Ironing support interfaces (#9548)

* Generate support interface iron extrusion

* Always ironing last

* Add options

* Move ironing speed to speed tab

* Don't iron places that are covered by upper support layers

* Disable support interface spacing settings when support ironing is enabled

* Update text

src/libslic3r/GCode.cpp

@@ -4325,10 +4325,16 @@ LayerResult GCode::process_layer(
 
                     ExtrusionRole support_extrusion_role = instance_to_print.object_by_extruder.support_extrusion_role;
                     bool is_overridden = support_extrusion_role == erSupportMaterialInterface ? support_intf_overridden : support_overridden;
-                    if (is_overridden == (print_wipe_extrusions != 0))
+                    if (is_overridden == (print_wipe_extrusions != 0)) {
                         gcode += this->extrude_support(
                             // support_extrusion_role is erSupportMaterial, erSupportTransition, erSupportMaterialInterface or erMixed for all extrusion paths.
-                            instance_to_print.object_by_extruder.support->chained_path_from(m_last_pos, support_extrusion_role));
+                            *instance_to_print.object_by_extruder.support, support_extrusion_role);
+
+                        // Make sure ironing is the last
+                        if (support_extrusion_role == erMixed || support_extrusion_role == erSupportMaterialInterface) {
+                            gcode += this->extrude_support(*instance_to_print.object_by_extruder.support, erIroning);
+                        }
+                    }
 
                     m_layer = layer_to_print.layer();
                     m_object_layer_over_raft = object_layer_over_raft;
@@ -5036,21 +5042,37 @@ std::string GCode::extrude_infill(const Print &print, const std::vector<ObjectBy
     return gcode;
 }
 
-std::string GCode::extrude_support(const ExtrusionEntityCollection &support_fills)
+std::string GCode::extrude_support(const ExtrusionEntityCollection &support_fills, const ExtrusionRole support_extrusion_role)
 {
     static constexpr const char *support_label            = "support material";
     static constexpr const char *support_interface_label  = "support material interface";
-    const char* support_transition_label = "support transition";
+    static constexpr const char* support_transition_label = "support transition";
+    static constexpr const char* support_ironing_label    = "support ironing";
 
     std::string gcode;
     if (! support_fills.entities.empty()) {
+
+        ExtrusionEntitiesPtr extrusions;
+        extrusions.reserve(support_fills.entities.size());
+        for (ExtrusionEntity* ee : support_fills.entities) {
+            const auto role = ee->role();
+            if ((role == support_extrusion_role) || (support_extrusion_role == erMixed && role != erIroning)) {
+                extrusions.emplace_back(ee);
+            }
+        }
+        if (extrusions.empty())
+            return gcode;
+
+        chain_and_reorder_extrusion_entities(extrusions, &m_last_pos);
+
         const double  support_speed            = m_config.support_speed.value;
         const double  support_interface_speed  = m_config.get_abs_value("support_interface_speed");
-        for (const ExtrusionEntity *ee : support_fills.entities) {
+        for (const ExtrusionEntity *ee : extrusions) {
             ExtrusionRole role = ee->role();
-            assert(role == erSupportMaterial || role == erSupportMaterialInterface || role == erSupportTransition);
+            assert(role == erSupportMaterial || role == erSupportMaterialInterface || role == erSupportTransition || role == erIroning);
             const char* label = (role == erSupportMaterial) ? support_label :
-                ((role == erSupportMaterialInterface) ? support_interface_label : support_transition_label);
+                ((role == erSupportMaterialInterface) ? support_interface_label : 
+                ((role == erIroning) ? support_ironing_label : support_transition_label));
             // BBS
             //const double speed = (role == erSupportMaterial) ? support_speed : support_interface_speed;
             const double speed = -1.0;
@@ -5067,7 +5089,7 @@ std::string GCode::extrude_support(const ExtrusionEntityCollection &support_fill
                 gcode += this->extrude_loop(*loop, label, speed);
             }
             else if (collection) {
-                gcode += extrude_support(*collection);
+                gcode += extrude_support(*collection, support_extrusion_role);
             }
             else {
                 throw Slic3r::InvalidArgument("Unknown extrusion type");

src/libslic3r/GCode.hpp

@@ -449,7 +449,7 @@ private:
 
     std::string     extrude_perimeters(const Print& print, const std::vector<ObjectByExtruder::Island::Region>& by_region, bool is_first_layer, bool is_infill_first);
     std::string     extrude_infill(const Print& print, const std::vector<ObjectByExtruder::Island::Region>& by_region, bool ironing);
-    std::string     extrude_support(const ExtrusionEntityCollection& support_fills);
+    std::string     extrude_support(const ExtrusionEntityCollection& support_fills, const ExtrusionRole support_extrusion_role);
 
     // BBS
     LiftType to_lift_type(ZHopType z_hop_types);

src/libslic3r/Preset.cpp

@@ -789,6 +789,7 @@ static std::vector<std::string> s_Preset_print_options {
     "infill_direction", "solid_infill_direction", "rotate_solid_infill_direction",  "counterbore_hole_bridging",
     "minimum_sparse_infill_area", "reduce_infill_retraction","internal_solid_infill_pattern","gap_fill_target",
     "ironing_type", "ironing_pattern", "ironing_flow", "ironing_speed", "ironing_spacing", "ironing_angle", "ironing_inset",
+    "support_ironing", "support_ironing_pattern", "support_ironing_flow", "support_ironing_spacing",
     "max_travel_detour_distance",
     "fuzzy_skin", "fuzzy_skin_thickness", "fuzzy_skin_point_distance", "fuzzy_skin_first_layer", "fuzzy_skin_noise_type", "fuzzy_skin_scale", "fuzzy_skin_octaves", "fuzzy_skin_persistence",
     "max_volumetric_extrusion_rate_slope", "max_volumetric_extrusion_rate_slope_segment_length","extrusion_rate_smoothing_external_perimeter_only",

src/libslic3r/PrintConfig.cpp

@@ -4897,7 +4897,8 @@ void PrintConfigDef::init_fff_params()
     def = this->add("support_interface_spacing", coFloat);
     def->label = L("Top interface spacing");
     def->category = L("Support");
-    def->tooltip = L("Spacing of interface lines. Zero means solid interface.");
+    def->tooltip = L("Spacing of interface lines. Zero means solid interface.\n"
+                     "Force using solid interface when support ironing is enabled.");
     def->sidetext = L("mm");
     def->min = 0;
     def->mode = comAdvanced;
@@ -5193,6 +5194,48 @@ void PrintConfigDef::init_fff_params()
     def->mode = comAdvanced;
     def->set_default_value(new ConfigOptionBool(false));
     
+    def = this->add("support_ironing", coBool);
+    def->label = L("Ironing Support Interface");
+    def->category = L("Support");
+    def->tooltip = L("Ironing is using small flow to print on same height of support interface again to make it more smooth. "
+                     "This setting controls whether support interface being ironed. When enabled, support interface will be extruded as solid too.");
+    def->mode = comAdvanced;
+    def->set_default_value(new ConfigOptionBool(false));
+
+    def                = this->add("support_ironing_pattern", coEnum);
+    def->label         = L("Support Ironing Pattern");
+    def->tooltip       = L("The pattern that will be used when ironing.");
+    def->category      = L("Support");
+    def->enum_keys_map = &ConfigOptionEnum<InfillPattern>::get_enum_values();
+    def->enum_values.push_back("concentric");
+    def->enum_values.push_back("zig-zag");
+    def->enum_labels.push_back(L("Concentric"));
+    def->enum_labels.push_back(L("Rectilinear"));
+    def->mode = comAdvanced;
+    def->set_default_value(new ConfigOptionEnum<InfillPattern>(ipRectilinear));
+    
+    def = this->add("support_ironing_flow", coPercent);
+    def->label = L("Support Ironing flow");
+    def->category = L("Support");
+    def->tooltip = L("The amount of material to extrude during ironing. Relative to flow of normal support interface layer height. "
+                     "Too high value results in overextrusion on the surface.");
+    def->sidetext = "%";
+    def->ratio_over = "layer_height";
+    def->min = 0;
+    def->max = 100;
+    def->mode = comAdvanced;
+    def->set_default_value(new ConfigOptionPercent(10));
+
+    def = this->add("support_ironing_spacing", coFloat);
+    def->label = L("Support Ironing line spacing");
+    def->category = L("Support");
+    def->tooltip = L("The distance between the lines of ironing.");
+    def->sidetext = L("mm");
+    def->min = 0;
+    def->max = 1;
+    def->mode = comAdvanced;
+    def->set_default_value(new ConfigOptionFloat(0.1));
+
     def = this->add("activate_chamber_temp_control",coBools);
     def->label = L("Activate temperature control");
     def->tooltip = L("Enable this option for automated chamber temperature control. "

src/libslic3r/PrintConfig.hpp

@@ -849,6 +849,10 @@ PRINT_CONFIG_CLASS_DEFINE(
     ((ConfigOptionFloatOrPercent,      support_threshold_overlap))
     ((ConfigOptionFloat,               support_object_xy_distance))
     ((ConfigOptionFloat,               support_object_first_layer_gap))
+    ((ConfigOptionBool,                support_ironing))
+    ((ConfigOptionEnum<InfillPattern>, support_ironing_pattern))
+    ((ConfigOptionPercent,             support_ironing_flow))
+    ((ConfigOptionFloat,               support_ironing_spacing))
     ((ConfigOptionFloat,               xy_hole_compensation))
     ((ConfigOptionFloat,               xy_contour_compensation))
     ((ConfigOptionBool,                flush_into_objects))

src/libslic3r/PrintObject.cpp

@@ -1016,6 +1016,10 @@ bool PrintObject::invalidate_state_by_config_options(
             //|| opt_key == "independent_support_layer_height" // BBS
             || opt_key == "support_threshold_angle"
             || opt_key == "support_threshold_overlap"
+            || opt_key == "support_ironing"
+            || opt_key == "support_ironing_pattern"
+            || opt_key == "support_ironing_flow"
+            || opt_key == "support_ironing_spacing"
             || opt_key == "raft_expansion"
             || opt_key == "raft_first_layer_density"
             || opt_key == "raft_first_layer_expansion"

src/libslic3r/Support/SupportCommon.cpp

@@ -1605,6 +1605,9 @@ void generate_support_toolpaths(
         SupportGeneratorLayerExtruded                                     base_interface_layer;
         boost::container::static_vector<LayerCacheItem, 5>  nonempty;
 
+        float    ironing_angle;
+        Polygons polys_to_iron;
+
         void add_nonempty_and_sort() {
             for (SupportGeneratorLayerExtruded *item : { &bottom_contact_layer, &top_contact_layer, &interface_layer, &base_interface_layer, &base_layer })
                 if (! item->empty())
@@ -1694,6 +1697,12 @@ void generate_support_toolpaths(
                         base_layer = std::move(top_contact_layer);
                 }
             } else {
+                if (support_params.ironing && !top_contact_layer.empty()) {
+                    // Orca: save the top surface to be ironed later
+                    layer_cache.ironing_angle = support_interface_angle; // TODO: should we rotate 90 degrees?
+                    layer_cache.polys_to_iron = top_contact_layer.polygons_to_extrude();
+                }
+
                 loop_interface_processor.generate(top_contact_layer, support_params.support_material_interface_flow);
                 // If no loops are allowed, we treat the contact layer exactly as a generic interface layer.
                 // Merge interface_layer into top_contact_layer, as the top_contact_layer is not synchronized and therefore it will be used
@@ -1886,7 +1895,7 @@ void generate_support_toolpaths(
 
     // Now modulate the support layer height in parallel.
     tbb::parallel_for(tbb::blocked_range<size_t>(n_raft_layers, support_layers.size()),
-        [&support_layers, &layer_caches]
+        [&support_layers, &layer_caches, &support_params, &bbox_object]
             (const tbb::blocked_range<size_t>& range) {
         for (size_t support_layer_id = range.begin(); support_layer_id < range.end(); ++ support_layer_id) {
             SupportLayer &support_layer = *support_layers[support_layer_id];
@@ -1897,6 +1906,39 @@ void generate_support_toolpaths(
                 modulate_extrusion_by_overlapping_layers(layer_cache_item.layer_extruded->extrusions, *layer_cache_item.layer_extruded->layer, layer_cache_item.overlapping);
                 support_layer.support_fills.append(std::move(layer_cache_item.layer_extruded->extrusions));
             }
+
+            // Orca: Generate iron toolpath for contact layer
+            if (!layer_cache.polys_to_iron.empty()) {
+                auto f = std::unique_ptr<Fill>(Fill::new_from_type(support_params.ironing_pattern));
+                f->set_bounding_box(bbox_object);
+                f->layer_id        = support_layer.id();
+                f->z               = support_layer.print_z;
+                f->overlap         = 0;
+                f->angle           = layer_cache.ironing_angle;
+                f->spacing         = support_params.ironing_spacing;
+                f->link_max_length = (coord_t) scale_(3. * f->spacing);
+
+                ExPolygons polys_to_iron = union_safety_offset_ex(layer_cache.polys_to_iron);
+                layer_cache.polys_to_iron.clear();
+
+                // Find the layer above that directly overlaps current layer, clip the overlapped part
+                if (support_layer_id < support_layers.size() - 1) {
+                    const auto& upper_layer = support_layers[support_layer_id + 1];
+                    if (!upper_layer->support_islands.empty() && upper_layer->bottom_z() <= support_layer.print_z + EPSILON) {
+                        polys_to_iron = diff_ex(polys_to_iron, upper_layer->support_islands);
+                    }
+                }
+
+                fill_expolygons_generate_paths(
+                    // Destination
+                    support_layer.support_fills.entities,
+                    // Regions to fill
+                    std::move(polys_to_iron),
+                    // Filler and its parameters
+                    f.get(), 1.f,
+                    // Extrusion parameters
+                    ExtrusionRole::erIroning, support_params.ironing_flow);
+            }
         }
     });
 

src/libslic3r/Support/SupportParameters.hpp

@@ -48,6 +48,11 @@ struct SupportParameters {
         this->support_material_interface_flow = Slic3r::support_material_interface_flow(&object, float(slicing_params.layer_height));
     	this->raft_interface_flow                = support_material_interface_flow;
 
+        this->ironing = object_config.support_ironing;
+        this->ironing_flow = support_material_interface_flow.with_height(support_material_interface_flow.height() * 0.01 * object_config.support_ironing_flow.value);
+        this->ironing_spacing = object_config.support_ironing_spacing;
+        this->ironing_pattern = object_config.support_ironing_pattern;
+
         // Calculate a minimum support layer height as a minimum over all extruders, but not smaller than 10um.
         this->support_layer_height_min = scaled<coord_t>(0.01);
         for (auto lh : print_config.min_layer_height.values)
@@ -90,9 +95,11 @@ struct SupportParameters {
 
         this->base_angle = Geometry::deg2rad(float(object_config.support_angle.value));
         this->interface_angle = Geometry::deg2rad(float(object_config.support_angle.value + 90.));
-        this->interface_spacing = object_config.support_interface_spacing.value + this->support_material_interface_flow.spacing();
+        // Orca: Force solid support interface when using support ironing
+        this->interface_spacing = (this->ironing ? 0 : object_config.support_interface_spacing.value) + this->support_material_interface_flow.spacing();
         this->interface_density = std::min(1., this->support_material_interface_flow.spacing() / this->interface_spacing);
-        double raft_interface_spacing = object_config.support_interface_spacing.value + this->raft_interface_flow.spacing();
+        // Orca: Force solid support interface when using support ironing
+        double raft_interface_spacing = (this->ironing ? 0 : object_config.support_interface_spacing.value) + this->raft_interface_flow.spacing();
         this->raft_interface_density = std::min(1., this->raft_interface_flow.spacing() / raft_interface_spacing);
         this->support_spacing = object_config.support_base_pattern_spacing.value + this->support_material_flow.spacing();
         this->support_density = std::min(1., this->support_material_flow.spacing() / this->support_spacing);
@@ -260,6 +267,11 @@ struct SupportParameters {
 		
     bool independent_layer_height = false;
     const double thresh_big_overhang = Slic3r::sqr(scale_(10));
+
+	bool          ironing;
+    Flow          ironing_flow; // Flow at the interface ironing.
+    InfillPattern ironing_pattern;
+    float         ironing_spacing;
 };
 
 } // namespace Slic3r

src/slic3r/GUI/ConfigManipulation.cpp

@@ -224,6 +224,17 @@ void ConfigManipulation::update_print_fff_config(DynamicPrintConfig* config, con
         apply(config, &new_conf);
         is_msg_dlg_already_exist = false;
     }
+    if (config->opt_float("support_ironing_spacing") < 0.05)
+    {
+        const wxString msg_text = _(L("Too small ironing spacing.\nReset to 0.1"));
+        MessageDialog dialog(nullptr, msg_text, "", wxICON_WARNING | wxOK);
+        DynamicPrintConfig new_conf = *config;
+        is_msg_dlg_already_exist = true;
+        dialog.ShowModal();
+        new_conf.set_key_value("support_ironing_spacing", new ConfigOptionFloat(0.1));
+        apply(config, &new_conf);
+        is_msg_dlg_already_exist = false;
+    }
 
     if (config->option<ConfigOptionFloat>("initial_layer_print_height")->value < EPSILON)
     {
@@ -634,10 +645,18 @@ void ConfigManipulation::toggle_print_fff_options(DynamicPrintConfig *config, co
     toggle_line("bridge_no_support", !support_is_normal_tree);
     toggle_line("support_critical_regions_only", is_auto(support_type) && support_is_tree);
 
-    for (auto el : { "support_interface_spacing", "support_interface_filament",
+    for (auto el : { "support_interface_filament",
         "support_interface_loop_pattern", "support_bottom_interface_spacing" })
         toggle_field(el, have_support_material && have_support_interface);
 
+    bool can_ironing_support = have_raft || (have_support_material && config->opt_int("support_interface_top_layers") > 0);
+    toggle_field("support_ironing", can_ironing_support);
+    bool has_support_ironing = can_ironing_support && config->opt_bool("support_ironing");
+    for (auto el : {"support_ironing_pattern", "support_ironing_flow", "support_ironing_spacing" })
+        toggle_line(el, has_support_ironing);
+    // Orca: Force solid support interface when using support ironing
+    toggle_field("support_interface_spacing", have_support_material && have_support_interface && !has_support_ironing);
+
     bool have_skirt_height = have_skirt &&
     (config->opt_int("skirt_height") > 1 || config->opt_enum<DraftShield>("draft_shield") != dsEnabled);
     toggle_line("support_speed", have_support_material || have_skirt_height);
@@ -656,9 +675,11 @@ void ConfigManipulation::toggle_print_fff_options(DynamicPrintConfig *config, co
         toggle_field(el, have_support_material && !(support_is_normal_tree && !have_raft));
 
     bool has_ironing = (config->opt_enum<IroningType>("ironing_type") != IroningType::NoIroning);
-    for (auto el : { "ironing_pattern", "ironing_flow", "ironing_spacing", "ironing_speed", "ironing_angle", "ironing_inset"})
+    for (auto el : { "ironing_pattern", "ironing_flow", "ironing_spacing", "ironing_angle", "ironing_inset"})
         toggle_line(el, has_ironing);
     
+    toggle_line("ironing_speed", has_ironing || has_support_ironing);
+
     bool have_sequential_printing = (config->opt_enum<PrintSequence>("print_sequence") == PrintSequence::ByObject);
     // for (auto el : { "extruder_clearance_radius", "extruder_clearance_height_to_rod", "extruder_clearance_height_to_lid" })
     //     toggle_field(el, have_sequential_printing);

src/slic3r/GUI/Tab.cpp

@@ -2090,7 +2090,6 @@ void TabPrint::build()
         optgroup = page->new_optgroup(L("Ironing"), L"param_ironing");
         optgroup->append_single_option_line("ironing_type", "parameter/ironing");
         optgroup->append_single_option_line("ironing_pattern");
-        optgroup->append_single_option_line("ironing_speed");
         optgroup->append_single_option_line("ironing_flow");
         optgroup->append_single_option_line("ironing_spacing");
         optgroup->append_single_option_line("ironing_inset");
@@ -2203,6 +2202,7 @@ void TabPrint::build()
         optgroup->append_single_option_line("internal_solid_infill_speed");
         optgroup->append_single_option_line("top_surface_speed");
         optgroup->append_single_option_line("gap_infill_speed");
+        optgroup->append_single_option_line("ironing_speed");
         optgroup->append_single_option_line("support_speed");
         optgroup->append_single_option_line("support_interface_speed");
         optgroup = page->new_optgroup(L("Overhang speed"), L"param_overhang_speed", 15);
@@ -2278,6 +2278,12 @@ void TabPrint::build()
         optgroup->append_single_option_line("support_interface_filament", "support#support-filament");
         optgroup->append_single_option_line("support_interface_not_for_body", "support#support-filament");
 
+        optgroup = page->new_optgroup(L("Support ironing"), L"param_ironing");
+        optgroup->append_single_option_line("support_ironing");
+        optgroup->append_single_option_line("support_ironing_pattern");
+        optgroup->append_single_option_line("support_ironing_flow");
+        optgroup->append_single_option_line("support_ironing_spacing");
+
         //optgroup = page->new_optgroup(L("Options for support material and raft"));
 
         // Support