Do a slightly thinner interface layer at the top of support material structures by taking into account the diameter of bridge extrudates (nophead's idea)

lib/Slic3r/ExtrusionPath.pm

@@ -19,7 +19,7 @@ has 'polyline' => (
 );
 
 # height is the vertical thickness of the extrusion expressed in mm
-has 'height'       => (is => 'ro');
+has 'height'       => (is => 'rw');
 has 'flow_spacing' => (is => 'rw');
 has 'role'         => (is => 'rw', required => 1);
 

lib/Slic3r/GCode.pm

@@ -6,7 +6,7 @@ use Slic3r::ExtrusionPath ':roles';
 use Slic3r::Geometry qw(scale unscale scaled_epsilon points_coincide PI X Y);
 
 has 'multiple_extruders' => (is => 'ro', default => sub {0} );
-has 'layer'              => (is => 'rw');
+has 'layer'              => (is => 'rw');  # this is not very correct, we should replace it with explicit layer_id and avoid using $self->layer->flow at all here because it's too general
 has 'shift_x'            => (is => 'rw', default => sub {0} );
 has 'shift_y'            => (is => 'rw', default => sub {0} );
 has 'z'                  => (is => 'rw', default => sub {0} );
@@ -52,16 +52,12 @@ my %role_speeds = (
 
 sub change_layer {
     my $self = shift;
-    my ($layer) = @_;
+    my ($layer, %params) = @_;
     
     $self->layer($layer);
-    my $z = $Slic3r::Config->z_offset + $layer->print_z * &Slic3r::SCALING_FACTOR;
     
     my $gcode = "";
-    
+    $gcode .= $self->move_z($layer->print_z) unless $params{dont_move_z};
-    $gcode .= $self->retract(move_z => $z);
-    $gcode .= $self->G0(undef, $z, 0, 'move to next layer (' . $layer->id . ')')
-        if $self->z != $z && !$self->lifted;
     
     $gcode .= $Slic3r::Config->replace_options($Slic3r::Config->layer_gcode) . "\n"
         if $Slic3r::Config->layer_gcode;
@@ -69,6 +65,21 @@ sub change_layer {
     return $gcode;
 }
 
+# this method accepts Z in scaled coordinates
+sub move_z {
+    my $self = shift;
+    my ($z, $comment) = @_;
+    
+    $z = $Slic3r::Config->z_offset + $z * &Slic3r::SCALING_FACTOR;
+    
+    my $gcode = "";
+    $gcode .= $self->retract(move_z => $z);
+    $gcode .= $self->G0(undef, $z, 0, $comment || 'move to next layer (' . $self->layer->id . ')')
+        if $self->z != $z && !$self->lifted;
+    
+    return $gcode;
+}
+
 sub extrude {
     my $self = shift;
     

lib/Slic3r/Layer.pm

@@ -18,14 +18,15 @@ has 'flow'              => (is => 'ro', default => sub { $Slic3r::flow });
 has 'slices'            => (is => 'rw');
 
 # ordered collection of extrusion paths to fill surfaces for support material
-has 'support_fills'     => (is => 'rw');
+has 'support_fills'             => (is => 'rw');
+has 'support_interface_fills'   => (is => 'rw');
 
 sub _trigger_id {
     my $self = shift;
     $_->_trigger_layer for @{$self->regions || []};
 }
 
-# Z used for slicing
+# Z used for slicing in scaled coordinates
 sub _build_slice_z {
     my $self = shift;
     
@@ -36,17 +37,37 @@ sub _build_slice_z {
         / &Slic3r::SCALING_FACTOR;  #/
 }
 
-# Z used for printing
+# Z used for printing in scaled coordinates
 sub _build_print_z {
     my $self = shift;
     return ($Slic3r::Config->get_value('first_layer_height') + ($self->id * $Slic3r::Config->layer_height)) / &Slic3r::SCALING_FACTOR;
 }
 
+# layer height in unscaled coordinates
 sub _build_height {
     my $self = shift;
     return $self->id == 0 ? $Slic3r::Config->get_value('first_layer_height') : $Slic3r::Config->layer_height;
 }
 
+# layer height of interface paths in unscaled coordinates
+sub support_material_interface_height {
+    my $self = shift;
+    
+    return $self->height if $self->id == 0;
+    
+    # this is not very correct because:
+    # - we should sum our height with the actual upper layers height (which might be different)
+    # - we should use the actual flow of the upper layer bridges, not the default one
+    # ...but we're close enough for now
+    return 2*$self->height - $self->flow->nozzle_diameter;
+}
+
+# Z used for printing support material interface in scaled coordinates
+sub support_material_interface_z {
+    my $self = shift;
+    return $self->print_z - ($self->height - $self->support_material_interface_height) / &Slic3r::SCALING_FACTOR;
+}
+
 sub region {
     my $self = shift;
     my ($region_id) = @_;

lib/Slic3r/Print.pm

@@ -702,8 +702,8 @@ sub write_gcode {
                 if $Slic3r::Config->bed_temperature && $Slic3r::Config->bed_temperature != $Slic3r::Config->first_layer_bed_temperature;
         }
         
-        # go to layer (just use the first one, we only need Z from it)
+        # set new layer, but don't move Z as support material interfaces may need an intermediate one
-        $gcode .= $gcodegen->change_layer($self->objects->[$object_copies->[0][0]]->layers->[$layer_id]);
+        $gcode .= $gcodegen->change_layer($self->objects->[$object_copies->[0][0]]->layers->[$layer_id], dont_move_z => 1);
         $gcodegen->elapsed_time(0);
         
         # extrude skirt
@@ -742,6 +742,23 @@ sub write_gcode {
             $gcodegen->shift_x($shift[X] + unscale $copy->[X]);
             $gcodegen->shift_y($shift[Y] + unscale $copy->[Y]);
             
+            # extrude support material before other things because it might use a lower Z
+            # and also because we avoid travelling on other things when printing it
+            if ($Slic3r::Config->support_material) {
+                $gcode .= $gcodegen->move_z($layer->support_material_interface_z)
+                    if @{ $layer->support_interface_fills->paths };
+                $gcode .= $gcodegen->set_extruder($self->extruders->[$Slic3r::Config->support_material_extruder-1]);
+                $gcode .= $gcodegen->extrude_path($_, 'support material interface') 
+                    for $layer->support_interface_fills->shortest_path($gcodegen->last_pos);
+                
+                $gcode .= $gcodegen->move_z($layer->print_z);
+                $gcode .= $gcodegen->extrude_path($_, 'support material') 
+                    for $layer->support_fills->shortest_path($gcodegen->last_pos);
+            }
+            
+            # set actual Z
+            $gcode .= $gcodegen->move_z($layer->print_z);
+            
             foreach my $region_id (0 .. ($self->regions_count-1)) {
                 my $layerm = $layer->regions->[$region_id];
                 my $region = $self->regions->[$region_id];
@@ -766,13 +783,6 @@ sub write_gcode {
                     }
                 }
             }
-                
-            # extrude support material
-            if ($layer->support_fills) {
-                $gcode .= $gcodegen->set_extruder($self->extruders->[$Slic3r::Config->support_material_extruder-1]);
-                $gcode .= $gcodegen->extrude_path($_, 'support material') 
-                    for $layer->support_fills->shortest_path($gcodegen->last_pos);
-            }
         }
         return if !$gcode;
         

lib/Slic3r/Print/Object.pm

@@ -517,7 +517,8 @@ sub generate_support_material {
     
     # determine support regions in each layer (for upper layers)
     Slic3r::debugf "Detecting regions\n";
-    my %layers = ();
+    my %layers = ();            # this represents the areas of each layer having to support upper layers (excluding interfaces)
+    my %layers_interfaces = (); # this represents the areas of each layer having an overhang in the immediately upper layer
     {
         my @current_support_regions = ();   # expolygons we've started to support (i.e. below the empty interface layers)
         my @queue = ();                     # the number of items of this array determines the number of empty interface layers
@@ -525,6 +526,10 @@ sub generate_support_material {
             my $layer = $self->layers->[$i];
             my $lower_layer = $i > 0 ? $self->layers->[$i-1] : undef;
             
+            # $queue[-1] contains the overhangs of the upper layer, regardless of any empty interface layers
+            # $queue[0] contains the overhangs of the first upper layer above the empty interface layers
+            $layers_interfaces{$i} = [@{ $queue[-1] || [] }];
+            
             # step 1: generate support material in current layer (for upper layers)
             push @current_support_regions, @{ shift @queue } if @queue && $i < $#{$self->layers};
             
@@ -535,7 +540,10 @@ sub generate_support_material {
             
             $layers{$i} = diff_ex(
                 [ map @$_, @current_support_regions ],
-                [ map @$_, map $_->offset_ex($distance_from_object), @{$layer->slices} ],
+                [
+                    (map @$_, map $_->offset_ex($distance_from_object), @{$layer->slices}),
+                    (map @$_, @{ $layers_interfaces{$i} }),
+                ],
             );
             $_->simplify($flow->scaled_spacing * 2) for @{$layers{$i}};
             
@@ -599,12 +607,13 @@ sub generate_support_material {
     Slic3r::debugf "Applying patterns\n";
     {
         my $clip_pattern = sub {
-            my ($layer_id, $expolygons) = @_;
+            my ($layer_id, $expolygons, $height) = @_;
             my @paths = ();
             foreach my $expolygon (@$expolygons) {
                 push @paths,
                     map $_->pack,
                     map {
+                        $_->height($height);
                         $_->flow_spacing($self->print->first_layer_support_material_flow->spacing)
                             if $layer_id == 0;
                         $_;
@@ -616,29 +625,41 @@ sub generate_support_material {
             return @paths;
         };
         my %layer_paths = ();
+        my %layer_interface_paths = ();
+        my $process_layer = sub {
+            my ($layer_id) = @_;
+            
+            my $layer = $self->layers->[$layer_id];
+            my $paths           = [ $clip_pattern->($layer_id, $layers{$layer_id}, $layer->height) ];
+            my $interface_paths = [ $clip_pattern->($layer_id, $layers_interfaces{$layer_id}, $layer->support_material_interface_height) ];
+            return ($paths, $interface_paths);
+        };
         Slic3r::parallelize(
             items => [ keys %layers ],
             thread_cb => sub {
                 my $q = shift;
                 my $paths = {};
+                my $interface_paths = {};
                 while (defined (my $layer_id = $q->dequeue)) {
-                    $paths->{$layer_id} = [ $clip_pattern->($layer_id, $layers{$layer_id}) ];
+                    ($paths->{$layer_id}, $interface_paths->{$layer_id}) = $process_layer->($layer_id);
                 }
-                return $paths;
+                return [ $paths, $interface_paths ];
             },
             collect_cb => sub {
                 my $paths = shift;
-                $layer_paths{$_} = $paths->{$_} for keys %$paths;
+                ($layer_paths{$_}, $layer_interface_paths{$_}) = @{ $paths->{$_} } for keys %$paths;
             },
             no_threads_cb => sub {
-                $layer_paths{$_} = [ $clip_pattern->($_, $layers{$_}) ] for keys %layers;
+                ($layer_paths{$_}, $layer_interface_paths{$_}) = $process_layer->($_) for keys %layers;
             },
         );
         
         foreach my $layer_id (keys %layer_paths) {
             my $layer = $self->layers->[$layer_id];
             $layer->support_fills(Slic3r::ExtrusionPath::Collection->new);
+            $layer->support_interface_fills(Slic3r::ExtrusionPath::Collection->new);
             push @{$layer->support_fills->paths}, @{$layer_paths{$layer_id}};
+            push @{$layer->support_interface_fills->paths}, @{$layer_interface_paths{$layer_id}};
         }
     }
 }