Re implement wall roofing (#2021)

Ultimaker · Jan 29, 2024 · 8085fd0 · 8085fd0
2 parents 94543ac + 0ad6a45
commit 8085fd0
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Showing 6 changed files with 224 additions and 61 deletions.
diff --git a/include/InsetOrderOptimizer.h b/include/InsetOrderOptimizer.h
@@ -1,4 +1,4 @@
-// Copyright (c) 2022 Ultimaker B.V.
+// Copyright (c) 2024 Ultimaker B.V.
 // CuraEngine is released under the terms of the AGPLv3 or higher
 
 #ifndef INSET_ORDER_OPTIMIZER_H
@@ -43,8 +43,10 @@ class InsetOrderOptimizer
         LayerPlan& gcode_layer,
         const Settings& settings,
         const int extruder_nr,
-        const GCodePathConfig& inset_0_non_bridge_config,
-        const GCodePathConfig& inset_X_non_bridge_config,
+        const GCodePathConfig& inset_0_default_config,
+        const GCodePathConfig& inset_X_default_config,
+        const GCodePathConfig& inset_0_roofing_config,
+        const GCodePathConfig& inset_X_roofing_config,
         const GCodePathConfig& inset_0_bridge_config,
         const GCodePathConfig& inset_X_bridge_config,
         const bool retract_before_outer_wall,
@@ -90,8 +92,10 @@ class InsetOrderOptimizer
     LayerPlan& gcode_layer_;
     const Settings& settings_;
     const size_t extruder_nr_;
-    const GCodePathConfig& inset_0_non_bridge_config_;
-    const GCodePathConfig& inset_X_non_bridge_config_;
+    const GCodePathConfig& inset_0_default_config_;
+    const GCodePathConfig& inset_X_default_config_;
+    const GCodePathConfig& inset_0_roofing_config_;
+    const GCodePathConfig& inset_X_roofing_config_;
     const GCodePathConfig& inset_0_bridge_config_;
     const GCodePathConfig& inset_X_bridge_config_;
     const bool retract_before_outer_wall_;

diff --git a/include/LayerPlan.h b/include/LayerPlan.h
@@ -1,4 +1,4 @@
-// Copyright (c) 2023 UltiMaker
+// Copyright (c) 2024 UltiMaker
 // CuraEngine is released under the terms of the AGPLv3 or higher
 
 #ifndef LAYER_PLAN_H
@@ -96,6 +96,7 @@ class LayerPlan : public NoCopy
     coord_t comb_move_inside_distance_; //!< Whenever using the minimum boundary for combing it tries to move the coordinates inside by this distance after calculating the combing.
     Polygons bridge_wall_mask_; //!< The regions of a layer part that are not supported, used for bridging
     Polygons overhang_mask_; //!< The regions of a layer part where the walls overhang
+    Polygons roofing_mask_; //!< The regions of a layer part where the walls are exposed to the air
 
     const std::vector<FanSpeedLayerTimeSettings> fan_speed_layer_time_settings_per_extruder_;
 
@@ -257,6 +258,13 @@ class LayerPlan : public NoCopy
      */
     void setOverhangMask(const Polygons& polys);
 
+    /*!
+     * Set roofing_mask.
+     *
+     * \param polys The areas of the part currently being processed that will require roofing.
+     */
+    void setRoofingMask(const Polygons& polys);
+
     /*!
      * Travel to a certain point, with all of the procedures necessary to do so.
      *
@@ -395,8 +403,10 @@ class LayerPlan : public NoCopy
      * \param p1 The end vertex of the line.
      * \param settings The settings which should apply to this line added to the
      * layer plan.
-     * \param non_bridge_config The config with which to print the wall lines
-     * that are not spanning a bridge.
+     * \param default_config The config with which to print the wall lines
+     * that are not spanning a bridge or are exposed to air.
+     * \param roofing_config The config with which to print the wall lines
+     * that are exposed to air.
      * \param bridge_config The config with which to print the wall lines that
      * are spanning a bridge.
      * \param flow The ratio with which to multiply the extrusion amount.
@@ -413,7 +423,8 @@ class LayerPlan : public NoCopy
         const Point2LL& p0,
         const Point2LL& p1,
         const Settings& settings,
-        const GCodePathConfig& non_bridge_config,
+        const GCodePathConfig& default_config,
+        const GCodePathConfig& roofing_config,
         const GCodePathConfig& bridge_config,
         double flow,
         const Ratio width_factor,
@@ -426,10 +437,10 @@ class LayerPlan : public NoCopy
      * \param wall The vertices of the wall to add.
      * \param start_idx The index of the starting vertex to start at.
      * \param settings The settings which should apply to this wall added to the layer plan.
-     * \param non_bridge_config The config with which to print the wall lines
-     * that are not spanning a bridge.
-     * \param bridge_config The config with which to print the wall lines that
-     * are spanning a bridge.
+     * \param default_config The config with which to print the wall lines
+     * that are not spanning a bridge or are exposed to air.
+     * \param roofing_config The config with which to print the wall lines
+     * that are exposed to air.
      * \param wall_0_wipe_dist The distance to travel along the wall after it
      * has been laid down, in order to wipe the start and end of the wall
      * \param flow_ratio The ratio with which to multiply the extrusion amount.
@@ -440,7 +451,8 @@ class LayerPlan : public NoCopy
         ConstPolygonRef wall,
         int start_idx,
         const Settings& settings,
-        const GCodePathConfig& non_bridge_config,
+        const GCodePathConfig& default_config,
+        const GCodePathConfig& roofing_config,
         const GCodePathConfig& bridge_config,
         coord_t wall_0_wipe_dist,
         double flow_ratio,
@@ -451,8 +463,10 @@ class LayerPlan : public NoCopy
      * \param wall The wall of type ExtrusionJunctions
      * \param start_idx The index of the starting vertex to start at.
      * \param mesh The current mesh being added to the layer plan.
-     * \param non_bridge_config The config with which to print the wall lines
-     * that are not spanning a bridge.
+     * \param default_config The config with which to print the wall lines
+     * that are not spanning a bridge or are exposed to air.
+     * \param roofing_config The config with which to print the wall lines
+     * that are exposed to air.
      * \param bridge_config The config with which to print the wall lines that
      * are spanning a bridge
      * \param wall_0_wipe_dist The distance to travel along the wall after it
@@ -469,7 +483,8 @@ class LayerPlan : public NoCopy
         const ExtrusionLine& wall,
         int start_idx,
         const Settings& settings,
-        const GCodePathConfig& non_bridge_config,
+        const GCodePathConfig& default_config,
+        const GCodePathConfig& roofing_config,
         const GCodePathConfig& bridge_config,
         coord_t wall_0_wipe_dist,
         double flow_ratio,
@@ -490,7 +505,10 @@ class LayerPlan : public NoCopy
      * Add walls (polygons) to the gcode with optimized order.
      * \param walls The walls
      * \param settings The settings which should apply to these walls added to the layer plan.
-     * \param non_bridge_config The config with which to print the wall lines that are not spanning a bridge
+     * \param default_config The config with which to print the wall lines
+     * that are not spanning a bridge or are exposed to air.
+     * \param roofing_config The config with which to print the wall lines
+     * that are exposed to air.
      * \param bridge_config The config with which to print the wall lines that are spanning a bridge
      * \param z_seam_config Optional configuration for z-seam
      * \param wall_0_wipe_dist The distance to travel along each wall after it has been laid down, in order to wipe the start and end of the wall together
@@ -501,7 +519,8 @@ class LayerPlan : public NoCopy
     void addWalls(
         const Polygons& walls,
         const Settings& settings,
-        const GCodePathConfig& non_bridge_config,
+        const GCodePathConfig& default_config,
+        const GCodePathConfig& roofing_config,
         const GCodePathConfig& bridge_config,
         const ZSeamConfig& z_seam_config = ZSeamConfig(),
         coord_t wall_0_wipe_dist = 0,
@@ -625,7 +644,7 @@ class LayerPlan : public NoCopy
             return start_idx;
         }
 
-        Polygons air_below(bridge_wall_mask_.unionPolygons(overhang_mask_));
+        const auto air_below = bridge_wall_mask_.unionPolygons(overhang_mask_);
 
         unsigned curr_idx = start_idx;
 

diff --git a/src/FffGcodeWriter.cpp b/src/FffGcodeWriter.cpp
@@ -1,4 +1,4 @@
-// Copyright (c) 2023 UltiMaker
+// Copyright (c) 2024 UltiMaker
 // CuraEngine is released under the terms of the AGPLv3 or higher
 
 #include "FffGcodeWriter.h"
@@ -690,6 +690,8 @@ void FffGcodeWriter::processRaft(const SliceDataStorage& storage)
                     config,
                     config,
                     config,
+                    config,
+                    config,
                     retract_before_outer_wall,
                     wipe_dist,
                     wipe_dist,
@@ -851,6 +853,8 @@ void FffGcodeWriter::processRaft(const SliceDataStorage& storage)
                 config,
                 config,
                 config,
+                config,
+                config,
                 retract_before_outer_wall,
                 wipe_dist,
                 wipe_dist,
@@ -1043,6 +1047,8 @@ void FffGcodeWriter::processRaft(const SliceDataStorage& storage)
                     config,
                     config,
                     config,
+                    config,
+                    config,
                     retract_before_outer_wall,
                     wipe_dist,
                     wipe_dist,
@@ -2239,6 +2245,8 @@ bool FffGcodeWriter::processSingleLayerInfill(
                     mesh_config.infill_config[0],
                     mesh_config.infill_config[0],
                     mesh_config.infill_config[0],
+                    mesh_config.infill_config[0],
+                    mesh_config.infill_config[0],
                     retract_before_outer_wall,
                     wipe_dist,
                     wipe_dist,
@@ -2587,13 +2595,37 @@ bool FffGcodeWriter::processInsets(
             Polygons overhang_region = part.outline.offset(-half_outer_wall_width).difference(outlines_below.offset(10 + overhang_width - half_outer_wall_width)).offset(10);
             gcode_layer.setOverhangMask(overhang_region);
         }
+
+        const auto roofing_mask = [&gcode_layer, &mesh, &boundaryBox]() -> Polygons
+        {
+            const size_t roofing_layer_count = std::min(mesh.settings.get<size_t>("roofing_layer_count"), mesh.settings.get<size_t>("top_layers"));
+
+            if (gcode_layer.getLayerNr() + roofing_layer_count >= mesh.layers.size())
+            {
+                return Polygons();
+            }
+
+            auto roofing_mask = Polygons();
+            for (const auto& layer_part : mesh.layers[gcode_layer.getLayerNr() + roofing_layer_count].parts)
+            {
+                if (boundaryBox.hit(layer_part.boundaryBox))
+                {
+                    roofing_mask.add(layer_part.outline);
+                }
+            }
+            return roofing_mask;
+        }();
+
+        gcode_layer.setRoofingMask(roofing_mask);
     }
     else
     {
         // clear to disable use of bridging settings
         gcode_layer.setBridgeWallMask(Polygons());
         // clear to disable overhang detection
         gcode_layer.setOverhangMask(Polygons());
+        // clear to disable use of roofing settings
+        gcode_layer.setRoofingMask(Polygons());
     }
 
     if (spiralize && extruder_nr == mesh.settings.get<ExtruderTrain&>("wall_0_extruder_nr").extruder_nr_ && ! part.spiral_wall.empty())
@@ -2611,16 +2643,11 @@ bool FffGcodeWriter::processInsets(
         else
         {
             // Print the spiral walls of other parts as single walls without Z gradient.
-            gcode_layer.addWalls(part.spiral_wall, mesh.settings, mesh_config.inset0_config, mesh_config.inset0_config);
+            gcode_layer.addWalls(part.spiral_wall, mesh.settings, mesh_config.inset0_config, mesh_config.inset0_config, mesh_config.inset0_config);
         }
     }
     else
     {
-        // TODO use roofing config for layers-parts that are exposed to air
-        auto use_roofing_config = false;
-        const GCodePathConfig& inset0_config = use_roofing_config ? mesh_config.inset0_roofing_config : mesh_config.inset0_config;
-        const GCodePathConfig& insetX_config = use_roofing_config ? mesh_config.insetX_roofing_config : mesh_config.insetX_config;
-
         // Main case: Optimize the insets with the InsetOrderOptimizer.
         const coord_t wall_x_wipe_dist = 0;
         const ZSeamConfig z_seam_config(
@@ -2634,8 +2661,10 @@ bool FffGcodeWriter::processInsets(
             gcode_layer,
             mesh.settings,
             extruder_nr,
-            inset0_config,
-            insetX_config,
+            mesh_config.inset0_config,
+            mesh_config.insetX_config,
+            mesh_config.inset0_roofing_config,
+            mesh_config.insetX_roofing_config,
             mesh_config.bridge_inset0_config,
             mesh_config.bridge_insetX_config,
             mesh.settings.get<bool>("travel_retract_before_outer_wall"),
@@ -3061,6 +3090,8 @@ void FffGcodeWriter::processSkinPrintFeature(
                     config,
                     config,
                     config,
+                    config,
+                    config,
                     retract_before_outer_wall,
                     wipe_dist,
                     wipe_dist,
@@ -3324,6 +3355,8 @@ bool FffGcodeWriter::processSupportInfill(const SliceDataStorage& storage, Layer
                 config,
                 config,
                 config,
+                config,
+                config,
                 retract_before_outer_wall,
                 wipe_dist,
                 wipe_dist,
@@ -3500,6 +3533,8 @@ bool FffGcodeWriter::processSupportInfill(const SliceDataStorage& storage, Layer
                     config,
                     config,
                     config,
+                    config,
+                    config,
                     retract_before_outer_wall,
                     wipe_dist,
                     wipe_dist,
@@ -3636,6 +3671,8 @@ bool FffGcodeWriter::addSupportRoofsToGCode(
             config,
             config,
             config,
+            config,
+            config,
             retract_before_outer_wall,
             wipe_dist,
             wipe_dist,
@@ -3747,6 +3784,8 @@ bool FffGcodeWriter::addSupportBottomsToGCode(const SliceDataStorage& storage, L
             config,
             config,
             config,
+            config,
+            config,
             retract_before_outer_wall,
             wipe_dist,
             wipe_dist,

diff --git a/src/InsetOrderOptimizer.cpp b/src/InsetOrderOptimizer.cpp
@@ -1,4 +1,4 @@
-// Copyright (c) 2023 UltiMaker
+// Copyright (c) 2024 UltiMaker
 // CuraEngine is released under the terms of the AGPLv3 or higher
 
 #include "InsetOrderOptimizer.h"
@@ -38,8 +38,10 @@ InsetOrderOptimizer::InsetOrderOptimizer(
     LayerPlan& gcode_layer,
     const Settings& settings,
     const int extruder_nr,
-    const GCodePathConfig& inset_0_non_bridge_config,
-    const GCodePathConfig& inset_X_non_bridge_config,
+    const GCodePathConfig& inset_0_default_config,
+    const GCodePathConfig& inset_X_default_config,
+    const GCodePathConfig& inset_0_roofing_config,
+    const GCodePathConfig& inset_X_roofing_config,
     const GCodePathConfig& inset_0_bridge_config,
     const GCodePathConfig& inset_X_bridge_config,
     const bool retract_before_outer_wall,
@@ -54,8 +56,10 @@ InsetOrderOptimizer::InsetOrderOptimizer(
     , gcode_layer_(gcode_layer)
     , settings_(settings)
     , extruder_nr_(extruder_nr)
-    , inset_0_non_bridge_config_(inset_0_non_bridge_config)
-    , inset_X_non_bridge_config_(inset_X_non_bridge_config)
+    , inset_0_default_config_(inset_0_default_config)
+    , inset_X_default_config_(inset_X_default_config)
+    , inset_0_roofing_config_(inset_0_roofing_config)
+    , inset_X_roofing_config_(inset_X_roofing_config)
     , inset_0_bridge_config_(inset_0_bridge_config)
     , inset_X_bridge_config_(inset_X_bridge_config)
     , retract_before_outer_wall_(retract_before_outer_wall)
@@ -114,23 +118,38 @@ bool InsetOrderOptimizer::addToLayer()
     for (const PathOrdering<const ExtrusionLine*>& path : order_optimizer.paths_)
     {
         if (path.vertices_->empty())
+        {
             continue;
+        }
 
         const bool is_outer_wall = path.vertices_->inset_idx_ == 0; // or thin wall 'gap filler'
         const bool is_gap_filler = path.vertices_->is_odd_;
-        const GCodePathConfig& non_bridge_config = is_outer_wall ? inset_0_non_bridge_config_ : inset_X_non_bridge_config_;
+        const GCodePathConfig& default_config = is_outer_wall ? inset_0_default_config_ : inset_X_default_config_;
+        const GCodePathConfig& roofing_config = is_outer_wall ? inset_0_roofing_config_ : inset_X_roofing_config_;
         const GCodePathConfig& bridge_config = is_outer_wall ? inset_0_bridge_config_ : inset_X_bridge_config_;
         const coord_t wipe_dist = is_outer_wall && ! is_gap_filler ? wall_0_wipe_dist_ : wall_x_wipe_dist_;
         const bool retract_before = is_outer_wall ? retract_before_outer_wall_ : false;
 
-        const bool revert_inset = alternate_walls && (path.vertices_->inset_idx_ % 2);
-        const bool revert_layer = alternate_walls && (layer_nr_ % 2);
+        const bool revert_inset = alternate_walls && (path.vertices_->inset_idx_ % 2 != 0);
+        const bool revert_layer = alternate_walls && (layer_nr_ % 2 != 0);
         const bool backwards = path.backwards_ != (revert_inset != revert_layer);
         const size_t start_index = (backwards != path.backwards_) ? path.vertices_->size() - (path.start_vertex_ + 1) : path.start_vertex_;
         const bool linked_path = ! path.is_closed_;
 
         gcode_layer_.setIsInside(true); // Going to print walls, which are always inside.
-        gcode_layer_.addWall(*path.vertices_, start_index, settings_, non_bridge_config, bridge_config, wipe_dist, flow, retract_before, path.is_closed_, backwards, linked_path);
+        gcode_layer_.addWall(
+            *path.vertices_,
+            start_index,
+            settings_,
+            default_config,
+            roofing_config,
+            bridge_config,
+            wipe_dist,
+            flow,
+            retract_before,
+            path.is_closed_,
+            backwards,
+            linked_path);
         added_something = true;
     }
     return added_something;