Make the exclude-object outline tolerance a user setting (#16503)

* Make the exclude-object outline tolerance configurable

Signed-off-by: Sergei Rozhkov <zmod@zmod.link>

* fix(config): move exclude_object_tolerance to developer mode

Signed-off-by: Sergei Rozhkov <zmod@zmod.link>

* fix(config): move exclude_object_tolerance to expert mode

Signed-off-by: Sergei Rozhkov <zmod@zmod.link>

* feat(ui): hide exclude_object_tolerance for non-Klipper firmwares

mend

Signed-off-by: Sergei Rozhkov <zmod@zmod.link>

* Test that a larger exclude object tolerance writes fewer outline points

Signed-off-by: Sergei Rozhkov <zmod@zmod.link>

---------

Signed-off-by: Sergei Rozhkov <zmod@zmod.link>

localization/i18n/OrcaSlicer.pot

@@ -15648,6 +15648,12 @@ msgstr ""
 msgid "Enable this option to add EXCLUDE OBJECT command in G-code."
 msgstr ""
 
+msgid "Outline tolerance"
+msgstr ""
+
+msgid "Maximum deviation of the object outline written to EXCLUDE_OBJECT_DEFINE from the original outline. Larger values give fewer points, which helps firmware that stalls while parsing G-code with many objects. 0 keeps every point."
+msgstr ""
+
 msgid "Verbose G-code"
 msgstr ""
 

src/libslic3r/Preset.cpp

@@ -1421,6 +1421,7 @@ static std::vector<std::string> s_Preset_print_options{
     "initial_layer_travel_acceleration",
     "initial_layer_travel_jerk",
     "exclude_object",
+    "exclude_object_tolerance",
     "slow_down_layers",
     "infill_anchor",
     "infill_anchor_max",

src/libslic3r/Print.cpp

@@ -309,6 +309,7 @@ bool Print::invalidate_state_by_config_options(const ConfigOptionResolver & /* n
         "gcode_comments",
         "gcode_label_objects", 
         "exclude_object",
+        "exclude_object_tolerance",
         "support_material_interface_fan_speed",
         "internal_bridge_fan_speed", // ORCA: Add support for separate internal bridge fan speed control
         "ironing_fan_speed",
@@ -6929,7 +6930,7 @@ BoundingBoxf3 PrintInstance::get_bounding_box() const {
 
 Polygon PrintInstance::get_convex_hull_2d() {
     Polygon poly = print_object->model_object()->convex_hull_2d(model_instance->get_matrix());
-    poly.douglas_peucker(scale_(0.1));
+    poly.douglas_peucker(scale_(print_object->print()->config().exclude_object_tolerance.value));
     return poly;
 }
 

src/libslic3r/PrintConfig.cpp

@@ -4629,6 +4629,17 @@ void PrintConfigDef::init_fff_params()
     def->mode = comAdvanced;
     def->set_default_value(new ConfigOptionBool(false));
 
+    def = this->add("exclude_object_tolerance", coFloat);
+    def->label = L("Outline tolerance");
+    def->tooltip = L("Maximum deviation of the object outline written to EXCLUDE_OBJECT_DEFINE from the "
+                     "original outline. Larger values give fewer points, which helps firmware that stalls "
+                     "while parsing G-code with many objects. 0 keeps every point.");
+    def->sidetext = L("mm");
+    def->min = 0;
+    def->max = 5;
+    def->mode = comExpert;
+    def->set_default_value(new ConfigOptionFloat(0.1));
+
     def = this->add("gcode_comments", coBool);
     def->label = L("Verbose G-code");
     def->tooltip = L("Enable this to get a commented G-code file, with each line explained by a descriptive text. "

src/libslic3r/PrintConfig.hpp

@@ -2130,6 +2130,7 @@ PRINT_CONFIG_CLASS_DERIVED_DEFINE(
     ((ConfigOptionPercents,            filament_shrinkage_compensation_z))
     ((ConfigOptionBool,                gcode_label_objects))
     ((ConfigOptionBool,                exclude_object))
+    ((ConfigOptionFloat,               exclude_object_tolerance))
     ((ConfigOptionFloats,             grab_length))
     ((ConfigOptionBool,                gcode_comments))
     ((ConfigOptionInt,                 slow_down_layers))

src/slic3r/GUI/ConfigManipulation.cpp

@@ -1245,6 +1245,8 @@ void ConfigManipulation::toggle_print_fff_options(DynamicPrintConfig *config, in
     if(gcf_is_klipper)
         toggle_field("accel_to_decel_factor", config->opt_bool("accel_to_decel_enable"));
 
+    toggle_line("exclude_object_tolerance", gcf_is_klipper && config->opt_bool("exclude_object"));
+
     bool have_make_overhang_printable = config->opt_bool("make_overhang_printable");
     toggle_line("make_overhang_printable_angle", have_make_overhang_printable);
     toggle_line("make_overhang_printable_hole_size", have_make_overhang_printable);

src/slic3r/GUI/Tab.cpp

@@ -3269,6 +3269,7 @@ void TabPrint::build()
         optgroup->append_single_option_line("gcode_comments", "others_settings_g_code_output#verbose-g-code");
         optgroup->append_single_option_line("gcode_label_objects", "others_settings_g_code_output#label-objects");
         optgroup->append_single_option_line("exclude_object", "others_settings_g_code_output#exclude-objects");
+        optgroup->append_single_option_line("exclude_object_tolerance", "others_settings_g_code_output#outline-tolerance");
         option = optgroup->get_option("filename_format");
         // option.opt.full_width = true;
         option.opt.is_code = true;

tests/fff_print/test_gcode.cpp

@@ -51,6 +51,44 @@ TEST_CASE("Klipper object labels name each copy without the characters Klipper c
     }
 }
 
+// The outline written to EXCLUDE_OBJECT_DEFINE is simplified with exclude_object_tolerance. A larger value must
+// leave fewer points, which keeps the exclude-object array small on printers that stall while parsing it.
+TEST_CASE("A larger exclude object tolerance writes fewer outline points", "[GCode]")
+{
+    const auto slice_with_tolerance = [](const std::string &tolerance) {
+        DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+        config.set_deserialize_strict({{"gcode_flavor", "klipper"}, {"exclude_object", "1"},
+                                       {"exclude_object_tolerance", tolerance}});
+        // Default facet angle (2 degrees): 180 hull points, well inside either tolerance.
+        return Test::slice({make_cylinder(20., 5.)}, config);
+    };
+    // Points of the POLYGON=[[x,y],...] on the first EXCLUDE_OBJECT_DEFINE line.
+    const auto polygon_points = [](const std::string &gcode) {
+        const size_t define = gcode.find("EXCLUDE_OBJECT_DEFINE");
+        REQUIRE(define != std::string::npos);
+        const size_t begin = gcode.find("POLYGON=", define);
+        REQUIRE(begin != std::string::npos);
+        const std::string polygon = gcode.substr(begin, gcode.find('\n', begin) - begin);
+        size_t points = 1;
+        for (size_t pos = polygon.find("],["); pos != std::string::npos; pos = polygon.find("],[", pos + 1))
+            ++points;
+        return points;
+    };
+
+    const size_t fine   = polygon_points(slice_with_tolerance("0.1"));
+    const size_t coarse = polygon_points(slice_with_tolerance("0.4"));
+    INFO("points at 0.1 mm: " << fine << ", at 0.4 mm: " << coarse);
+    CHECK(coarse >= 4);
+    CHECK(coarse < fine);
+}
+
+// Existing profiles must keep writing the outlines they wrote when the tolerance was a constant 0.1 mm.
+TEST_CASE("The exclude object tolerance defaults to the former fixed 0.1 mm", "[GCode]")
+{
+    CHECK_THAT(DynamicPrintConfig::full_print_config().opt_float("exclude_object_tolerance"),
+               Catch::Matchers::WithinAbs(0.1, 1e-9));
+}
+
 // Firmwares read the compatibility header lines (Anycubic's GoKlipper heats the bed with
 // first_layer_bed_temperature), so they must describe the filament the plate prints, not filament 1.
 TEST_CASE("The G-code header names the first layer temperatures of the filament the plate prints", "[GCode]")