Various support improvements and bugfixes (#2202)

* Organic supports: Added check for variable layer height, with which Organic supports are not compatible. Fixes prusa3d/PrusaSlicer#9528 and similar. Check the object max Z against build volume Z in Print::validate(). Cherry-picked from prusa3d/PrusaSlicer@5b94971 * Fix crash with default tree support * Show "support_critical_regions_only" only when using auto normal tree supports (#2195) * Fix organic tree check --------- Co-authored-by: Vojtech Bubnik <[email protected]>
SoftFever · Sep 24, 2023 · 7ef43f6 · 7ef43f6
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diff --git a/src/libslic3r/Model.hpp b/src/libslic3r/Model.hpp
@@ -1,3 +1,15 @@
+///|/ Copyright (c) Prusa Research 2016 - 2023 Tomáš Mészáros @tamasmeszaros, Oleksandra Iushchenko @YuSanka, Enrico Turri @enricoturri1966, Lukáš Matěna @lukasmatena, Vojtěch Bubník @bubnikv, Filip Sykala @Jony01, Lukáš Hejl @hejllukas, David Kocík @kocikdav, Vojtěch Král @vojtechkral
+///|/ Copyright (c) 2019 John Drake @foxox
+///|/ Copyright (c) 2019 Sijmen Schoon
+///|/ Copyright (c) 2017 Eyal Soha @eyal0
+///|/ Copyright (c) Slic3r 2014 - 2015 Alessandro Ranellucci @alranel
+///|/
+///|/ ported from lib/Slic3r/Model.pm:
+///|/ Copyright (c) Prusa Research 2016 - 2022 Vojtěch Bubník @bubnikv, Enrico Turri @enricoturri1966
+///|/ Copyright (c) Slic3r 2012 - 2016 Alessandro Ranellucci @alranel
+///|/
+///|/ PrusaSlicer is released under the terms of the AGPLv3 or higher
+///|/
 #ifndef slic3r_Model_hpp_
 #define slic3r_Model_hpp_
 
@@ -398,6 +410,10 @@ class ModelObject final : public ObjectBase
     bool                    is_seam_painted() const;
     // Checks if any of object volume is painted using the multi-material painting gizmo.
     bool                    is_mm_painted() const;
+    // This object may have a varying layer height by painting or by a table.
+    // Even if true is returned, the layer height profile may be "flat" with no difference to default layering.
+    bool                    has_custom_layering() const 
+        { return ! this->layer_config_ranges.empty() || ! this->layer_height_profile.empty(); }
 
     ModelInstance*          add_instance();
     ModelInstance*          add_instance(const ModelInstance &instance);

diff --git a/src/libslic3r/Print.cpp b/src/libslic3r/Print.cpp
@@ -1,3 +1,25 @@
+///|/ Copyright (c) Prusa Research 2016 - 2023 Lukáš Matěna @lukasmatena, Tomáš Mészáros @tamasmeszaros, Enrico Turri @enricoturri1966, Vojtěch Bubník @bubnikv, Pavel Mikuš @Godrak, Oleksandra Iushchenko @YuSanka, Lukáš Hejl @hejllukas, Filip Sykala @Jony01, Roman Beránek @zavorka, David Kocík @kocikdav
+///|/ Copyright (c) BambuStudio 2023 manch1n @manch1n
+///|/ Copyright (c) SuperSlicer 2023 Remi Durand @supermerill
+///|/ Copyright (c) 2021 Martin Budden
+///|/ Copyright (c) 2020 Paul Arden @ardenpm
+///|/ Copyright (c) 2019 Thomas Moore
+///|/ Copyright (c) 2019 Bryan Smith
+///|/ Copyright (c) Slic3r 2013 - 2016 Alessandro Ranellucci @alranel
+///|/ Copyright (c) 2014 Petr Ledvina @ledvinap
+///|/
+///|/ ported from lib/Slic3r/Print.pm:
+///|/ Copyright (c) Prusa Research 2016 - 2018 Vojtěch Bubník @bubnikv, Tomáš Mészáros @tamasmeszaros
+///|/ Copyright (c) Slic3r 2011 - 2016 Alessandro Ranellucci @alranel
+///|/ Copyright (c) 2012 - 2013 Mark Hindess
+///|/ Copyright (c) 2013 Devin Grady
+///|/ Copyright (c) 2012 - 2013 Mike Sheldrake @mesheldrake
+///|/ Copyright (c) 2012 Henrik Brix Andersen @henrikbrixandersen
+///|/ Copyright (c) 2012 Michael Moon
+///|/ Copyright (c) 2011 Richard Goodwin
+///|/
+///|/ PrusaSlicer is released under the terms of the AGPLv3 or higher
+///|/
 #include "Exception.hpp"
 #include "Print.hpp"
 #include "BoundingBox.hpp"
@@ -1034,6 +1056,53 @@ StringObjectException Print::validate(StringObjectException *warning, Polygons*
             return {L("The spiral vase mode does not work when an object contains more than one materials."), nullptr, "spiral_mode"};
     }
 
+    // Cache of layer height profiles for checking:
+    // 1) Whether all layers are synchronized if printing with wipe tower and / or unsynchronized supports.
+    // 2) Whether layer height is constant for Organic supports.
+    // 3) Whether build volume Z is not violated.
+    std::vector<std::vector<coordf_t>> layer_height_profiles;
+    auto layer_height_profile = [this, &layer_height_profiles](const size_t print_object_idx) -> const std::vector<coordf_t>& {
+        const PrintObject       &print_object = *m_objects[print_object_idx];
+        if (layer_height_profiles.empty())
+            layer_height_profiles.assign(m_objects.size(), std::vector<coordf_t>());
+        std::vector<coordf_t>   &profile      = layer_height_profiles[print_object_idx];
+        if (profile.empty())
+            PrintObject::update_layer_height_profile(*print_object.model_object(), print_object.slicing_parameters(), profile);
+        return profile;
+    };
+
+    // Checks that the print does not exceed the max print height
+    for (size_t print_object_idx = 0; print_object_idx < m_objects.size(); ++ print_object_idx) {
+        const PrintObject &print_object = *m_objects[print_object_idx];
+        //FIXME It is quite expensive to generate object layers just to get the print height!
+        if (auto layers = generate_object_layers(print_object.slicing_parameters(), layer_height_profile(print_object_idx));
+            ! layers.empty() && layers.back() > this->config().printable_height + EPSILON) {
+            return
+                // Test whether the last slicing plane is below or above the print volume.
+                { 0.5 * (layers[layers.size() - 2] + layers.back()) > this->config().printable_height + EPSILON ?
+                format(_u8L("The object %1% exceeds the maximum build volume height."), print_object.model_object()->name) :
+                format(_u8L("While the object %1% itself fits the build volume, its last layer exceeds the maximum build volume height."), print_object.model_object()->name) +
+                " " + _u8L("You might want to reduce the size of your model or change current print settings and retry.") };
+        }
+    }
+
+    // Some of the objects has variable layer height applied by painting or by a table.
+    bool has_custom_layering = std::find_if(m_objects.begin(), m_objects.end(), 
+        [](const PrintObject *object) { return object->model_object()->has_custom_layering(); }) 
+        != m_objects.end();
+
+    // Custom layering is not allowed for tree supports as of now.
+    for (size_t print_object_idx = 0; print_object_idx < m_objects.size(); ++ print_object_idx)
+        if (const PrintObject &print_object = *m_objects[print_object_idx];
+            print_object.has_support_material() && is_tree(print_object.config().support_type.value) && (print_object.config().support_style.value == smsOrganic || 
+                // Orca: use organic as default
+                print_object.config().support_style.value == smsDefault) &&
+            print_object.model_object()->has_custom_layering()) {
+            if (const std::vector<coordf_t> &layers = layer_height_profile(print_object_idx); ! layers.empty())
+                if (! check_object_layers_fixed(print_object.slicing_parameters(), layers))
+                    return {_u8L("Variable layer height is not supported with Organic supports.") };
+        }
+
     if (this->has_wipe_tower() && ! m_objects.empty()) {
         // Make sure all extruders use same diameter filament and have the same nozzle diameter
         // EPSILON comparison is used for nozzles and 10 % tolerance is used for filaments
@@ -1081,19 +1150,8 @@ StringObjectException Print::validate(StringObjectException *warning, Polygons*
 #endif
 
         if (m_objects.size() > 1) {
-            bool                                has_custom_layering = false;
-            std::vector<std::vector<coordf_t>>  layer_height_profiles;
-            for (const PrintObject *object : m_objects) {
-                has_custom_layering = ! object->model_object()->layer_config_ranges.empty() || ! object->model_object()->layer_height_profile.empty();
-                if (has_custom_layering) {
-                    layer_height_profiles.assign(m_objects.size(), std::vector<coordf_t>());
-                    break;
-                }
-            }
             const SlicingParameters &slicing_params0 = m_objects.front()->slicing_parameters();
-            size_t            tallest_object_idx = 0;
-            if (has_custom_layering)
-                PrintObject::update_layer_height_profile(*m_objects.front()->model_object(), slicing_params0, layer_height_profiles.front());
+            size_t                  tallest_object_idx = 0;
             for (size_t i = 1; i < m_objects.size(); ++ i) {
                 const PrintObject       *object         = m_objects[i];
                 const SlicingParameters &slicing_params = object->slicing_parameters();
@@ -1111,8 +1169,9 @@ StringObjectException Print::validate(StringObjectException *warning, Polygons*
                 if (!equal_layering(slicing_params, slicing_params0))
                     return  { L("The prime tower requires that all objects are sliced with the same layer heights."), object };
                 if (has_custom_layering) {
-                    PrintObject::update_layer_height_profile(*object->model_object(), slicing_params, layer_height_profiles[i]);
-                    if (*(layer_height_profiles[i].end()-2) > *(layer_height_profiles[tallest_object_idx].end()-2))
+                    auto &lh         = layer_height_profile(i);
+                    auto &lh_tallest = layer_height_profile(tallest_object_idx);
+                    if (*(lh.end() - 2) > *(lh_tallest.end() - 2))
                         tallest_object_idx = i;
                 }
             }
@@ -1198,7 +1257,9 @@ StringObjectException Print::validate(StringObjectException *warning, Polygons*
 
                 // Prusa: Fixing crashes with invalid tip diameter or branch diameter
                 // https://github.com/prusa3d/PrusaSlicer/commit/96b3ae85013ac363cd1c3e98ec6b7938aeacf46d
-                if (object->config().support_style == smsOrganic) {
+                if (is_tree(object->config().support_type.value) && (object->config().support_style == smsOrganic ||
+                    // Orca: use organic as default
+                    object->config().support_style == smsDefault)) {
                     float extrusion_width = std::min(
                         support_material_flow(object).width(),
                         support_material_interface_flow(object).width());

diff --git a/src/libslic3r/PrintObject.cpp b/src/libslic3r/PrintObject.cpp
@@ -1,3 +1,12 @@
+///|/ Copyright (c) Prusa Research 2016 - 2023 Lukáš Hejl @hejllukas, Pavel Mikuš @Godrak, Lukáš Matěna @lukasmatena, Vojtěch Bubník @bubnikv, Enrico Turri @enricoturri1966, Oleksandra Iushchenko @YuSanka, David Kocík @kocikdav, Roman Beránek @zavorka
+///|/ Copyright (c) 2021 Justin Schuh @jschuh
+///|/ Copyright (c) 2021 Ilya @xorza
+///|/ Copyright (c) 2016 Joseph Lenox @lordofhyphens
+///|/ Copyright (c) Slic3r 2014 - 2016 Alessandro Ranellucci @alranel
+///|/ Copyright (c) 2015 Maksim Derbasov @ntfshard
+///|/
+///|/ PrusaSlicer is released under the terms of the AGPLv3 or higher
+///|/
 #include "Exception.hpp"
 #include "Print.hpp"
 #include "BoundingBox.hpp"
@@ -2086,6 +2095,8 @@ bool PrintObject::update_layer_height_profile(const ModelObject &model_object, c
         // use the constructor because the assignement is crashing on ASAN OsX
         layer_height_profile = std::vector<coordf_t>(model_object.layer_height_profile.get());
 //        layer_height_profile = model_object.layer_height_profile;
+        // The layer height returned is sampled with high density for the UI layer height painting
+        // and smoothing tool to work.
         updated = true;
     }
 
@@ -2100,6 +2111,7 @@ bool PrintObject::update_layer_height_profile(const ModelObject &model_object, c
     if (layer_height_profile.empty() || layer_height_profile[1] != slicing_parameters.first_object_layer_height) {
         //layer_height_profile = layer_height_profile_adaptive(slicing_parameters, model_object.layer_config_ranges, model_object.volumes);
         layer_height_profile = layer_height_profile_from_ranges(slicing_parameters, model_object.layer_config_ranges);
+        // The layer height profile is already compressed.
         updated = true;
     }
 
@@ -2539,7 +2551,9 @@ void PrintObject::_generate_support_material()
     support_material.generate(*this);
 
     if (this->config().enable_support.value && is_tree(this->config().support_type.value)) {
-        if (this->config().support_style.value == smsOrganic || this->config().support_style.value == smsDefault) {
+        if (this->config().support_style.value == smsOrganic ||
+            // Orca: use organic as default
+            this->config().support_style.value == smsDefault) {
             fff_tree_support_generate(*this, std::function<void()>([this]() { this->throw_if_canceled(); }));
         } else {
             TreeSupport tree_support(*this, m_slicing_params);

diff --git a/src/libslic3r/Slicing.cpp b/src/libslic3r/Slicing.cpp
@@ -1,3 +1,7 @@
+///|/ Copyright (c) Prusa Research 2016 - 2023 Vojtěch Bubník @bubnikv, Enrico Turri @enricoturri1966, David Kocík @kocikdav, Lukáš Matěna @lukasmatena, Oleksandra Iushchenko @YuSanka
+///|/
+///|/ PrusaSlicer is released under the terms of the AGPLv3 or higher
+///|/
 #include <limits>
 
 #include "libslic3r.h"
@@ -321,7 +325,7 @@ std::vector<double> layer_height_profile_adaptive(const SlicingParameters& slici
         print_z += height;
     }
 
-    double z_gap = slicing_params.object_print_z_height() - layer_height_profile[layer_height_profile.size() - 2];
+    double z_gap = slicing_params.object_print_z_height() - *(layer_height_profile.end() - 2);
     if (z_gap > 0.0)
     {
         layer_height_profile.push_back(slicing_params.object_print_z_height());
@@ -685,6 +689,40 @@ std::vector<coordf_t> generate_object_layers(
     return out;
 }
 
+// Check whether the layer height profile describes a fixed layer height profile.
+bool check_object_layers_fixed(
+    const SlicingParameters     &slicing_params,
+    const std::vector<coordf_t> &layer_height_profile)
+{
+    assert(layer_height_profile.size() >= 4);
+    assert(layer_height_profile.size() % 2 == 0);
+    assert(layer_height_profile[0] == 0);
+
+    if (layer_height_profile.size() != 4 && layer_height_profile.size() != 8)
+        return false;
+
+    bool fixed_step1 = is_approx(layer_height_profile[1], layer_height_profile[3]);
+    bool fixed_step2 = layer_height_profile.size() == 4 || 
+            (layer_height_profile[2] == layer_height_profile[4] && is_approx(layer_height_profile[5], layer_height_profile[7]));
+
+    if (! fixed_step1 || ! fixed_step2)
+        return false;
+
+    if (layer_height_profile[2] < 0.5 * slicing_params.first_object_layer_height + EPSILON ||
+        ! is_approx(layer_height_profile[3], slicing_params.first_object_layer_height))
+        return false;
+
+    double z_max = layer_height_profile[layer_height_profile.size() - 2];
+    double z_2nd = slicing_params.first_object_layer_height + 0.5 * slicing_params.layer_height;
+    if (z_2nd > z_max)
+        return true;
+    if (z_2nd < *(layer_height_profile.end() - 4) + EPSILON ||
+        ! is_approx(layer_height_profile.back(), slicing_params.layer_height))
+        return false;
+
+    return true;
+}
+
 int generate_layer_height_texture(
 	const SlicingParameters 	&slicing_params,
 	const std::vector<coordf_t> &layers,

diff --git a/src/libslic3r/Slicing.hpp b/src/libslic3r/Slicing.hpp
@@ -1,3 +1,7 @@
+///|/ Copyright (c) Prusa Research 2016 - 2023 Vojtěch Bubník @bubnikv, Lukáš Matěna @lukasmatena, David Kocík @kocikdav, Enrico Turri @enricoturri1966, Oleksandra Iushchenko @YuSanka, Vojtěch Král @vojtechkral
+///|/
+///|/ PrusaSlicer is released under the terms of the AGPLv3 or higher
+///|/
 // Based on implementation by @platsch
 
 #ifndef slic3r_Slicing_hpp_
@@ -133,11 +137,11 @@ inline bool equal_layering(const SlicingParameters &sp1, const SlicingParameters
 typedef std::pair<coordf_t,coordf_t> t_layer_height_range;
 typedef std::map<t_layer_height_range, ModelConfig> t_layer_config_ranges;
 
-extern std::vector<coordf_t> layer_height_profile_from_ranges(
+std::vector<coordf_t> layer_height_profile_from_ranges(
     const SlicingParameters     &slicing_params,
     const t_layer_config_ranges &layer_config_ranges);
 
-extern std::vector<double> layer_height_profile_adaptive(
+std::vector<double> layer_height_profile_adaptive(
     const SlicingParameters& slicing_params,
     const ModelObject& object, float quality_factor);
 
@@ -150,7 +154,7 @@ struct HeightProfileSmoothingParams
     HeightProfileSmoothingParams(unsigned int radius, bool keep_min) : radius(radius), keep_min(keep_min) {}
 };
 
-extern std::vector<double> smooth_height_profile(
+std::vector<double> smooth_height_profile(
     const std::vector<double>& profile, const SlicingParameters& slicing_params,
     const HeightProfileSmoothingParams& smoothing_params);
 
@@ -161,7 +165,7 @@ enum LayerHeightEditActionType : unsigned int {
     LAYER_HEIGHT_EDIT_ACTION_SMOOTH   = 3
 };
 
-extern void adjust_layer_height_profile(
+void adjust_layer_height_profile(
     const SlicingParameters     &slicing_params,
     std::vector<coordf_t>       &layer_height_profile,
     coordf_t                     z,
@@ -171,14 +175,19 @@ extern void adjust_layer_height_profile(
 
 // Produce object layers as pairs of low / high layer boundaries, stored into a linear vector.
 // The object layers are based at z=0, ignoring the raft layers.
-extern std::vector<coordf_t> generate_object_layers(
+std::vector<coordf_t> generate_object_layers(
+    const SlicingParameters     &slicing_params,
+    const std::vector<coordf_t> &layer_height_profile);
+
+// Check whether the layer height profile describes a fixed layer height profile.
+bool check_object_layers_fixed(
     const SlicingParameters     &slicing_params,
     const std::vector<coordf_t> &layer_height_profile);
 
 // Produce a 1D texture packed into a 2D texture describing in the RGBA format
 // the planned object layers.
 // Returns number of cells used by the texture of the 0th LOD level.
-extern int generate_layer_height_texture(
+int generate_layer_height_texture(
     const SlicingParameters     &slicing_params,
     const std::vector<coordf_t> &layers,
     void *data, int rows, int cols, bool level_of_detail_2nd_level);

diff --git a/src/libslic3r/Support/SupportCommon.cpp b/src/libslic3r/Support/SupportCommon.cpp
@@ -1794,7 +1794,9 @@ void generate_support_toolpaths(
                     filler->link_max_length = coord_t(scale_(filler->spacing * link_max_length_factor / density));
                     sheath  = true;
                     no_sort = true;
-                } else if (config.support_style == SupportMaterialStyle::smsOrganic) {
+                } else if (config.support_style == SupportMaterialStyle::smsOrganic ||
+                    // Orca: use organic as default
+                    config.support_style == smsDefault) {
                     tree_supports_generate_paths(base_layer.extrusions, base_layer.polygons_to_extrude(), flow, support_params);
                     done = true;
                 }

diff --git a/src/libslic3r/Support/SupportMaterial.cpp b/src/libslic3r/Support/SupportMaterial.cpp
@@ -696,6 +696,9 @@ class SupportGridPattern
         case smsTreeSlim:
         case smsTreeStrong:
         case smsTreeHybrid:
+
+        // Orca: use organic as default
+        case smsDefault:
         case smsOrganic:
 //            assert(false);
             [[fallthrough]];

diff --git a/src/libslic3r/Support/TreeSupport.cpp b/src/libslic3r/Support/TreeSupport.cpp
@@ -3530,8 +3530,10 @@ static void generate_support_areas(Print &print, const BuildVolume &build_volume
             auto t_place = std::chrono::high_resolution_clock::now();
 
             // ### draw these points as circles
-
-            if (print_object.config().support_style.value != smsOrganic)
+
+            if (print_object.config().support_style.value != smsOrganic &&
+                // Orca: use organic as default
+                print_object.config().support_style.value != smsDefault)
                 draw_areas(*print.get_object(processing.second.front()), volumes, config, overhangs, move_bounds, 
                     bottom_contacts, top_contacts, intermediate_layers, layer_storage, throw_on_cancel);
             else {