "_" + std::to_string(cluster_idx) + "_" + std::to_string(job_idx) + "_" +
"_total_area",
to_lines(total_fill_area), to_lines(expansion_area), to_lines(deep_infill_area), to_lines(anchors));
#endif
std::vector<CandidateSurface> expanded_surfaces; std::vector<CandidateSurface> expanded_surfaces;
expanded_surfaces.reserve(surfaces_by_layer[lidx].size()); expanded_surfaces.reserve(surfaces_by_layer[lidx].size());
for (const CandidateSurface &candidate : surfaces_by_layer[lidx]) { for (const CandidateSurface &candidate : surfaces_by_layer[lidx]) {
const Flow &flow = candidate.region->bridging_flow(frSolidInfill, true); const Flow &flow = candidate.region->bridging_flow(frSolidInfill, true);
Polygons area_to_be_bridge = intersection(candidate.new_polys, deep_infill_area); Polygons area_to_be_bridge = expand(candidate.new_polys, flow.scaled_spacing());
area_to_be_bridge = intersection(area_to_be_bridge, deep_infill_area);
Polygons limiting_area = union_(area_to_be_bridge, expansion_area);
if (area_to_be_bridge.empty()) if (area_to_be_bridge.empty())
continue; continue;
area_to_be_bridge = expand(area_to_be_bridge, flow.scaled_spacing());
Polylines boundary_plines = to_polylines(expand(total_fill_area, 1.3 * flow.scaled_spacing())); Polylines boundary_plines = to_polylines(expand(total_fill_area, 1.3 * flow.scaled_spacing()));
{ {
Polylines expansion_plines = to_polylines(expansion_area); Polylines limiting_plines = to_polylines(expand(limiting_area, 0.3*flow.spacing()));
boundary_plines.insert(boundary_plines.end(), expansion_plines.begin(), expansion_plines.end()); boundary_plines.insert(boundary_plines.end(), limiting_plines.begin(), limiting_plines.end());
Polylines expanded_expansion_plines = to_polylines(expand(expansion_area, 1.3 * flow.scaled_spacing()));
boundary_plines.insert(boundary_plines.end(), expanded_expansion_plines.begin(), expanded_expansion_plines.end());
} }
#ifdef DEBUG_BRIDGE_OVER_INFILL
int r = rand();
debug_draw(std::to_string(lidx) + "_" + std::to_string(cluster_idx) + "_" + std::to_string(job_idx) + "_" +
"_anchors_" + std::to_string(r),
to_lines(area_to_be_bridge), to_lines(boundary_plines), to_lines(anchors), to_lines(expansion_area));
#endif
double bridging_angle = 0; double bridging_angle = 0;
if (!anchors.empty()) { if (!anchors.empty()) {
bridging_angle = determine_bridging_angle(area_to_be_bridge, to_lines(anchors), bridging_angle = determine_bridging_angle(area_to_be_bridge, to_lines(anchors),
@ -2145,14 +2168,13 @@ void PrintObject::bridge_over_infill()
} }
bridging_area = opening(bridging_area, flow.scaled_spacing()); bridging_area = opening(bridging_area, flow.scaled_spacing());
bridging_area = intersection(bridging_area, limiting_area);
bridging_area = intersection(bridging_area, total_fill_area); bridging_area = intersection(bridging_area, total_fill_area);
expansion_area = diff(expansion_area, bridging_area); expansion_area = diff(expansion_area, bridging_area);
#ifdef DEBUG_BRIDGE_OVER_INFILL #ifdef DEBUG_BRIDGE_OVER_INFILL
debug_draw(std::to_string(lidx) + "_" + std::to_string(cluster_idx) + "_" + std::to_string(job_idx) + debug_draw(std::to_string(lidx) + "_" + std::to_string(cluster_idx) + "_" + std::to_string(job_idx) + "_" + "_expanded_bridging" + std::to_string(r),
"_expanded_bridging", to_lines(layer->lslices), to_lines(boundary_plines), to_lines(candidate.new_polys), to_lines(bridging_area));
to_lines(layer->lslices), to_lines(boundary_plines), to_lines(candidate.new_polys),
to_lines(bridging_area));
#endif #endif
expanded_surfaces.push_back(CandidateSurface(candidate.original_surface, candidate.layer_index, bridging_area, expanded_surfaces.push_back(CandidateSurface(candidate.original_surface, candidate.layer_index, bridging_area,