ENH: improve archor of internal bridge

Add loop inside sparse infill of lower layer
to provide archor for internal bridge.

This option controls how many lower layers generate
loop path.

Signed-off-by: salt.wei <salt.wei@bambulab.com>
Change-Id: Ifdb6db9090115732aa2cacf5d155b587a10e18fc
(cherry picked from commit 4fdb87ecd5c2e680f6bad2d018ba39cd05f787ce)

resources/profiles/BBL.json

@@ -1,7 +1,7 @@
 {
     "name": "Bambulab",
     "url": "http://www.bambulab.com/Parameters/vendor/BBL.json",
-    "version": "01.04.00.06",
+    "version": "01.04.00.07",
     "force_update": "0",
     "description": "the initial version of BBL configurations",
     "machine_model_list": [

resources/profiles/BBL/process/fdm_process_bbl_0.08.json

@@ -5,6 +5,7 @@
     "instantiation": "false",
     "inherits": "fdm_process_bbl_common",
     "layer_height": "0.08",
+    "elefant_foot_compensation": "0.15",
     "bottom_shell_layers": "7",
     "top_shell_layers": "9",
     "bridge_flow": "1",

resources/profiles/BBL/process/fdm_process_bbl_0.12.json

@@ -6,7 +6,9 @@
     "inherits": "fdm_process_bbl_common",
     "layer_height": "0.12",
     "bottom_shell_layers": "5",
-    "top_shell_layers": "6",
+    "elefant_foot_compensation": "0.15",
+    "top_shell_layers": "5",
+    "top_shell_thickness": "0.6",
     "bridge_flow": "1",
     "initial_layer_speed": "50",
     "initial_layer_infill_speed": "105",

resources/profiles/BBL/process/fdm_process_bbl_0.16.json

@@ -5,8 +5,10 @@
     "instantiation": "false",
     "inherits": "fdm_process_bbl_common",
     "layer_height": "0.16",
+    "elefant_foot_compensation": "0.15",
     "bottom_shell_layers": "4",
-    "top_shell_layers": "5",
+    "top_shell_layers": "4",
+    "top_shell_thickness": "0.6",
     "bridge_flow": "1",
     "initial_layer_speed": "50",
     "initial_layer_infill_speed": "105",

resources/profiles/BBL/process/fdm_process_bbl_0.20.json

@@ -5,8 +5,10 @@
     "instantiation": "false",
     "inherits": "fdm_process_bbl_common",
     "layer_height": "0.2",
+    "elefant_foot_compensation": "0.15",
     "bottom_shell_layers": "3",
-    "top_shell_layers": "4",
+    "top_shell_layers": "3",
+    "top_shell_thickness": "0.6",
     "bridge_flow": "1",
     "initial_layer_speed": "50",
     "initial_layer_infill_speed": "105",

resources/profiles/BBL/process/fdm_process_bbl_0.24.json

@@ -5,9 +5,11 @@
     "instantiation": "false",
     "inherits": "fdm_process_bbl_common",
     "layer_height": "0.24",
+    "elefant_foot_compensation": "0.15",
     "top_surface_line_width": "0.45",
     "bottom_shell_layers": "3",
-    "top_shell_layers": "4",
+    "top_shell_layers": "3",
+    "top_shell_thickness": "0.6",
     "bridge_flow": "1",
     "initial_layer_speed": "50",
     "initial_layer_infill_speed": "105",

resources/profiles/BBL/process/fdm_process_bbl_0.28.json

@@ -5,9 +5,11 @@
     "instantiation": "false",
     "inherits": "fdm_process_bbl_common",
     "layer_height": "0.28",
+    "elefant_foot_compensation": "0.15",
     "top_surface_line_width": "0.45",
     "bottom_shell_layers": "3",
-    "top_shell_layers": "4",
+    "top_shell_layers": "3",
+    "top_shell_thickness": "0.6",
     "bridge_flow": "1",
     "initial_layer_speed": "50",
     "initial_layer_infill_speed": "105",

resources/profiles/BBL/process/fdm_process_bbl_common.json

@@ -30,6 +30,7 @@
     "infill_direction": "45",
     "sparse_infill_density": "15%",
     "sparse_infill_pattern": "grid",
+    "internal_bridge_support_thickness": "0.8",
     "initial_layer_acceleration": "500",
     "initial_layer_line_width": "0.5",
     "initial_layer_print_height": "0.2",

src/libslic3r/Fill/Fill.cpp

@@ -46,6 +46,8 @@ struct SurfaceFillParams
     // 1000mm is roughly the maximum length line that fits into a 32bit coord_t.
     float 			anchor_length     = 1000.f;
     float 			anchor_length_max = 1000.f;
+    //BBS
+    bool            with_loop = false;
 
     // width, height of extrusion, nozzle diameter, is bridge
     // For the output, for fill generator.
@@ -77,6 +79,7 @@ struct SurfaceFillParams
 //		RETURN_COMPARE_NON_EQUAL_TYPED(unsigned, dont_adjust);
 		RETURN_COMPARE_NON_EQUAL(anchor_length);
 		RETURN_COMPARE_NON_EQUAL(anchor_length_max);
+		RETURN_COMPARE_NON_EQUAL(with_loop);
 		RETURN_COMPARE_NON_EQUAL(flow.width());
 		RETURN_COMPARE_NON_EQUAL(flow.height());
 		RETURN_COMPARE_NON_EQUAL(flow.nozzle_diameter());
@@ -97,6 +100,7 @@ struct SurfaceFillParams
 //				this->dont_adjust   	== rhs.dont_adjust 		&&
 				this->anchor_length  	== rhs.anchor_length    &&
 				this->anchor_length_max == rhs.anchor_length_max &&
+				this->with_loop         == rhs.with_loop       &&
 				this->flow 				== rhs.flow 			&&
 				this->extrusion_role	== rhs.extrusion_role;
 	}
@@ -147,6 +151,8 @@ std::vector<SurfaceFill> group_fills(const Layer &layer)
 		        params.extruder 	 = layerm.region().extruder(extrusion_role);
 		        params.pattern 		 = region_config.sparse_infill_pattern.value;
 		        params.density       = float(region_config.sparse_infill_density);
+				//BBS
+				params.with_loop     = surface.surface_type == stInternalWithLoop;
 
 		        if (surface.is_solid()) {
 		            params.density = 100.f;
@@ -465,6 +471,7 @@ void Layer::make_fills(FillAdaptive::Octree* adaptive_fill_octree, FillAdaptive:
 		params.extrusion_role = surface_fill.params.extrusion_role;
 		params.using_internal_flow = using_internal_flow;
 		params.no_extrusion_overlap = surface_fill.params.overlap;
+		params.with_loop = surface_fill.params.with_loop;
 
 		LayerRegion* layerm = this->m_regions[surface_fill.region_id];
 		for (ExPolygon& expoly : surface_fill.expolygons) {

src/libslic3r/Fill/FillBase.cpp

@@ -29,7 +29,7 @@
 namespace Slic3r {
 
 //BBS: 0% of sparse_infill_line_width, no anchor at the start of sparse infill
-float Fill::infill_anchor = 0;
+float Fill::infill_anchor = 400;
 //BBS: 20mm
 float Fill::infill_anchor_max = 20;
 
@@ -122,6 +122,7 @@ void Fill::fill_surface_extrusion(const Surface* surface, const FillParams& para
 {
     Polylines polylines;
     ThickPolylines thick_polylines;
+    if (!params.with_loop) {
         try {
             if (params.use_arachne)
                 thick_polylines = this->fill_surface_arachne(surface, params);
@@ -129,6 +130,49 @@ void Fill::fill_surface_extrusion(const Surface* surface, const FillParams& para
                 polylines = this->fill_surface(surface, params);
         }
         catch (InfillFailedException&) {}
+    }
+    //BBS: add handling for infill pattern with loop
+    else {
+        Slic3r::ExPolygons expp = offset_ex(surface->expolygon, float(scale_(this->overlap - 0.5 * this->spacing)));
+        Polylines loop_polylines = to_polylines(expp);
+        {
+            //BBS: clip the loop
+            size_t j = 0;
+            for (size_t i = 0; i < loop_polylines.size(); ++i) {
+                loop_polylines[i].clip_end(this->loop_clipping);
+                if (loop_polylines[i].is_valid()) {
+                    if (j < i)
+                        loop_polylines[j] = std::move(loop_polylines[i]);
+                    ++j;
+                }
+            }
+            if (j < loop_polylines.size())
+                loop_polylines.erase(loop_polylines.begin() + int(j), loop_polylines.end());
+        }
+
+        if (!loop_polylines.empty()) {
+            if (params.use_arachne)
+                append(thick_polylines, to_thick_polylines(std::move(loop_polylines), scaled<coord_t>(this->spacing)));
+            else
+                append(polylines, std::move(loop_polylines));
+            expp = offset_ex(expp, float(scale_(0 - 0.5 * this->spacing)));
+        } else {
+            //BBS: the area is too narrow to place a loop, return to original expolygon
+            expp = { surface->expolygon };
+        }
+
+        Surface temp_surface = *surface;
+        for (ExPolygon& ex : expp) {
+            temp_surface.expolygon = ex;
+            try {
+                if (params.use_arachne)
+                    append(thick_polylines, std::move(this->fill_surface_arachne(&temp_surface, params)));
+                else
+                    append(polylines, std::move(this->fill_surface(&temp_surface, params)));
+            }
+            catch (InfillFailedException&) {}
+        }
+    }
 
     if (!polylines.empty() || !thick_polylines.empty()) {
         // calculate actual flow from spacing (which might have been adjusted by the infill

src/libslic3r/Fill/FillBase.hpp

@@ -67,6 +67,8 @@ struct FillParams
     bool        use_arachne{ false };
     // Layer height for Concentric infill with Arachne.
     coordf_t    layer_height    { 0.f };
+    //BBS
+    bool        with_loop       { false };
 
     // BBS
     Flow            flow;

src/libslic3r/Preset.cpp

@@ -730,7 +730,7 @@ static std::vector<std::string> s_Preset_print_options {
      "gcode_add_line_number", "enable_arc_fitting", "infill_combination", /*"adaptive_layer_height",*/
      "support_bottom_interface_spacing", "enable_overhang_speed", "overhang_1_4_speed", "overhang_2_4_speed", "overhang_3_4_speed", "overhang_4_4_speed",
      "initial_layer_infill_speed", "only_one_wall_top", 
-     "timelapse_type"
+     "timelapse_type", "internal_bridge_support_thickness"
 };
 
 static std::vector<std::string> s_Preset_filament_options {

src/libslic3r/PrintConfig.cpp

@@ -916,6 +916,19 @@ void PrintConfigDef::init_fff_params()
     def->mode = comAdvanced;
     def->set_default_value(new ConfigOptionBool(true));
 
+    def = this->add("internal_bridge_support_thickness", coFloat);
+    def->label = L("Internal bridge support thickness");
+    def->category = L("Strength");
+    def->tooltip = L("When sparse infill density is low, the internal solid infill or internal bridge may have no archor at the end of line. "
+                     "This cause falling and bad quality when printing internal solid infill. "
+                     "When enable this feature, loop paths will be added to the sparse fill of the lower layers for specific thickness, so that better archor can be provided for internal bridge. "
+                     "0 means disable this feature");
+    def->sidetext = L("mm");
+    def->min = 0;
+    def->max = 2;
+    def->mode = comAdvanced;
+    def->set_default_value(new ConfigOptionFloat(0));
+
     auto def_top_fill_pattern = def = this->add("top_surface_pattern", coEnum);
     def->label = L("Top surface pattern");
     def->category = L("Strength");

src/libslic3r/PrintConfig.hpp

@@ -655,6 +655,7 @@ PRINT_CONFIG_CLASS_DEFINE(
     ((ConfigOptionBool,               detect_narrow_internal_solid_infill))
     // ((ConfigOptionBool,               adaptive_layer_height))
     ((ConfigOptionFloat,              support_bottom_interface_spacing))
+    ((ConfigOptionFloat,              internal_bridge_support_thickness))
 )
 
 // This object is mapped to Perl as Slic3r::Config::PrintRegion.

src/libslic3r/PrintObject.cpp

@@ -770,7 +770,9 @@ bool PrintObject::invalidate_state_by_config_options(
             || opt_key == "solid_infill_filament"
             || opt_key == "sparse_infill_line_width"
             || opt_key == "ensure_vertical_shell_thickness"
-            || opt_key == "bridge_angle") {
+            || opt_key == "bridge_angle"
+            //BBS
+            || opt_key == "internal_bridge_support_thickness") {
             steps.emplace_back(posPrepareInfill);
         } else if (
                opt_key == "top_surface_pattern"
@@ -1611,6 +1613,7 @@ void PrintObject::bridge_over_infill()
 
             Layer       *layer       = *layer_it;
             LayerRegion *layerm      = layer->m_regions[region_id];
+            const PrintObjectConfig& object_config = layer->object()->config();
             //BBS: enable thick bridge for internal bridge only
             Flow         bridge_flow = layerm->bridging_flow(frSolidInfill, true);
 
@@ -1678,8 +1681,43 @@ void PrintObject::bridge_over_infill()
                     (layerm->fill_surfaces.surfaces.end() - 1)->bridge_angle = ibd.angle;
                 }
             }
+
             for (ExPolygon &ex : not_to_bridge)
                 layerm->fill_surfaces.surfaces.push_back(Surface(stInternalSolid, ex));
+
+            //BBS: modify stInternal to be stInternalWithLoop to give better support to internal bridge
+            if (!to_bridge.empty()){
+                float internal_loop_thickness = object_config.internal_bridge_support_thickness.value;
+                double bottom_z = layer->print_z - layer->height - internal_loop_thickness + EPSILON;
+                //BBS: lighting infill doesn't support this feature. Don't need to add loop when infill density is high than 50%
+                if (region.config().sparse_infill_pattern != InfillPattern::ipLightning && region.config().sparse_infill_density.value < 50)
+                    for (int i = int(layer_it - m_layers.begin()) - 1; i >= 0; --i) {
+                        const Layer* lower_layer = m_layers[i];
+
+                        if (lower_layer->print_z < bottom_z) break;
+
+                        for (LayerRegion* lower_layerm : lower_layer->m_regions) {
+                            Polygons lower_internal;
+                            lower_layerm->fill_surfaces.filter_by_type(stInternal, &lower_internal);
+                            ExPolygons internal_with_loop = intersection_ex(lower_internal, to_bridge);
+                            ExPolygons internal = diff_ex(lower_internal, to_bridge);
+                            if (internal_with_loop.empty()) {
+                                //BBS: don't need to do anything
+                            }
+                            else if (internal.empty()) {
+                                lower_layerm->fill_surfaces.change_to_new_type(stInternal, stInternalWithLoop);
+                            }
+                            else {
+                                lower_layerm->fill_surfaces.remove_type(stInternal);
+                                for (ExPolygon& ex : internal_with_loop)
+                                    lower_layerm->fill_surfaces.surfaces.push_back(Surface(stInternalWithLoop, ex));
+                                for (ExPolygon& ex : internal)
+                                    lower_layerm->fill_surfaces.surfaces.push_back(Surface(stInternal, ex));
+                            }
+                        }
+                    }
+            }
+
             /*
             # exclude infill from the layers below if needed
             # see discussion at https://github.com/alexrj/Slic3r/issues/240

src/libslic3r/Surface.hpp

@@ -15,6 +15,8 @@ enum SurfaceType {
     stBottomBridge,
     // Normal sparse infill.
     stInternal,
+    // Normal sparse infill.
+    stInternalWithLoop,
     // Full infill, supporting the top surfaces and/or defining the verticall wall thickness.
     stInternalSolid,
     // 1st layer of dense infill over sparse infill, printed with a bridging extrusion flow.

src/libslic3r/SurfaceCollection.hpp

@@ -37,6 +37,12 @@ public:
     	for (Surface &surface : this->surfaces)
     		surface.surface_type = type;
     }
+    //BBS
+    void change_to_new_type(SurfaceType old_type, SurfaceType new_type) {
+        for (Surface& surface : this->surfaces)
+            if (surface.surface_type == old_type)
+                surface.surface_type = new_type;
+    }
 
     void clear() { surfaces.clear(); }
     bool empty() const { return surfaces.empty(); }

src/slic3r/GUI/Tab.cpp

@@ -1815,6 +1815,7 @@ void TabPrint::build()
         optgroup->append_single_option_line("infill_combination");
         optgroup->append_single_option_line("detect_narrow_internal_solid_infill");
         optgroup->append_single_option_line("ensure_vertical_shell_thickness");
+        optgroup->append_single_option_line("internal_bridge_support_thickness");
 
     page = add_options_page(L("Speed"), "empty");
         optgroup = page->new_optgroup(L("Initial layer speed"), L"param_speed_first", 15);