WIP Ensure vertical wall thickness rework: bugfixes

src/libslic3r/Algorithm/RegionExpansion.cpp

@@ -153,6 +153,46 @@ static inline void merge_splits(ClipperLib_Z::Paths &paths, std::vector<std::pai
     }
 }
 
+using AABBTreeBBoxes = AABBTreeIndirect::Tree<2, coord_t>;
+
+static AABBTreeBBoxes build_aabb_tree_over_expolygons(const ExPolygons &expolygons) 
+{
+    // Calculate bounding boxes of internal slices.
+    std::vector<AABBTreeIndirect::BoundingBoxWrapper> bboxes;
+    bboxes.reserve(expolygons.size());
+    for (size_t i = 0; i < expolygons.size(); ++ i)
+        bboxes.emplace_back(i, get_extents(expolygons[i].contour));
+    // Build AABB tree over bounding boxes of boundary expolygons.
+    AABBTreeBBoxes out;
+    out.build_modify_input(bboxes);
+    return out;
+}
+
+static int sample_in_expolygons(
+    // AABB tree over boundary expolygons
+    const AABBTreeBBoxes &aabb_tree, 
+    const ExPolygons     &expolygons,
+    const Point          &sample)
+{
+    int out = -1;
+    AABBTreeIndirect::traverse(aabb_tree,
+        [&sample](const AABBTreeBBoxes::Node &node) {
+            return node.bbox.contains(sample);
+        },
+        [&expolygons, &sample, &out](const AABBTreeBBoxes::Node &node) {
+            assert(node.is_leaf());
+            assert(node.is_valid());
+            if (expolygons[node.idx].contains(sample)) {
+                out = int(node.idx);
+                // Stop traversal.
+                return false;
+            }
+            // Continue traversal.
+            return true;
+        });
+    return out;
+}
+
 std::vector<WaveSeed> wave_seeds(
     // Source regions that are supposed to touch the boundary.
     const ExPolygons      &src,
@@ -211,19 +251,7 @@ std::vector<WaveSeed> wave_seeds(
     // AABBTree over bounding boxes of boundaries.
     // Only built if necessary, that is if any of the seed contours is closed, thus there is no intersection point
     // with the boundary and all Z coordinates of the closed contour point to the source contour.
-    using AABBTree = AABBTreeIndirect::Tree<2, coord_t>;
+    AABBTreeBBoxes aabb_tree;
-    AABBTree aabb_tree;
-    auto init_aabb_tree = [&aabb_tree, &boundary]() {
-        if (aabb_tree.empty()) {
-            // Calculate bounding boxes of internal slices.
-            std::vector<AABBTreeIndirect::BoundingBoxWrapper> bboxes;
-            bboxes.reserve(boundary.size());
-            for (size_t i = 0; i < boundary.size(); ++ i)
-                bboxes.emplace_back(i, get_extents(boundary[i].contour));
-            // Build AABB tree over bounding boxes of boundary expolygons.
-            aabb_tree.build_modify_input(bboxes);
-        }
-    };
 
     // Sort paths into their respective islands.
     // Each src x boundary will be processed (wave expanded) independently.
@@ -262,24 +290,9 @@ std::vector<WaveSeed> wave_seeds(
             // This should be a closed contour.
             assert(front == back && front.z() >= idx_boundary_end && front.z() < idx_src_end);
             // Find a source boundary expolygon of one sample of this closed path.
-            init_aabb_tree();
+            if (aabb_tree.empty())
-            Point sample(front.x(), front.y());
+                aabb_tree = build_aabb_tree_over_expolygons(boundary);
-            int boundary_id = -1;
+            int boundary_id = sample_in_expolygons(aabb_tree, boundary, Point(front.x(), front.y()));
-            AABBTreeIndirect::traverse(aabb_tree,
-                [&sample](const AABBTree::Node &node) {
-                    return node.bbox.contains(sample);
-                },
-                [&boundary, &sample, &boundary_id](const AABBTree::Node &node) {
-                    assert(node.is_leaf());
-                    assert(node.is_valid());
-                    if (boundary[node.idx].contains(sample)) {
-                        boundary_id = int(node.idx);
-                        // Stop traversal.
-                        return false;
-                    }
-                    // Continue traversal.
-                    return true;
-                });
             // Boundary that contains the sample point was found.
             assert(boundary_id >= 0);
             if (boundary_id >= 0)
@@ -431,6 +444,7 @@ std::vector<RegionExpansionEx> propagate_waves_ex(const WaveSeeds &seeds, const
             for (ExPolygon &ex : expolys)
                 out.push_back({ std::move(ex), it->src_id, it->boundary_id });
         }
+        it = it2;
     }
     return out;
 }
@@ -477,21 +491,44 @@ std::vector<ExPolygon> expand_merge_expolygons(ExPolygons &&src, const ExPolygon
     ExPolygons out;
     out.reserve(src.size());
     for (auto it = expanded.begin(); it != expanded.end();) {
-        auto it2 = it;
-        acc.clear();
-        for (; it2 != expanded.end() && it->src_id == it2->src_id; ++ it2)
-            acc.emplace_back(std::move(it2->polygon));
         for (; last < it->src_id; ++ last)
             out.emplace_back(std::move(src[last]));
+        acc.clear();
+        assert(it->src_id == last);
+        for (; it != expanded.end() && it->src_id == last; ++ it)
+            acc.emplace_back(std::move(it->polygon));
         //FIXME offset & merging could be more efficient, for example one does not need to copy the source expolygon
-        append(acc, to_polygons(std::move(src[it->src_id])));
+        ExPolygon &src_ex = src[last ++];
+        assert(! src_ex.contour.empty());
+#if 0
+        {
+            static int iRun = 0;
+            BoundingBox bbox = get_extents(acc);
+            bbox.merge(get_extents(src_ex));
+            SVG svg(debug_out_path("expand_merge_expolygons-failed-union=%d.svg", iRun ++).c_str(), bbox);
+            svg.draw(acc);
+            svg.draw_outline(acc, "black", scale_(0.05));
+            svg.draw(src_ex, "red");
+            svg.Close();
+        }
+#endif
+        Point sample = src_ex.contour.front();
+        append(acc, to_polygons(std::move(src_ex)));
         ExPolygons merged = union_safety_offset_ex(acc);
         // Expanding one expolygon by waves should not change connectivity of the source expolygon:
         // Single expolygon should be produced possibly with increased number of holes.
-        assert(merged.size() == 1);
+        if (merged.size() > 1) {
-        if (! merged.empty())
+            // assert(merged.size() == 1);
+            // There is something wrong with the initial waves. Most likely the bridge was not valid at all
+            // or the boundary region was very close to some bridge edge, but not really touching.
+            // Pick only a single merged expolygon, which contains one sample point of the source expolygon.
+            auto aabb_tree = build_aabb_tree_over_expolygons(merged);
+            int id = sample_in_expolygons(aabb_tree, merged, sample);
+            assert(id != -1);
+            if (id != -1)
+                out.emplace_back(std::move(merged[id]));
+        } else if (merged.size() == 1)
             out.emplace_back(std::move(merged.front()));
-        it = it2;
     }
     for (; last < uint32_t(src.size()); ++ last)
         out.emplace_back(std::move(src[last]));

src/libslic3r/LayerRegion.cpp

@@ -183,16 +183,17 @@ Surfaces expand_bridges_detect_orientations(
 
     // Cache for detecting bridge orientation and merging regions with overlapping expansions.
     struct Bridge {
-        ExPolygon  expolygon;
+        ExPolygon                                       expolygon;
-        uint32_t   group_id;
+        uint32_t                                        group_id;
-        double     angle = -1;
+        std::vector<RegionExpansionEx>::const_iterator  bridge_expansion_begin;
+        double                                          angle = -1;
     };
     std::vector<Bridge> bridges;
     {
         bridges.reserve(bridges_ex.size());
         uint32_t group_id = 0;
         for (ExPolygon &ex : bridges_ex)
-            bridges.push_back({ std::move(ex), group_id ++ });
+            bridges.push_back({ std::move(ex), group_id ++, bridge_expansions.end() });
         bridges_ex.clear();
     }
 
@@ -243,15 +244,24 @@ Surfaces expand_bridges_detect_orientations(
         std::sort(bridge_anchors.begin(), bridge_anchors.end(), Algorithm::lower_by_src_and_boundary);
         auto it_bridge_anchor = bridge_anchors.begin();
         Lines lines;
+        Polygons anchor_areas;
         for (uint32_t bridge_id = 0; bridge_id < uint32_t(bridges.size()); ++ bridge_id) {
             Bridge &bridge = bridges[bridge_id];
-            lines.clear();
+//            lines.clear();
-            for (++ it_bridge_anchor; it_bridge_anchor != bridge_anchors.end() && it_bridge_anchor->src == bridge_id; ++ it_bridge_anchor)
+            anchor_areas.clear();
-                if (Points &polyline = it_bridge_anchor->path; polyline.size() >= 2) {
+            int32_t last_anchor_id = -1;
-                    reserve_more_power_of_2(lines, polyline.size() - 1);
+            for (; it_bridge_anchor != bridge_anchors.end() && it_bridge_anchor->src == bridge_id; ++ it_bridge_anchor) {
-                    for (size_t i = 1; i < polyline.size(); ++ i)
+                if (last_anchor_id != int(it_bridge_anchor->boundary)) {
-                        lines.push_back({ polyline[i - 1], polyline[1] });
+                    last_anchor_id = int(it_bridge_anchor->boundary);
+                    append(anchor_areas, std::move(to_polygons(shells[last_anchor_id])));
                 }
+//                if (Points &polyline = it_bridge_anchor->path; polyline.size() >= 2) {
+//                    reserve_more_power_of_2(lines, polyline.size() - 1);
+//                    for (size_t i = 1; i < polyline.size(); ++ i)
+//                        lines.push_back({ polyline[i - 1], polyline[1] });
+//                }
+            }
+            lines = to_lines(diff_pl(to_polylines(bridge.expolygon), expand(anchor_areas, float(SCALED_EPSILON))));
             auto [bridging_dir, unsupported_dist] = detect_bridging_direction(lines, to_polygons(bridge.expolygon));
             bridge.angle = M_PI + std::atan2(bridging_dir.y(), bridging_dir.x());
             // #if 1
@@ -273,12 +283,23 @@ Surfaces expand_bridges_detect_orientations(
     {
         Polygons acc;
         Surface templ{ stBottomBridge, {} };
+        std::sort(bridge_expansions.begin(), bridge_expansions.end(), [](auto &l, auto &r) {
+            return l.src_id < r.src_id || (l.src_id == r.src_id && l.boundary_id < r.boundary_id);
+        });
+        for (auto it = bridge_expansions.begin(); it != bridge_expansions.end(); ) {
+            bridges[it->src_id].bridge_expansion_begin = it;
+            uint32_t src_id = it->src_id;
+            for (++ it; it != bridge_expansions.end() && it->src_id == src_id; ++ it) ;
+        }
         for (uint32_t bridge_id = 0; bridge_id < uint32_t(bridges.size()); ++ bridge_id) {
             acc.clear();
             for (uint32_t bridge_id2 = bridge_id; bridge_id2 < uint32_t(bridges.size()); ++ bridge_id2)
                 if (group_id(bridge_id) == bridge_id) {
                     append(acc, to_polygons(std::move(bridges[bridge_id2].expolygon)));
-                    append(acc, to_polygons(std::move(bridge_expansions[bridge_id2].expolygon)));
+                    auto it_bridge_expansion = bridges[bridge_id2].bridge_expansion_begin;
+                    assert(it_bridge_expansion == bridge_expansions.end() || it_bridge_expansion->src_id == bridge_id2);
+                    for (; it_bridge_expansion != bridge_expansions.end() && it_bridge_expansion->src_id == bridge_id2; ++ it_bridge_expansion)
+                        append(acc, to_polygons(std::move(it_bridge_expansion->expolygon)));
                 }
             //FIXME try to be smart and pick the best bridging angle for all?
             templ.bridge_angle = bridges[bridge_id].angle;
@@ -355,8 +376,8 @@ void LayerRegion::process_external_surfaces(const Layer *lower_layer, const Poly
         const double custom_angle = this->region().config().bridge_angle.value;
         const auto   params = Algorithm::RegionExpansionParameters::build(expansion_bottom_bridge, expansion_step, max_nr_expansion_steps);
         bridges.surfaces = custom_angle > 0 ?
-            expand_bridges_detect_orientations(m_fill_surfaces.surfaces, shells, params) :
+            expand_merge_surfaces(m_fill_surfaces.surfaces, stBottomBridge, shells, params, custom_angle) :
-            expand_merge_surfaces(m_fill_surfaces.surfaces, stBottomBridge, shells, params, custom_angle);
+            expand_bridges_detect_orientations(m_fill_surfaces.surfaces, shells, params);
         BOOST_LOG_TRIVIAL(trace) << "Processing external surface, detecting bridges - done";
 #if 0
         {