From 2e61d9eab2dcf2fef3511bb5606641cb9509eee1 Mon Sep 17 00:00:00 2001
From: Kiss Lorand <50251547+kisslorand@users.noreply.github.com>
Date: Wed, 22 Apr 2026 00:08:55 +0300
Subject: [PATCH] Correct gap fill width bounds in outer-only and mixed-wall
 cases (#12057)

---
 src/libslic3r/PerimeterGenerator.cpp | 6 +++---
 1 file changed, 3 insertions(+), 3 deletions(-)

diff --git a/src/libslic3r/PerimeterGenerator.cpp b/src/libslic3r/PerimeterGenerator.cpp
index 1fa4d58bb0..f8827923f4 100644
--- a/src/libslic3r/PerimeterGenerator.cpp
+++ b/src/libslic3r/PerimeterGenerator.cpp
@@ -1562,9 +1562,9 @@ void PerimeterGenerator::process_classic()
         } // for each loop of an island
 
         // fill gaps
-        if (! gaps.empty()) {
-            // collapse
-            double min = 0.2 * perimeter_width * (1 - INSET_OVERLAP_TOLERANCE);
+        if (! gaps.empty()) { // collapse
+            // ORCA: Use the smaller width as the lower bound to avoid overestimating safe overlap
+            double min = 0.2 * std::min(perimeter_width, ext_perimeter_width) * (1 - INSET_OVERLAP_TOLERANCE);
             double max = 2. * perimeter_spacing;
             ExPolygons gaps_ex = diff_ex(
                 //FIXME offset2 would be enough and cheaper.