ENH: ease removal of tree supports

Previously tree supports are harder to remove than normal
supports. We learn from normal supports and improve the gap between
object and supports.

Jira: STUDIO-3530

Change-Id: I229a7b869b334bdf4c5aba96c9450213b83457f2

src/libslic3r/Layer.hpp

@@ -196,6 +196,40 @@ public:
     //BBS: this function calculate the maximum void grid area of sparse infill of this layer. Just estimated value
     coordf_t get_sparse_infill_max_void_area();
 
+    // FN_HIGHER_EQUAL: the provided object pointer has a Z value >= of an internal threshold.
+    // Find the first item with Z value >= of an internal threshold of fn_higher_equal.
+    // If no vec item with Z value >= of an internal threshold of fn_higher_equal is found, return vec.size()
+    // If the initial idx is size_t(-1), then use binary search.
+    // Otherwise search linearly upwards.
+    template<typename IteratorType, typename IndexType, typename FN_HIGHER_EQUAL>
+    static IndexType idx_higher_or_equal(IteratorType begin, IteratorType end, IndexType idx, FN_HIGHER_EQUAL fn_higher_equal)
+    {
+        auto size = int(end - begin);
+        if (size == 0) {
+            idx = 0;
+            }
+        else if (idx == IndexType(-1)) {
+            // First of the batch of layers per thread pool invocation. Use binary search.
+            int idx_low = 0;
+            int idx_high = std::max(0, size - 1);
+            while (idx_low + 1 < idx_high) {
+                int idx_mid = (idx_low + idx_high) / 2;
+                if (fn_higher_equal(begin[idx_mid]))
+                    idx_high = idx_mid;
+                else
+                    idx_low = idx_mid;
+                }
+            idx = fn_higher_equal(begin[idx_low]) ? idx_low :
+                (fn_higher_equal(begin[idx_high]) ? idx_high : size);
+            }
+        else {
+            // For the other layers of this batch of layers, search incrementally, which is cheaper than the binary search.
+            while (int(idx) < size && !fn_higher_equal(begin[idx]))
+                ++idx;
+            }
+        return idx;
+    }
+
 protected:
     friend class PrintObject;
     friend std::vector<Layer*> new_layers(PrintObject*, const std::vector<coordf_t>&);

src/libslic3r/SupportMaterial.cpp

@@ -2834,41 +2834,10 @@ PrintObjectSupportMaterial::MyLayersPtr PrintObjectSupportMaterial::bottom_conta
     return bottom_contacts;
 }
 
-// FN_HIGHER_EQUAL: the provided object pointer has a Z value >= of an internal threshold.
-// Find the first item with Z value >= of an internal threshold of fn_higher_equal.
-// If no vec item with Z value >= of an internal threshold of fn_higher_equal is found, return vec.size()
-// If the initial idx is size_t(-1), then use binary search.
-// Otherwise search linearly upwards.
-template<typename IteratorType, typename IndexType, typename FN_HIGHER_EQUAL>
-IndexType idx_higher_or_equal(IteratorType begin, IteratorType end, IndexType idx, FN_HIGHER_EQUAL fn_higher_equal)
-{
-    auto size = int(end - begin);
-    if (size == 0) {
-        idx = 0;
-    } else if (idx == IndexType(-1)) {
-        // First of the batch of layers per thread pool invocation. Use binary search.
-        int idx_low  = 0;
-        int idx_high = std::max(0, size - 1);
-        while (idx_low + 1 < idx_high) {
-            int idx_mid  = (idx_low + idx_high) / 2;
-            if (fn_higher_equal(begin[idx_mid]))
-                idx_high = idx_mid;
-            else
-                idx_low  = idx_mid;
-        }
-        idx =  fn_higher_equal(begin[idx_low])  ? idx_low  :
-              (fn_higher_equal(begin[idx_high]) ? idx_high : size);
-    } else {
-        // For the other layers of this batch of layers, search incrementally, which is cheaper than the binary search.
-        while (int(idx) < size && ! fn_higher_equal(begin[idx]))
-            ++ idx;
-    }
-    return idx;
-}
 template<typename T, typename IndexType, typename FN_HIGHER_EQUAL>
 IndexType idx_higher_or_equal(const std::vector<T>& vec, IndexType idx, FN_HIGHER_EQUAL fn_higher_equal)
 {
-    return idx_higher_or_equal(vec.begin(), vec.end(), idx, fn_higher_equal);
+    return Layer::idx_higher_or_equal(vec.begin(), vec.end(), idx, fn_higher_equal);
 }
 
 // FN_LOWER_EQUAL: the provided object pointer has a Z value <= of an internal threshold.
@@ -3353,7 +3322,7 @@ void PrintObjectSupportMaterial::trim_support_layers_by_object(
                 assert(! support_layer.polygons.empty() && support_layer.print_z >= m_slicing_params.raft_contact_top_z + EPSILON);
                 // Find the overlapping object layers including the extra above / below gap.
                 coordf_t z_threshold = support_layer.bottom_print_z() - gap_extra_below + EPSILON;
-                idx_object_layer_overlapping = idx_higher_or_equal(
+                idx_object_layer_overlapping = Layer::idx_higher_or_equal(
                     object.layers().begin(), object.layers().end(), idx_object_layer_overlapping,
                     [z_threshold](const Layer *layer){ return layer->print_z >= z_threshold; });
                 // Collect all the object layers intersecting with this layer.

src/libslic3r/TreeSupport.cpp

@@ -1959,7 +1959,8 @@ coordf_t TreeSupport::calc_branch_radius(coordf_t base_radius, coordf_t mm_to_to
     return radius;
 }
 
-ExPolygons avoid_object_remove_extra_small_parts(ExPolygons &expolys, const ExPolygons &avoid_region) {
+template<typename RegionType> // RegionType could be ExPolygons or Polygons
+ExPolygons avoid_object_remove_extra_small_parts(ExPolygons &expolys, const RegionType&avoid_region) {
     ExPolygons expolys_out;
     for (auto expoly : expolys) {
         auto  expolys_avoid = diff_ex(expoly, avoid_region);
@@ -1977,6 +1978,82 @@ ExPolygons avoid_object_remove_extra_small_parts(ExPolygons &expolys, const ExPo
     return expolys_out;
 }
 
+Polygons TreeSupport::get_trim_support_regions(
+    const PrintObject& object,
+    SupportLayer* support_layer_ptr,
+    const coordf_t       gap_extra_above,
+    const coordf_t       gap_extra_below,
+    const coordf_t       gap_xy)
+{
+    static const double sharp_tail_xy_gap = 0.2f;
+    static const double no_overlap_xy_gap = 0.2f;
+    double gap_xy_scaled = scale_(gap_xy);
+    SupportLayer& support_layer = *support_layer_ptr;
+    auto m_print_config = object.print()->config();
+
+    size_t idx_object_layer_overlapping = size_t(-1);
+
+    auto is_layers_overlap = [](const SupportLayer& support_layer, const Layer& object_layer, coordf_t bridging_height = 0.f) -> bool {
+        if (std::abs(support_layer.print_z - object_layer.print_z) < EPSILON)
+            return true;
+
+        coordf_t object_lh = bridging_height > EPSILON ? bridging_height : object_layer.height;
+        if (support_layer.print_z < object_layer.print_z && support_layer.print_z > object_layer.print_z - object_lh)
+            return true;
+
+        if (support_layer.print_z > object_layer.print_z && support_layer.bottom_z() < object_layer.print_z - EPSILON)
+            return true;
+
+        return false;
+        };
+
+    // Find the overlapping object layers including the extra above / below gap.
+    coordf_t z_threshold = support_layer.bottom_z() - gap_extra_below + EPSILON;
+    idx_object_layer_overlapping = Layer::idx_higher_or_equal(
+        object.layers().begin(), object.layers().end(), idx_object_layer_overlapping,
+        [z_threshold](const Layer* layer) { return layer->print_z >= z_threshold; });
+    // Collect all the object layers intersecting with this layer.
+    Polygons polygons_trimming;
+    size_t i = idx_object_layer_overlapping;
+    for (; i < object.layers().size(); ++i) {
+        const Layer& object_layer = *object.layers()[i];
+        if (object_layer.bottom_z() > support_layer.print_z + gap_extra_above - EPSILON)
+            break;
+
+        bool is_overlap = is_layers_overlap(support_layer, object_layer);
+        for (const ExPolygon& expoly : object_layer.lslices) {
+            // BBS
+            bool is_sharptail = !intersection_ex({ expoly }, object_layer.sharp_tails).empty();
+            coordf_t trimming_offset = is_sharptail ? scale_(sharp_tail_xy_gap) :
+                is_overlap ? gap_xy_scaled :
+                scale_(no_overlap_xy_gap);
+            polygons_append(polygons_trimming, offset({ expoly }, trimming_offset, SUPPORT_SURFACES_OFFSET_PARAMETERS));
+            }
+        }
+    if (!m_slicing_params.soluble_interface && m_object_config->thick_bridges) {
+        // Collect all bottom surfaces, which will be extruded with a bridging flow.
+        for (; i < object.layers().size(); ++i) {
+            const Layer& object_layer = *object.layers()[i];
+            bool some_region_overlaps = false;
+            for (LayerRegion* region : object_layer.regions()) {
+                coordf_t bridging_height = region->region().bridging_height_avg(m_print_config);
+                if (object_layer.print_z - bridging_height > support_layer.print_z + gap_extra_above - EPSILON)
+                    break;
+                some_region_overlaps = true;
+
+                bool is_overlap = is_layers_overlap(support_layer, object_layer, bridging_height);
+                coordf_t trimming_offset = is_overlap ? gap_xy_scaled : scale_(no_overlap_xy_gap);
+                polygons_append(polygons_trimming,
+                    offset(region->fill_surfaces.filter_by_type(stBottomBridge), trimming_offset, SUPPORT_SURFACES_OFFSET_PARAMETERS));
+                }
+            if (!some_region_overlaps)
+                break;
+            }
+        }
+
+    return polygons_trimming;
+}
+
 void TreeSupport::draw_circles(const std::vector<std::vector<Node*>>& contact_nodes)
 {
     const PrintObjectConfig &config = m_object->config();
@@ -2171,7 +2248,8 @@ void TreeSupport::draw_circles(const std::vector<std::vector<Node*>>& contact_no
                 roof_1st_layer = std::move(offset2_ex(roof_1st_layer, contact_dist_scaled, -contact_dist_scaled));
 
                 // avoid object
-                auto avoid_region_interface = m_ts_data->get_collision(m_ts_data->m_xy_distance, layer_nr);
+                //ExPolygons avoid_region_interface = m_ts_data->get_collision(m_ts_data->m_xy_distance, layer_nr);
+                Polygons avoid_region_interface = get_trim_support_regions(*m_object, ts_layer, m_slicing_params.gap_object_support, m_slicing_params.gap_support_object, m_ts_data->m_xy_distance);
                 if (has_circle_node) {
                     roof_areas = avoid_object_remove_extra_small_parts(roof_areas, avoid_region_interface);
                     roof_1st_layer = avoid_object_remove_extra_small_parts(roof_1st_layer, avoid_region_interface);
@@ -2248,7 +2326,7 @@ void TreeSupport::draw_circles(const std::vector<std::vector<Node*>>& contact_no
             }
         });
 
-#if 1
+
         if (with_lightning_infill)
         {
             const bool global_lightning_infill = true;
@@ -2433,7 +2511,7 @@ void TreeSupport::draw_circles(const std::vector<std::vector<Node*>>& contact_no
                     }
                 }
             }
-#endif
+
 
 #ifdef SUPPORT_TREE_DEBUG_TO_SVG
     for (int layer_nr = m_object->layer_count() - 1; layer_nr >= 0; layer_nr--) {

src/libslic3r/TreeSupport.hpp

@@ -20,6 +20,7 @@ namespace Slic3r
 {
 class PrintObject;
 class TreeSupport;
+class SupportLayer;
 
 struct LayerHeightData
 {
@@ -494,6 +495,14 @@ private:
     Polygons contact_nodes_to_polygon(const std::vector<Node*>& contact_nodes, Polygons layer_contours, int layer_nr, std::vector<double>& radiis, std::vector<bool>& is_interface);
     coordf_t calc_branch_radius(coordf_t base_radius, size_t layers_to_top, size_t tip_layers, double diameter_angle_scale_factor);
     coordf_t calc_branch_radius(coordf_t base_radius, coordf_t mm_to_top, double diameter_angle_scale_factor);
+
+    // similar to SupportMaterial::trim_support_layers_by_object
+    Polygons get_trim_support_regions(
+        const PrintObject& object,
+        SupportLayer* support_layer_ptr,
+        const coordf_t       gap_extra_above,
+        const coordf_t       gap_extra_below,
+        const coordf_t       gap_xy);
 };
 
 }