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Fixing Zero extrusion print moves and overlapping regions in first layer
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#184

No E distances generated when support is selected. bug?
#175
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@bubnikv
bubnikv committed Mar 27, 2017
1 parent 67126d6 commit 640698d
Showing 1 changed file with 67 additions and 57 deletions.
124 changes: 67 additions & 57 deletions xs/src/libslic3r/SupportMaterial.cpp
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Original file line number Diff line number Diff line change
Expand Up @@ -747,45 +747,52 @@ PrintObjectSupportMaterial::MyLayersPtr PrintObjectSupportMaterial::top_contact_
new_layer.height = 0.;
if (layer_id == 0) {
// This is a raft contact layer sitting directly on the print bed.
assert(this->has_raft());
new_layer.bottom_z = m_slicing_params.raft_interface_top_z;
new_layer.height = m_slicing_params.contact_raft_layer_height;
} else if (this->synchronize_layers()) {
// Align bottom of this layer with a top of the closest object layer
// while not trespassing into the 1st layer and keeping the support layer thickness bounded.
int layer_id_below = int(layer_id) - 1;
for (; layer_id_below >= 0; -- layer_id_below) {
layer_below = object.layers[layer_id_below];
if (layer_below->print_z <= new_layer.print_z - m_support_layer_height_min) {
// This is a feasible support layer height.
new_layer.bottom_z = layer_below->print_z;
new_layer.height = new_layer.print_z - new_layer.bottom_z;
assert(new_layer.height <= m_slicing_params.max_suport_layer_height);
break;
}
}
if (layer_id_below == -1) {
// Could not align with any of the top surfaces of object layers.
if (this->has_raft()) {
// If having a raft, all the other layers will be aligned one with the other.
} else {
// Give up, ignore this layer.
continue;
} else {
// Ignore this contact area if it's too low.
// Don't want to print a layer below the first layer height as it may not stick well.
//FIXME there may be a need for a single layer support, then one may decide to print it either as a bottom contact or a top contact
// and it may actually make sense to do it with a thinner layer than the first layer height.
if (new_layer.print_z < m_slicing_params.first_print_layer_height - EPSILON) {
// This contact layer is below the first layer height, therefore not printable. Don't support this surface.
continue;
} else if (new_layer.print_z < m_slicing_params.first_print_layer_height + EPSILON) {
// Align the layer with the 1st layer height.
new_layer.print_z = m_slicing_params.first_print_layer_height;
new_layer.bottom_z = 0;
new_layer.height = m_slicing_params.first_print_layer_height;
} else if (this->synchronize_layers()) {
// Align bottom of this layer with a top of the closest object layer
// while not trespassing into the 1st layer and keeping the support layer thickness bounded.
int layer_id_below = int(layer_id) - 1;
for (; layer_id_below >= 0; -- layer_id_below) {
layer_below = object.layers[layer_id_below];
if (layer_below->print_z <= new_layer.print_z - m_support_layer_height_min) {
// This is a feasible support layer height.
new_layer.bottom_z = layer_below->print_z;
new_layer.height = new_layer.print_z - new_layer.bottom_z;
assert(new_layer.height <= m_slicing_params.max_suport_layer_height);
break;
}
}
if (layer_id_below == -1) {
// Could not align with any of the top surfaces of object layers.
if (this->has_raft()) {
// If having a raft, all the other layers will be aligned one with the other.
} else {
// Give up, ignore this layer.
continue;
}
}
} else {
// Don't know the height of the top contact layer yet. The top contact layer is printed with a normal flow and
// its height will be set adaptively later on.
}
} else {
// Don't know the height of the top contact layer yet. The top contact layer is printed with a normal flow and
// its height will be set adaptively later on.
}
}

// Ignore this contact area if it's too low.
// Don't want to print a layer below the first layer height as it may not stick well.
//FIXME there may be a need for a single layer support, then one may decide to print it either as a bottom contact or a top contact
// and it may actually make sense to do it with a thinner layer than the first layer height.
if (new_layer.print_z < m_slicing_params.first_print_layer_height - EPSILON)
// This contact layer is below the first layer height, therefore not printable. Don't support this surface.
continue;

#if 0
new_layer.polygons = std::move(contact_polygons);
#else
Expand Down Expand Up @@ -1138,7 +1145,11 @@ PrintObjectSupportMaterial::MyLayersPtr PrintObjectSupportMaterial::raft_and_int
return intermediate_layers;
std::sort(extremes.begin(), extremes.end());

assert(extremes.front().z() > m_slicing_params.raft_interface_top_z - EPSILON && (m_slicing_params.raft_layers() == 1 || extremes.front().z() > m_slicing_params.first_print_layer_height - EPSILON));
assert(extremes.empty() ||
(extremes.front().z() > m_slicing_params.raft_interface_top_z - EPSILON &&
(m_slicing_params.raft_layers() == 1 || // only raft contact layer
extremes.front().layer->layer_type == sltTopContact || // first extreme is a top contact layer
extremes.front().z() > m_slicing_params.first_print_layer_height - EPSILON)));

// bool synchronize = m_slicing_params.soluble_interface || this->synchronize_layers();
bool synchronize = this->synchronize_layers();
Expand All @@ -1151,20 +1162,33 @@ PrintObjectSupportMaterial::MyLayersPtr PrintObjectSupportMaterial::raft_and_int
for (size_t idx_extreme = 0; idx_extreme < extremes.size(); ++ idx_extreme) {
LayerExtreme &extr2 = extremes[idx_extreme];
coordf_t extr2z = extr2.z();
if (std::abs(extr2z - m_slicing_params.raft_interface_top_z) < EPSILON)
// This is a raft contact layer.
if (std::abs(extr2z - m_slicing_params.raft_interface_top_z) < EPSILON) {
// This is a raft contact layer, its height has been decided in this->top_contact_layers().
assert(extr2.layer->layer_type == sltTopContact);
continue;
LayerExtreme *extr1 = (idx_extreme == 0) ? NULL : &extremes[idx_extreme - 1];
coordf_t extr1z = (extr1 == NULL) ? m_slicing_params.raft_interface_top_z : extr1->z();
}
if (std::abs(extr2z - m_slicing_params.first_print_layer_height) < EPSILON) {
// This is a 1st layer supporting some of the early object print layers, its height has been decided in this->top_contact_layers().
assert(extr2.layer->layer_type == sltTopContact);
continue;
}
assert(extr2z >= m_slicing_params.raft_interface_top_z + EPSILON);
assert(extr2z >= m_slicing_params.first_print_layer_height + EPSILON);
LayerExtreme *extr1 = (idx_extreme == 0) ? nullptr : &extremes[idx_extreme - 1];
// Fuse a support layer firmly to the raft top interface (not to the raft contacts).
coordf_t extr1z = (extr1 == nullptr) ? m_slicing_params.raft_interface_top_z : extr1->z();
assert(extr2z > extr1z + EPSILON);
if (std::abs(extr1z) < EPSILON) {
// This layer interval starts with the 1st layer. Print the 1st layer using the prescribed 1st layer thickness.
assert(intermediate_layers.empty());
assert(extr2z > m_slicing_params.first_print_layer_height - EPSILON);
assert(! m_slicing_params.has_raft());
assert(intermediate_layers.empty() || intermediate_layers.back()->print_z <= m_slicing_params.first_print_layer_height);
// At this point only layers above first_print_layer_heigth + EPSILON are expected as the other cases were captured earlier.
assert(extr2z >= m_slicing_params.first_print_layer_height + EPSILON);
// Generate a new intermediate layer.
MyLayer &layer_new = layer_allocate(layer_storage, sltIntermediate);
layer_new.bottom_z = 0.;
layer_new.print_z = extr1z = std::min(extr2z, m_slicing_params.first_print_layer_height);
layer_new.height = extr1z;
layer_new.print_z = extr1z = m_slicing_params.first_print_layer_height;
layer_new.height = extr1z;
intermediate_layers.push_back(&layer_new);
// Continue printing the other layers up to extr2z.
}
Expand All @@ -1179,25 +1203,11 @@ PrintObjectSupportMaterial::MyLayersPtr PrintObjectSupportMaterial::raft_and_int
if (! synchronize && ! m_slicing_params.soluble_interface && extr2.layer->layer_type == sltTopContact) {
// This is a top interface layer, which does not have a height assigned yet. Do it now.
assert(extr2.layer->height == 0.);
assert(extr1z > m_slicing_params.first_print_layer_height - EPSILON);
extr2.layer->height = step;
extr2.layer->bottom_z = extr2z = extr2.layer->print_z - step;
-- n_layers_extra;
if (extr2.layer->bottom_z < m_slicing_params.first_print_layer_height) {
// Split the span into two layers: the top layer up to the first layer height,
// and the new intermediate layer below.
// 1) Adjust the bottom of this top layer.
assert(n_layers_extra == 0);
extr2.layer->bottom_z = extr2z = m_slicing_params.first_print_layer_height;
extr2.layer->height = extr2.layer->print_z - extr2.layer->bottom_z;
// 2) Insert a new intermediate layer.
MyLayer &layer_new = layer_allocate(layer_storage, sltIntermediate);
layer_new.bottom_z = extr1z;
layer_new.print_z = m_slicing_params.first_print_layer_height;
layer_new.height = layer_new.print_z - layer_new.bottom_z;
assert(intermediate_layers.empty() || intermediate_layers.back()->print_z <= layer_new.print_z);
intermediate_layers.push_back(&layer_new);
if (-- n_layers_extra == 0)
continue;
}
}
coordf_t extr2z_large_steps = extr2z;
if (synchronize) {
Expand Down

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