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Fix of support missing under horizontal overhang #6058

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There was a bug for more than 4 years, which likely triggers now more
often with the introduction of raft_contact_distance parameter,
which is usually significantly smaller than support_material_contact_distance.
There were no support towers built at the raft for contact layers
below the print_z of the first object layer.
This commit is contained in:
Vojtech Bubnik 2021-10-04 16:33:25 +02:00
parent e533d237f9
commit 6192c57368
1 changed files with 26 additions and 11 deletions
Download patch file Download diff file Expand all files Collapse all files

37
src/libslic3r/SupportMaterial.cpp
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@ -2055,21 +2055,21 @@ static inline PrintObjectSupportMaterial::MyLayer* detect_bottom_contacts(
// Trim the already created base layers above the current layer intersecting with the new bottom contacts layer. // Trim the already created base layers above the current layer intersecting with the new bottom contacts layer.
//FIXME Maybe this is no more needed, as the overlapping base layers are trimmed by the bottom layers at the final stage? //FIXME Maybe this is no more needed, as the overlapping base layers are trimmed by the bottom layers at the final stage?
touching = offset(touching, float(SCALED_EPSILON)); touching = offset(touching, float(SCALED_EPSILON));
for (int layer_id_above = layer_id + 1; layer_id_above < int(object.total_layer_count()); ++layer_id_above) { for (int layer_id_above = layer_id + 1; layer_id_above < int(object.total_layer_count()); ++ layer_id_above) {
const Layer &layer_above = *object.layers()[layer_id_above]; const Layer &layer_above = *object.layers()[layer_id_above];
if (layer_above.print_z > layer_new.print_z - EPSILON) if (layer_above.print_z > layer_new.print_z - EPSILON)
break; break;
if (! layer_support_areas[layer_id_above].empty()) { if (Polygons &above = layer_support_areas[layer_id_above]; ! above.empty()) {
#ifdef SLIC3R_DEBUG #ifdef SLIC3R_DEBUG
SVG::export_expolygons(debug_out_path("support-support-areas-raw-before-trimming-%d-with-%f-%lf.svg", iRun, layer.print_z, layer_above.print_z), SVG::export_expolygons(debug_out_path("support-support-areas-raw-before-trimming-%d-with-%f-%lf.svg", iRun, layer.print_z, layer_above.print_z),
{ { { union_ex(touching) }, { "touching", "blue", 0.5f } }, { { { union_ex(touching) }, { "touching", "blue", 0.5f } },
{ { union_safety_offset_ex(layer_support_areas[layer_id_above]) }, { "above", "red", "black", "", scaled<coord_t>(0.1f), 0.5f } } }); { { union_safety_offset_ex(above) }, { "above", "red", "black", "", scaled<coord_t>(0.1f), 0.5f } } });
#endif /* SLIC3R_DEBUG */ #endif /* SLIC3R_DEBUG */
layer_support_areas[layer_id_above] = diff(layer_support_areas[layer_id_above], touching); above = diff(above, touching);
#ifdef SLIC3R_DEBUG #ifdef SLIC3R_DEBUG
Slic3r::SVG::export_expolygons( Slic3r::SVG::export_expolygons(
debug_out_path("support-support-areas-raw-after-trimming-%d-with-%f-%lf.svg", iRun, layer.print_z, layer_above.print_z), debug_out_path("support-support-areas-raw-after-trimming-%d-with-%f-%lf.svg", iRun, layer.print_z, layer_above.print_z),
union_ex(layer_support_areas[layer_id_above])); union_ex(above));
#endif /* SLIC3R_DEBUG */ #endif /* SLIC3R_DEBUG */
} }
} }
@ -2622,10 +2622,9 @@ void PrintObjectSupportMaterial::generate_base_layers(
// New polygons for layer_intermediate. // New polygons for layer_intermediate.
Polygons polygons_new; Polygons polygons_new;
// Use the precomputed layer_support_areas. // Use the precomputed layer_support_areas. "idx_object_layer_above": above means above since the last iteration, not above after this call.
idx_object_layer_above = std::max(0, idx_lower_or_equal(object.layers().begin(), object.layers().end(), idx_object_layer_above, idx_object_layer_above = idx_lower_or_equal(object.layers().begin(), object.layers().end(), idx_object_layer_above,
[&layer_intermediate](const Layer *layer){ return layer->print_z <= layer_intermediate.print_z + EPSILON; })); [&layer_intermediate](const Layer* layer) { return layer->print_z <= layer_intermediate.print_z + EPSILON; });
polygons_new = layer_support_areas[idx_object_layer_above];
// Polygons to trim polygons_new. // Polygons to trim polygons_new.
Polygons polygons_trimming; Polygons polygons_trimming;
@ -2640,7 +2639,7 @@ void PrintObjectSupportMaterial::generate_base_layers(
idx_top_contact_above = idx_lower_or_equal(top_contacts, idx_top_contact_above, idx_top_contact_above = idx_lower_or_equal(top_contacts, idx_top_contact_above,
[&layer_intermediate](const MyLayer *layer){ return layer->bottom_z <= layer_intermediate.print_z - EPSILON; }); [&layer_intermediate](const MyLayer *layer){ return layer->bottom_z <= layer_intermediate.print_z - EPSILON; });
// Collect all the top_contact layer intersecting with this layer. // Collect all the top_contact layer intersecting with this layer.
for ( int idx_top_contact_overlapping = idx_top_contact_above; idx_top_contact_overlapping >= 0; -- idx_top_contact_overlapping) { for (int idx_top_contact_overlapping = idx_top_contact_above; idx_top_contact_overlapping >= 0; -- idx_top_contact_overlapping) {
MyLayer &layer_top_overlapping = *top_contacts[idx_top_contact_overlapping]; MyLayer &layer_top_overlapping = *top_contacts[idx_top_contact_overlapping];
if (layer_top_overlapping.print_z < layer_intermediate.bottom_z + EPSILON) if (layer_top_overlapping.print_z < layer_intermediate.bottom_z + EPSILON)
break; break;
@ -2651,6 +2650,22 @@ void PrintObjectSupportMaterial::generate_base_layers(
polygons_append(polygons_trimming, layer_top_overlapping.polygons); polygons_append(polygons_trimming, layer_top_overlapping.polygons);
} }
if (idx_object_layer_above < 0) {
// layer_support_areas are synchronized with object layers and they contain projections of the contact layers above them.
// This intermediate layer is not above any object layer, thus there is no information in layer_support_areas about
// towers supporting contact layers intersecting the first object layer. Project these contact layers now.
polygons_new = layer_support_areas.front();
double first_layer_z = object.layers().front()->print_z;
for (int i = idx_top_contact_above + 1; i < int(top_contacts.size()); ++ i) {
MyLayer &contacts = *top_contacts[i];
if (contacts.print_z > first_layer_z + EPSILON)
break;
assert(contacts.bottom_z > layer_intermediate.print_z - EPSILON);
polygons_append(polygons_new, contacts.polygons);
}
} else
polygons_new = layer_support_areas[idx_object_layer_above];
// Trimming the base layer with any overlapping bottom layer. // Trimming the base layer with any overlapping bottom layer.
// Following cases are recognized: // Following cases are recognized:
// 1) bottom.bottom_z >= base.top_z -> No overlap, no trimming needed. // 1) bottom.bottom_z >= base.top_z -> No overlap, no trimming needed.