Various infill improvements (#2716)

* Fix issue that sparse infill threshold no longer working

* Turn all internal sparse infill into solid infill if infill density is 100%

* Allow combining solid infill when sparse infill density is 100%

src/libslic3r/LayerRegion.cpp

@@ -446,6 +446,24 @@ void LayerRegion::process_external_surfaces(const Layer *lower_layer, const Poly
         RegionExpansionParameters::build(expansion_top, expansion_step, max_nr_expansion_steps), 
         sparse, expansion_params_into_sparse_infill, closing_radius);
 
+    // turn too small internal regions into solid regions according to the user setting
+    if (!this->layer()->object()->print()->config().spiral_mode && this->region().config().sparse_infill_density.value > 0) {
+        // scaling an area requires two calls!
+        double min_area = scale_(scale_(this->region().config().minimum_sparse_infill_area.value));
+        ExPolygons small_regions{};
+        sparse.erase(std::remove_if(sparse.begin(), sparse.end(), [min_area, &small_regions](ExPolygon& ex_polygon) {
+            if (ex_polygon.area() <= min_area) {
+                small_regions.push_back(ex_polygon);
+                return true;
+            }
+            return false;
+        }), sparse.end());
+
+        if (!small_regions.empty()) {
+            shells = union_ex(shells, small_regions);
+        }
+    }
+
 //    m_fill_surfaces.remove_types({ stBottomBridge, stBottom, stTop, stInternal, stInternalSolid });
     this->fill_surfaces.clear();
     reserve_more(this->fill_surfaces.surfaces, shells.size() + sparse.size() + bridges.size() + bottoms.size() + tops.size());
@@ -792,12 +810,10 @@ void LayerRegion::prepare_fill_surfaces()
                 surface.surface_type = stInternal;
     }
 
-    // turn too small internal regions into solid regions according to the user setting
-    if (! spiral_mode && this->region().config().sparse_infill_density.value > 0) {
-        // scaling an area requires two calls!
-        double min_area = scale_(scale_(this->region().config().minimum_sparse_infill_area.value));
+    if (!spiral_mode && fabs(this->region().config().sparse_infill_density.value - 100.) < EPSILON) {
+        // Turn all internal sparse infill into solid infill, if sparse_infill_density is 100%
         for (Surface &surface : this->fill_surfaces.surfaces)
-            if (surface.surface_type == stInternal && surface.area() <= min_area)
+            if (surface.surface_type == stInternal)
                 surface.surface_type = stInternalSolid;
     }
 

src/libslic3r/PrintConfig.cpp

@@ -1726,7 +1726,7 @@ def = this->add("filament_loading_speed", coFloats);
     def = this->add("sparse_infill_density", coPercent);
     def->label = L("Sparse infill density");
     def->category = L("Strength");
-    def->tooltip = L("Density of internal sparse infill, 100% means solid throughout");
+    def->tooltip = L("Density of internal sparse infill, 100% turns all sparse infill into solid infill and internal solid infill pattern will be used");
     def->sidetext = L("%");
     def->min = 0;
     def->max = 100;
@@ -5711,12 +5711,6 @@ std::map<std::string, std::string> validate(const FullPrintConfig &cfg, bool und
         error_message.emplace("internal_solid_infill_pattern", L("invalid value ") + cfg.internal_solid_infill_pattern.serialize());
     }
 
-    // --fill-density
-    if (fabs(cfg.sparse_infill_density.value - 100.) < EPSILON &&
-        ! print_config_def.get("top_surface_pattern")->has_enum_value(cfg.sparse_infill_pattern.serialize())) {
-        error_message.emplace("sparse_infill_pattern", cfg.sparse_infill_pattern.serialize() + L(" doesn't work at 100%% density "));
-    }
-
     // --skirt-height
     if (cfg.skirt_height < 0) {
         error_message.emplace("skirt_height", L("invalid value ") + std::to_string(cfg.skirt_height));

src/libslic3r/PrintObject.cpp

@@ -3315,6 +3315,13 @@ void PrintObject::combine_infill()
         const bool enable_combine_infill = region.config().infill_combination.value;
         if (enable_combine_infill == false || region.config().sparse_infill_density == 0.)
             continue;
+
+        // Support internal solid infill when sparse_infill_density is 100%
+        const bool          use_solid_infill = fabs(region.config().sparse_infill_density.value - 100.) < EPSILON;
+        const SurfaceType   surface_type     = use_solid_infill ? stInternalSolid : stInternal;
+        const InfillPattern infill_pattern   = use_solid_infill ? region.config().internal_solid_infill_pattern :
+                                                                  region.config().sparse_infill_pattern;
+
         // Limit the number of combined layers to the maximum height allowed by this regions' nozzle.
         //FIXME limit the layer height to max_layer_height
         double nozzle_diameter = std::min(
@@ -3361,10 +3368,10 @@ void PrintObject::combine_infill()
                 layerms.emplace_back(m_layers[i]->regions()[region_id]);
             // We need to perform a multi-layer intersection, so let's split it in pairs.
             // Initialize the intersection with the candidates of the lowest layer.
-            ExPolygons intersection = to_expolygons(layerms.front()->fill_surfaces.filter_by_type(stInternal));
+            ExPolygons intersection = to_expolygons(layerms.front()->fill_surfaces.filter_by_type(surface_type));
             // Start looping from the second layer and intersect the current intersection with it.
             for (size_t i = 1; i < layerms.size(); ++ i)
-                intersection = intersection_ex(layerms[i]->fill_surfaces.filter_by_type(stInternal), intersection);
+                intersection = intersection_ex(layerms[i]->fill_surfaces.filter_by_type(surface_type), intersection);
             double area_threshold = layerms.front()->infill_area_threshold();
             if (! intersection.empty() && area_threshold > 0.)
                 intersection.erase(std::remove_if(intersection.begin(), intersection.end(),
@@ -3384,21 +3391,21 @@ void PrintObject::combine_infill()
                 0.5f * layerms.back()->flow(frPerimeter).scaled_width() +
              // Because fill areas for rectilinear and honeycomb are grown
              // later to overlap perimeters, we need to counteract that too.
-                ((region.config().sparse_infill_pattern == ipRectilinear   ||
-                  region.config().sparse_infill_pattern == ipMonotonic     ||
-                  region.config().sparse_infill_pattern == ipGrid          ||
-                  region.config().sparse_infill_pattern == ipLine          ||
-                  region.config().sparse_infill_pattern == ipHoneycomb) ? 1.5f : 0.5f) *
+                ((infill_pattern == ipRectilinear   ||
+                  infill_pattern == ipMonotonic     ||
+                  infill_pattern == ipGrid          ||
+                  infill_pattern == ipLine          ||
+                  infill_pattern == ipHoneycomb) ? 1.5f : 0.5f) *
                     layerms.back()->flow(frSolidInfill).scaled_width();
             for (ExPolygon &expoly : intersection)
                 polygons_append(intersection_with_clearance, offset(expoly, clearance_offset));
             for (LayerRegion *layerm : layerms) {
-                Polygons internal = to_polygons(std::move(layerm->fill_surfaces.filter_by_type(stInternal)));
-                layerm->fill_surfaces.remove_type(stInternal);
-                layerm->fill_surfaces.append(diff_ex(internal, intersection_with_clearance), stInternal);
+                Polygons internal = to_polygons(std::move(layerm->fill_surfaces.filter_by_type(surface_type)));
+                layerm->fill_surfaces.remove_type(surface_type);
+                layerm->fill_surfaces.append(diff_ex(internal, intersection_with_clearance), surface_type);
                 if (layerm == layerms.back()) {
                     // Apply surfaces back with adjusted depth to the uppermost layer.
-                    Surface templ(stInternal, ExPolygon());
+                    Surface templ(surface_type, ExPolygon());
                     templ.thickness = 0.;
                     for (LayerRegion *layerm2 : layerms)
                         templ.thickness += layerm2->layer()->height;

src/slic3r/GUI/ConfigManipulation.cpp

@@ -419,43 +419,6 @@ void ConfigManipulation::update_print_fff_config(DynamicPrintConfig* config, con
         }
     }
 
-    if (config->option<ConfigOptionPercent>("sparse_infill_density")->value == 100) {
-        std::string  sparse_infill_pattern            = config->option<ConfigOptionEnum<InfillPattern>>("sparse_infill_pattern")->serialize();
-        const auto  &top_fill_pattern_values = config->def()->get("top_surface_pattern")->enum_values;
-        bool correct_100p_fill = std::find(top_fill_pattern_values.begin(), top_fill_pattern_values.end(), sparse_infill_pattern) != top_fill_pattern_values.end();
-        if (!correct_100p_fill) {
-            // get sparse_infill_pattern name from enum_labels for using this one at dialog_msg
-            const ConfigOptionDef *fill_pattern_def = config->def()->get("sparse_infill_pattern");
-            assert(fill_pattern_def != nullptr);
-            auto it_pattern = std::find(fill_pattern_def->enum_values.begin(), fill_pattern_def->enum_values.end(), sparse_infill_pattern);
-            assert(it_pattern != fill_pattern_def->enum_values.end());
-            if (it_pattern != fill_pattern_def->enum_values.end()) {
-                wxString msg_text = GUI::format_wxstr(_L("%1% infill pattern doesn't support 100%% density."),
-                    _(fill_pattern_def->enum_labels[it_pattern - fill_pattern_def->enum_values.begin()]));
-                if (is_global_config)
-                    msg_text += "\n" + _L("Switch to rectilinear pattern?\n"
-                                          "Yes - switch to rectilinear pattern automaticlly\n"
-                                          "No  - reset density to default non 100% value automaticlly") + "\n";
-                MessageDialog dialog(m_msg_dlg_parent, msg_text, "",
-                                                  wxICON_WARNING | (is_global_config ? wxYES | wxNO : wxOK) );
-                DynamicPrintConfig new_conf = *config;
-                is_msg_dlg_already_exist = true;
-                auto answer = dialog.ShowModal();
-                if (!is_global_config || answer == wxID_YES) {
-                    new_conf.set_key_value("sparse_infill_pattern", new ConfigOptionEnum<InfillPattern>(ipRectilinear));
-                    sparse_infill_density = 100;
-                }
-                else
-                    sparse_infill_density = wxGetApp().preset_bundle->prints.get_selected_preset().config.option<ConfigOptionPercent>("sparse_infill_density")->value;
-                new_conf.set_key_value("sparse_infill_density", new ConfigOptionPercent(sparse_infill_density));
-                apply(config, &new_conf);
-                if (cb_value_change)
-                    cb_value_change("sparse_infill_density", sparse_infill_density);
-                is_msg_dlg_already_exist = false;
-            }
-        }
-    }
-
     // BBS
     static const char* keys[] = { "support_filament", "support_interface_filament"};
     for (int i = 0; i < sizeof(keys) / sizeof(keys[0]); i++) {

src/slic3r/GUI/Tab.cpp

@@ -1927,13 +1927,13 @@ void TabPrint::build()
         optgroup->append_single_option_line("bottom_surface_pattern", "fill-patterns#Infill of the top surface and bottom surface");
         optgroup->append_single_option_line("bottom_shell_layers");
         optgroup->append_single_option_line("bottom_shell_thickness");
-        optgroup->append_single_option_line("internal_solid_infill_pattern");
 
         optgroup = page->new_optgroup(L("Infill"), L"param_infill");
         optgroup->append_single_option_line("sparse_infill_density");
         optgroup->append_single_option_line("sparse_infill_pattern", "fill-patterns#infill types and their properties of sparse");
         optgroup->append_single_option_line("infill_anchor");
         optgroup->append_single_option_line("infill_anchor_max");
+        optgroup->append_single_option_line("internal_solid_infill_pattern");
 
         optgroup->append_single_option_line("filter_out_gap_fill");