change parameter name, fix and improve intersection insertions

src/libslic3r/GCode.cpp

@@ -2916,7 +2916,7 @@ std::string GCode::_extrude(const ExtrusionPath &path, const std::string_view de
     bool                        variable_speed = false;
     std::vector<ProcessedPoint> new_points{};
     if (this->m_config.enable_dynamic_overhang_speeds && !this->on_first_layer() && is_perimeter(path.role())) {
-        new_points     = m_extrusion_quality_estimator.estimate_extrusion_quality(path, m_config.overhang_overlaps,
+        new_points     = m_extrusion_quality_estimator.estimate_extrusion_quality(path, m_config.overhang_steepness_levels,
                                                                                   m_config.dynamic_overhang_speeds,
                                                                                   m_config.get_abs_value("external_perimeter_speed"), speed);
         variable_speed = std::any_of(new_points.begin(), new_points.end(), [speed](const ProcessedPoint &p) { return p.speed != speed; });

src/libslic3r/GCode/ExtrusionProcessor.hpp

@@ -129,35 +129,48 @@ std::vector<ExtendedPoint> estimate_points_properties(const std::vector<P>
         next_point.distance                = distance + boundary_offset;
         next_point.nearest_prev_layer_line = nearest_line;
 
-        if (ADD_INTERSECTIONS) {
+        if (ADD_INTERSECTIONS &&
+            ((points.back().distance > boundary_offset + EPSILON) != (next_point.distance > boundary_offset + EPSILON))) {
             const ExtendedPoint &prev_point = points.back();
-            if ((prev_point.distance < min_malformation_dist) != (next_point.distance < min_malformation_dist)) { // one in air, one not
             auto intersections = unscaled_prev_layer.template intersections_with_line<true>(L{prev_point.position, next_point.position});
-                for (const auto &intersection : intersections) { points.emplace_back(intersection, boundary_offset, 1.0); }
-            }
-
-            if (PREV_LAYER_BOUNDARY_ONLY && prev_point.distance > min_malformation_dist &&
-                next_point.distance > min_malformation_dist) { // both in air
-                double line_len = (prev_point.position - next_point.position).norm();
-                if (line_len > 3.0) {
-                    double a0 = std::clamp((boundary_offset + prev_point.distance) / line_len, 0.0, 1.0);
-                    double a1 = std::clamp((boundary_offset + next_point.distance) / line_len, 0.0, 1.0);
-                    double t0 = std::min(a0, a1);
-                    double t1 = std::max(a0, a1);
-
-                    auto p0                         = prev_point.position + t0 * (next_point.position - prev_point.position);
-                    auto [p0_dist, p0_near_l, p0_x] = unscaled_prev_layer.signed_distance_from_lines_extra(p0);
-                    points.push_back(ExtendedPoint{p0, float(p0_dist + boundary_offset), p0_near_l});
-
-                    auto p1                         = prev_point.position + t1 * (next_point.position - prev_point.position);
-                    auto [p1_dist, p1_near_l, p1_x] = unscaled_prev_layer.signed_distance_from_lines_extra(p1);
-                    points.push_back(ExtendedPoint{p1, float(p1_dist + boundary_offset), p1_near_l});
-                }
+            for (const auto &intersection : intersections) {
+                points.emplace_back(intersection, boundary_offset);
             }
         }
         points.push_back(next_point);
     }
 
+    if (PREV_LAYER_BOUNDARY_ONLY && ADD_INTERSECTIONS) {
+        std::vector<ExtendedPoint> new_points;
+        new_points.reserve(points.size() * 2);
+        new_points.push_back(points.front());
+        for (int point_idx = 0; point_idx < int(points.size()) - 1; ++point_idx) {
+            const ExtendedPoint &curr = points[point_idx];
+            const ExtendedPoint &next = points[point_idx + 1];
+
+            if ((curr.distance > 0 && curr.distance < boundary_offset + 2.0f) &&
+                (next.distance > 0 && next.distance < boundary_offset + 2.0f)) {
+                double line_len = (next.position - curr.position).norm();
+                if (line_len > 4.0f) {
+                    double a0 = std::clamp((curr.distance + 2 * boundary_offset) / line_len, 0.0, 1.0);
+                    double a1 = std::clamp(1.0f - (next.distance + 2 * boundary_offset) / line_len, 0.0, 1.0);
+                    double t0 = std::min(a0, a1);
+                    double t1 = std::max(a0, a1);
+
+                    auto p0                         = curr.position + t0 * (next.position - curr.position);
+                    auto [p0_dist, p0_near_l, p0_x] = unscaled_prev_layer.signed_distance_from_lines_extra(p0);
+                    new_points.push_back(ExtendedPoint{p0, float(p0_dist + boundary_offset), p0_near_l});
+
+                    auto p1                         = curr.position + t1 * (next.position - curr.position);
+                    auto [p1_dist, p1_near_l, p1_x] = unscaled_prev_layer.signed_distance_from_lines_extra(p1);
+                    new_points.push_back(ExtendedPoint{p1, float(p1_dist + boundary_offset), p1_near_l});
+                }
+            }
+            new_points.push_back(next);
+        }
+        points = std::move(new_points);
+    }
+
     for (int point_idx = 0; point_idx < int(points.size()); ++point_idx) {
         ExtendedPoint &a    = points[point_idx];
         ExtendedPoint &prev = points[point_idx > 0 ? point_idx - 1 : point_idx];
@@ -255,7 +268,7 @@ public:
                 return final_speed;
             };
 
-            float extrusion_speed = (calculate_speed(curr.distance) + calculate_speed(next.distance)) / 2.0f;
+            float extrusion_speed = std::min(calculate_speed(curr.distance), calculate_speed(next.distance));
 
             processed_points.push_back({scaled(curr.position), extrusion_speed});
         }

src/libslic3r/Preset.cpp

@@ -429,7 +429,7 @@ static std::vector<std::string> s_Preset_print_options {
     "fuzzy_skin", "fuzzy_skin_thickness", "fuzzy_skin_point_dist",
     "max_volumetric_extrusion_rate_slope_positive", "max_volumetric_extrusion_rate_slope_negative",
     "perimeter_speed", "small_perimeter_speed", "external_perimeter_speed", "infill_speed", "solid_infill_speed",
-    "enable_dynamic_overhang_speeds", "dynamic_overhang_speeds", "overhang_overlaps",
+    "enable_dynamic_overhang_speeds", "dynamic_overhang_speeds", "overhang_steepness_levels",
     "top_solid_infill_speed", "support_material_speed", "support_material_xy_spacing", "support_material_interface_speed",
     "bridge_speed", "gap_fill_speed", "gap_fill_enabled", "travel_speed", "travel_speed_z", "first_layer_speed", "first_layer_speed_over_raft", "perimeter_acceleration", "infill_acceleration",
     "bridge_acceleration", "first_layer_acceleration", "first_layer_acceleration_over_raft", "default_acceleration", "skirts", "skirt_distance", "skirt_height", "draft_shield",

src/libslic3r/PrintConfig.cpp

@@ -535,11 +535,11 @@ void PrintConfigDef::init_fff_params()
     def->mode       = comAdvanced;
     def->set_default_value(new ConfigOptionBool(true));
 
-    def             = this->add("overhang_overlaps", coPercents);
-    def->full_label = L("Overhang overlap percentage");
+    def             = this->add("overhang_steepness_levels", coPercents);
+    def->full_label = L("Steepness levels of overhangs");
     def->category   = L("Speed");
-    def->tooltip    = L("Controls percentage of overhang extrusion overlap with the previous layer."
-                        "Each overlap size then corresponds with the overhang speed set below.");
+    def->tooltip    = L("Controls overhang steepness, expressed as percentage of overlap of the extrusion with the previous layer. "
+                        "Each overhang level then corresponds with the overhang speed below.");
     def->sidetext   = L("%");
     def->min        = 0;
     def->max        = 100;
@@ -549,9 +549,8 @@ void PrintConfigDef::init_fff_params()
     def             = this->add("dynamic_overhang_speeds", coFloatsOrPercents);
     def->full_label = L("Dynamic speed on overhangs");
     def->category   = L("Speed");
-    def->tooltip    = L("This setting controls the speed of the overhangs for overlap values set above."
-                        "The final speed is calculated as an interpolation of the set speed values."
-                        "If set as percentage, the speeds are calculated over the external perimeter speed."
+    def->tooltip    = L("This setting controls the speed on the overhang with steepness value above. "
+                        "If set as percentage, the speed is calculated over the external perimeter speed."
                         );
     def->sidetext   = L("mm/s or %");
     def->min        = 0;

src/libslic3r/PrintConfig.hpp

@@ -565,7 +565,7 @@ PRINT_CONFIG_CLASS_DEFINE(
     ((ConfigOptionFloatOrPercent,       external_perimeter_extrusion_width))
     ((ConfigOptionFloatOrPercent,       external_perimeter_speed))
     ((ConfigOptionBool,                 enable_dynamic_overhang_speeds))
-    ((ConfigOptionPercents,             overhang_overlaps))
+    ((ConfigOptionPercents,             overhang_steepness_levels))
     ((ConfigOptionFloatsOrPercents,     dynamic_overhang_speeds))
     ((ConfigOptionBool,                 external_perimeters_first))
     ((ConfigOptionBool,                 extra_perimeters))

src/libslic3r/PrintObject.cpp

@@ -749,7 +749,7 @@ bool PrintObject::invalidate_state_by_config_options(
             || opt_key == "support_material_interface_speed"
             || opt_key == "bridge_speed"
             || opt_key == "enable_dynamic_overhang_speeds"
-            || opt_key == "overhang_overlaps"
+            || opt_key == "overhang_steepness_levels"
             || opt_key == "dynamic_overhang_speeds"
             || opt_key == "external_perimeter_speed"
             || opt_key == "infill_speed"

src/slic3r/GUI/ConfigManipulation.cpp

@@ -7,6 +7,7 @@
 #include "libslic3r/PresetBundle.hpp"
 #include "MsgDialog.hpp"
 
+#include <string>
 #include <wx/msgdlg.h>
 
 namespace Slic3r {
@@ -220,11 +221,13 @@ void ConfigManipulation::toggle_print_fff_options(DynamicPrintConfig* config)
     bool have_perimeters = config->opt_int("perimeters") > 0;
     for (auto el : { "extra_perimeters","extra_perimeters_on_overhangs", "ensure_vertical_shell_thickness", "thin_walls", "overhangs",
                     "seam_position","staggered_inner_seams", "external_perimeters_first", "external_perimeter_extrusion_width",
-                    "perimeter_speed", "small_perimeter_speed", "external_perimeter_speed", "enable_dynamic_overhang_speeds", "overhang_overlaps", "dynamic_overhang_speeds" })
+                    "perimeter_speed", "small_perimeter_speed", "external_perimeter_speed", "enable_dynamic_overhang_speeds", "overhang_steepness_levels", "dynamic_overhang_speeds" })
         toggle_field(el, have_perimeters);
 
-    toggle_field("overhang_overlaps", config->opt_bool("enable_dynamic_overhang_speeds"));
-    toggle_field("dynamic_overhang_speeds", config->opt_bool("enable_dynamic_overhang_speeds"));
+    for (size_t i = 0; i < 4; i++) {
+        toggle_field("overhang_steepness_levels#" + std::to_string(i), config->opt_bool("enable_dynamic_overhang_speeds"));
+        toggle_field("dynamic_overhang_speeds#" + std::to_string(i), config->opt_bool("enable_dynamic_overhang_speeds"));
+    }
 
     bool have_infill = config->option<ConfigOptionPercent>("fill_density")->value > 0;
     // infill_extruder uses the same logic as in Print::extruders()

src/slic3r/GUI/Tab.cpp

@@ -1538,7 +1538,7 @@ void TabPrint::build()
             optgroup->append_line(line);
         };
         optgroup->append_single_option_line("enable_dynamic_overhang_speeds");
-	    append_option_line(optgroup,"overhang_overlaps");
+	    append_option_line(optgroup,"overhang_steepness_levels");
         append_option_line(optgroup,"dynamic_overhang_speeds");
 
         optgroup = page->new_optgroup(L("Speed for non-print moves"));