Porting Orca Make Overhang Printable

src/libslic3r/ClipperUtils.cpp

@@ -769,6 +769,13 @@ Slic3r::ExPolygons diff_ex(const Slic3r::SurfacesPtr &subject, const Slic3r::Pol
     { return _clipper_ex(ClipperLib::ctDifference, ClipperUtils::SurfacesPtrProvider(subject), ClipperUtils::PolygonsProvider(clip), do_safety_offset); }
 Slic3r::ExPolygons diff_ex(const Slic3r::SurfacesPtr &subject, const Slic3r::ExPolygons &clip, ApplySafetyOffset do_safety_offset)
     { return _clipper_ex(ClipperLib::ctDifference, ClipperUtils::SurfacesPtrProvider(subject), ClipperUtils::ExPolygonsProvider(clip), do_safety_offset); }
+//Orca
+Slic3r::ExPolygons diff_ex(const Slic3r::ExPolygons& subject, const Slic3r::ExPolygon& clip, ApplySafetyOffset do_safety_offset)
+{
+    Slic3r::ExPolygons clip_temp;
+    clip_temp.push_back(clip);
+    return diff_ex(subject, clip_temp, do_safety_offset);
+}
 
 Slic3r::ExPolygons intersection_ex(const Slic3r::Polygons &subject, const Slic3r::Polygons &clip, ApplySafetyOffset do_safety_offset)
     { return _clipper_ex(ClipperLib::ctIntersection, ClipperUtils::PolygonsProvider(subject), ClipperUtils::PolygonsProvider(clip), do_safety_offset); }
@@ -788,6 +795,10 @@ Slic3r::ExPolygons intersection_ex(const Slic3r::Surfaces &subject, const Slic3r
     { return _clipper_ex(ClipperLib::ctIntersection, ClipperUtils::SurfacesProvider(subject), ClipperUtils::SurfacesProvider(clip), do_safety_offset); }
 Slic3r::ExPolygons intersection_ex(const Slic3r::SurfacesPtr &subject, const Slic3r::ExPolygons &clip, ApplySafetyOffset do_safety_offset)
     { return _clipper_ex(ClipperLib::ctIntersection, ClipperUtils::SurfacesPtrProvider(subject), ClipperUtils::ExPolygonsProvider(clip), do_safety_offset); }
+//Orca
+Slic3r::ExPolygons intersection_ex(const Slic3r::ExPolygons& subject, const Slic3r::ExPolygon& clip, ApplySafetyOffset do_safety_offset)
+    { return _clipper_ex(ClipperLib::ctIntersection, ClipperUtils::ExPolygonsProvider(subject), ClipperUtils::ExPolygonProvider(clip), do_safety_offset);}
+
 // May be used to "heal" unusual models (3DLabPrints etc.) by providing fill_type (pftEvenOdd, pftNonZero, pftPositive, pftNegative).
 Slic3r::ExPolygons union_ex(const Slic3r::Polygons &subject, ClipperLib::PolyFillType fill_type)
     { return _clipper_ex(ClipperLib::ctUnion, ClipperUtils::PolygonsProvider(subject), ClipperUtils::EmptyPathsProvider(), ApplySafetyOffset::No, fill_type); }
@@ -803,6 +814,10 @@ Slic3r::ExPolygons union_ex(const Slic3r::ExPolygons &subject, const Slic3r::Pol
     { return PolyTreeToExPolygons(clipper_do_polytree(ClipperLib::ctUnion, ClipperUtils::ExPolygonsProvider(subject), ClipperUtils::PolygonsProvider(subject2), ClipperLib::pftNonZero)); }
 Slic3r::ExPolygons union_ex(const Slic3r::Surfaces &subject)
     { return PolyTreeToExPolygons(clipper_do_polytree(ClipperLib::ctUnion, ClipperUtils::SurfacesProvider(subject), ClipperUtils::EmptyPathsProvider(), ClipperLib::pftNonZero)); }
+//Orca
+Slic3r::ExPolygons xor_ex(const Slic3r::ExPolygons &subject, const Slic3r::ExPolygon &clip, ApplySafetyOffset do_safety_offset) {
+    return _clipper_ex(ClipperLib::ctXor, ClipperUtils::ExPolygonsProvider(subject), ClipperUtils::ExPolygonProvider(clip), do_safety_offset);
+}
 
 template<typename PathsProvider1, typename PathsProvider2>
 Polylines _clipper_pl_open(ClipperLib::ClipType clipType, PathsProvider1 &&subject, PathsProvider2 &&clip)

src/libslic3r/ClipperUtils.hpp

@@ -448,6 +448,9 @@ Slic3r::ExPolygons diff_ex(const Slic3r::ExPolygons &subject, const Slic3r::Surf
 Slic3r::ExPolygons diff_ex(const Slic3r::Surfaces &subject, const Slic3r::Surfaces &clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
 Slic3r::ExPolygons diff_ex(const Slic3r::SurfacesPtr &subject, const Slic3r::Polygons &clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
 Slic3r::ExPolygons diff_ex(const Slic3r::SurfacesPtr &subject, const Slic3r::ExPolygons &clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
+//Orca
+Slic3r::ExPolygons diff_ex(const Slic3r::ExPolygons& subject, const Slic3r::ExPolygon& clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
+
 Slic3r::Polylines  diff_pl(const Slic3r::Polyline &subject, const Slic3r::Polygons &clip);
 Slic3r::Polylines  diff_pl(const Slic3r::Polylines &subject, const Slic3r::Polygons &clip);
 Slic3r::Polylines  diff_pl(const Slic3r::Polyline &subject, const Slic3r::ExPolygon &clip);
@@ -482,6 +485,9 @@ Slic3r::ExPolygons intersection_ex(const Slic3r::Surfaces &subject, const Slic3r
 Slic3r::ExPolygons intersection_ex(const Slic3r::Surfaces &subject, const Slic3r::ExPolygons &clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
 Slic3r::ExPolygons intersection_ex(const Slic3r::Surfaces &subject, const Slic3r::Surfaces &clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
 Slic3r::ExPolygons intersection_ex(const Slic3r::SurfacesPtr &subject, const Slic3r::ExPolygons &clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
+//Orca
+Slic3r::ExPolygons intersection_ex(const Slic3r::ExPolygons& subject, const Slic3r::ExPolygon& clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
+
 Slic3r::Polylines  intersection_pl(const Slic3r::Polylines &subject, const Slic3r::Polygon &clip);
 Slic3r::Polylines  intersection_pl(const Slic3r::Polyline &subject, const Slic3r::ExPolygon &clip);
 Slic3r::Polylines  intersection_pl(const Slic3r::Polylines &subject, const Slic3r::ExPolygon &clip);
@@ -522,6 +528,9 @@ Slic3r::ExPolygons union_ex(const Slic3r::Surfaces &subject);
 ClipperLib::PolyTree union_pt(const Slic3r::Polygons &subject);
 ClipperLib::PolyTree union_pt(const Slic3r::ExPolygons &subject);
 
+//Orca
+Slic3r::ExPolygons xor_ex(const Slic3r::ExPolygons &subject, const Slic3r::ExPolygon &clip, ApplySafetyOffset do_safety_offset = ApplySafetyOffset::No);
+
 Slic3r::Polygons union_pt_chained_outside_in(const Slic3r::Polygons &subject);
 
 ClipperLib::PolyNodes order_nodes(const ClipperLib::PolyNodes &nodes);

src/libslic3r/Preset.cpp

@@ -438,7 +438,7 @@ void Preset::set_visible_from_appconfig(const AppConfig &app_config)
 static std::vector<std::string> s_Preset_print_options {
     "layer_height", "first_layer_height", "perimeters", "spiral_vase", "slice_closing_radius", "slicing_mode",
     "top_solid_layers", "top_solid_min_thickness", "bottom_solid_layers", "bottom_solid_min_thickness",
-    "extra_perimeters", "extra_perimeters_on_overhangs", "avoid_crossing_curled_overhangs", "avoid_crossing_perimeters", "thin_walls", "overhangs",
+    "extra_perimeters", "extra_perimeters_on_overhangs", "make_overhang_printable", "make_overhang_printable_angle", "make_overhang_printable_hole_size", "avoid_crossing_curled_overhangs", "avoid_crossing_perimeters", "thin_walls", "overhangs",
     "seam_position","staggered_inner_seams", "external_perimeters_first", "fill_density", "fill_pattern", "top_fill_pattern", "bottom_fill_pattern",
     "infill_every_layers", /*"infill_only_where_needed",*/ "solid_infill_every_layers", "fill_angle", "bridge_angle",
     "solid_infill_below_area", "only_retract_when_crossing_perimeters", "infill_first",

src/libslic3r/Print.hpp

@@ -437,6 +437,8 @@ class PrintObject : public PrintObjectBaseWithState<Print, PrintObjectStep, posC
 
     std::pair<FillAdaptive::OctreePtr, FillAdaptive::OctreePtr> m_adaptive_fill_octrees;
     FillLightning::GeneratorPtr m_lightning_generator;
+//Orca
+    void apply_conical_overhang();
 };
 
 

src/libslic3r/PrintConfig.cpp

@@ -3482,6 +3482,35 @@ void PrintConfigDef::init_fff_params()
     def->min = 0;
     def->set_default_value(new ConfigOptionFloatOrPercent(85, true));
 
+    def = this->add("make_overhang_printable", coBool);
+    def->label = L("Make overhang printable");
+    def->category = L("Advanced");
+    def->tooltip = L("Modify the geometry to print overhangs without support material.  Disabling modifier must include the object full horizontal dimensions.");
+    def->mode = comAdvanced;
+    def->set_default_value(new ConfigOptionBool(false));
+
+    def = this->add("make_overhang_printable_angle", coFloat);
+    def->label = L("Make overhang printable maximum angle");
+    def->category = L("Advanced");
+    def->tooltip = L("Maximum angle of overhangs to allow after making more steep overhangs printable."
+                     "90° will not change the model at all and allow any overhang, while 0 will "
+                     "replace all overhangs with conical material.");
+    def->sidetext = L("°");
+    def->mode = comAdvanced;
+    def->min = 0.;
+    def->max = 90.;
+    def->set_default_value(new ConfigOptionFloat(55.));
+
+    def = this->add("make_overhang_printable_hole_size", coFloat);
+    def->label = L("Make overhang printable hole area");
+    def->category = L("Advanced");
+    def->tooltip = L("Maximum area of a hole in the base of the model before it's filled by conical material."
+                     "A value of 0 will fill all the holes in the model base.");
+    def->sidetext = L("mm²");
+    def->mode = comAdvanced;
+    def->min = 0.;
+    def->set_default_value(new ConfigOptionFloat(0.));
+
     // Declare retract values for filament profile, overriding the printer's extruder profile.
     for (const char *opt_key : {
         // floats

src/libslic3r/PrintConfig.hpp

@@ -599,6 +599,9 @@ PRINT_CONFIG_CLASS_DEFINE(
     ((ConfigOptionBool,                thick_bridges))
     ((ConfigOptionFloat,               xy_size_compensation))
     ((ConfigOptionBool,                wipe_into_objects))
+    // Orca
+    ((ConfigOptionFloat,               make_overhang_printable_angle))
+    ((ConfigOptionFloat,               make_overhang_printable_hole_size))
 )
 
 PRINT_CONFIG_CLASS_DEFINE(
@@ -662,6 +665,8 @@ PRINT_CONFIG_CLASS_DEFINE(
     ((ConfigOptionFloat,                top_solid_min_thickness))
     ((ConfigOptionFloatOrPercent,       top_solid_infill_speed))
     ((ConfigOptionBool,                 wipe_into_infill))
+    // Orca
+    ((ConfigOptionBool,                 make_overhang_printable))
 )
 
 PRINT_CONFIG_CLASS_DEFINE(

src/libslic3r/PrintObject.cpp

@@ -745,7 +745,10 @@ bool PrintObject::invalidate_state_by_config_options(
             || opt_key == "raft_layers"
             || opt_key == "raft_contact_distance"
             || opt_key == "slice_closing_radius"
-            || opt_key == "slicing_mode") {
+            || opt_key == "slicing_mode"
+            || opt_key == "make_overhang_printable"
+            || opt_key == "make_overhang_printable_angle"
+            || opt_key == "make_overhang_printable_hole_size") {
             steps.emplace_back(posSlice);
 		} else if (
                opt_key == "elefant_foot_compensation"

src/libslic3r/PrintObjectSlice.cpp

@@ -744,6 +744,9 @@ void PrintObject::slice_volumes()
         apply_mm_segmentation(*this, [print]() { print->throw_if_canceled(); });
     }
 
+    //Orca	
+    this->apply_conical_overhang();
+    m_print->throw_if_canceled();
 
     BOOST_LOG_TRIVIAL(debug) << "Slicing volumes - make_slices in parallel - begin";
     {
@@ -826,6 +829,108 @@ void PrintObject::slice_volumes()
     BOOST_LOG_TRIVIAL(debug) << "Slicing volumes - make_slices in parallel - end";
 }
 
+//Orca
+void PrintObject::apply_conical_overhang() {
+    BOOST_LOG_TRIVIAL(info) << "Make overhang printable...";
+
+    if (m_layers.empty()) {
+        return;
+    }
+
+    const double conical_overhang_angle = this->config().make_overhang_printable_angle;
+    if (conical_overhang_angle == 90.0) {
+        return;
+    }
+    const double angle_radians = conical_overhang_angle * M_PI / 180.;
+    const double max_hole_area = this->config().make_overhang_printable_hole_size; // in MM^2
+    const double tan_angle = tan(angle_radians); // the XY-component of the angle
+    BOOST_LOG_TRIVIAL(info) << "angle " << angle_radians << " maxHoleArea " << max_hole_area << " tan_angle "
+                            << tan_angle;
+    const coordf_t layer_thickness = m_config.layer_height.value;
+    const coordf_t max_dist_from_lower_layer = tan_angle * layer_thickness; // max dist which can be bridged, in MM
+    BOOST_LOG_TRIVIAL(info) << "layer_thickness " << layer_thickness << " max_dist_from_lower_layer "
+                            << max_dist_from_lower_layer;
+
+    // Pre-scale config
+    const coordf_t scaled_max_dist_from_lower_layer = -float(scale_(max_dist_from_lower_layer));
+    const coordf_t scaled_max_hole_area = float(scale_(scale_(max_hole_area)));
+
+
+    for (auto i = m_layers.rbegin() + 1; i != m_layers.rend(); ++i) {
+        m_print->throw_if_canceled();
+        Layer *layer = *i;
+        Layer *upper_layer = layer->upper_layer;
+
+        if (upper_layer == nullptr || upper_layer->empty()) {
+          continue;
+        }
+
+        // Skip if entire layer has this disabled
+        if (std::all_of(layer->m_regions.begin(), layer->m_regions.end(),
+                        [](const LayerRegion *r) { return  r->slices().empty() || !r->region().config().make_overhang_printable; })) {
+            continue;
+        }
+
+        //layer->export_region_slices_to_svg_debug("layer_before_conical_overhang");
+        //upper_layer->export_region_slices_to_svg_debug("upper_layer_before_conical_overhang");
+
+
+        // Merge the upper layer because we want to offset the entire layer uniformly, otherwise
+        // the model could break at the region boundary.
+        auto upper_poly = upper_layer->merged(float(SCALED_EPSILON));
+        upper_poly = union_ex(upper_poly);
+
+        // Avoid closing up of recessed holes in the base of a model.
+        // Detects when a hole is completely covered by the layer above and removes the hole from the layer above before
+        // adding it in.
+        // This should have no effect any time a hole in a layer interacts with any polygon in the layer above
+        if (scaled_max_hole_area > 0.0) {
+            // Merge layer for the same reason
+            auto current_poly = layer->merged(float(SCALED_EPSILON));
+            current_poly = union_ex(current_poly);
+
+            // Now go through all the holes in the current layer and check if they intersect anything in the layer above
+            // If not, then they're the top of a hole and should be cut from the layer above before the union
+            for (auto layer_polygon : current_poly) {
+                for (auto hole : layer_polygon.holes) {
+                    if (std::abs(hole.area()) < scaled_max_hole_area) {
+                        ExPolygon hole_poly(hole);
+                        auto hole_with_above = intersection_ex(upper_poly, hole_poly);
+                        if (!hole_with_above.empty()) {
+                            // The hole had some intersection with the above layer, check if it's a complete overlap
+                            auto hole_difference = xor_ex(hole_with_above, hole_poly);
+                            if (hole_difference.empty()) {
+                                // The layer above completely cover it, remove it from the layer above
+                                upper_poly = diff_ex(upper_poly, hole_poly);
+                            }
+                        }
+                    }
+                }
+            }
+        }
+
+        // Now offset the upper layer to be added into current layer
+        upper_poly = offset_ex(upper_poly, scaled_max_dist_from_lower_layer);
+
+        for (size_t region_id = 0; region_id < this->num_printing_regions(); ++region_id) {
+            // export_to_svg(debug_out_path("Surface-obj-%d-layer-%d-region-%d.svg", id().id, layer->id(), region_id).c_str(),
+            //               layer->m_regions[region_id]->slices.surfaces);
+
+            // Disable on given region
+            if (!upper_layer->m_regions[region_id]->region().config().make_overhang_printable) {
+                continue;
+            }
+
+            // Calculate the scaled upper poly that belongs to current region
+            auto p = intersection_ex(upper_layer->m_regions[region_id]->slices().surfaces, upper_poly);
+            // And now union it
+            ExPolygons layer_polygons = to_expolygons(layer->m_regions[region_id]->slices().surfaces);
+            layer->m_regions[region_id]->m_slices.set(union_ex(layer_polygons, p), stInternal);
+        }
+        //layer->export_region_slices_to_svg_debug("layer_after_conical_overhang");
+    }
+}
+
 std::vector<Polygons> PrintObject::slice_support_volumes(const ModelVolumeType model_volume_type) const
 {
     auto it_volume     = this->model_object()->volumes.begin();

src/slic3r/GUI/ConfigManipulation.cpp

@@ -345,6 +345,10 @@ void ConfigManipulation::toggle_print_fff_options(DynamicPrintConfig* config)
     toggle_field("min_feature_size", have_arachne);
     toggle_field("min_bead_width", have_arachne);
     toggle_field("thin_walls", !have_arachne);
+    //Orca
+    bool have_make_overhang_printable = config->opt_bool("make_overhang_printable");
+    toggle_field("make_overhang_printable_angle", have_make_overhang_printable);
+    toggle_field("make_overhang_printable_hole_size", have_make_overhang_printable);
 }
 
 void ConfigManipulation::update_print_sla_config(DynamicPrintConfig* config, const bool is_global_config/* = false*/)

src/slic3r/GUI/Tab.cpp

@@ -1689,6 +1689,11 @@ void TabPrint::build()
         optgroup->append_single_option_line("xy_size_compensation");
         optgroup->append_single_option_line("elefant_foot_compensation", "elephant-foot-compensation_114487");
 
+        optgroup = page->new_optgroup(L("Overhangs"));
+        optgroup->append_single_option_line("make_overhang_printable");
+        optgroup->append_single_option_line("make_overhang_printable_angle");
+        optgroup->append_single_option_line("make_overhang_printable_hole_size");
+
         optgroup = page->new_optgroup(L("Arachne perimeter generator"));
         optgroup->append_single_option_line("wall_transition_angle");
         optgroup->append_single_option_line("wall_transition_filter_deviation");