Merge branch 'main' into fix/arm64-build

src/libslic3r/Fill/Fill.cpp

@@ -1692,9 +1692,9 @@ void Layer::make_ironing()
 				ironing_params.just_infill 	= false;
 				// ORCA: Get filament-specific overrides if configured, otherwise use process values
 				size_t extruder_idx = ironing_params.extruder - 1;
-				ironing_params.line_spacing = (!config.filament_ironing_spacing.is_nil(extruder_idx)
+				ironing_params.line_spacing = std::max(IRONING_SPACING_MIN, !config.filament_ironing_spacing.is_nil(extruder_idx)
 					? config.filament_ironing_spacing.get_at(extruder_idx)
-					: config.ironing_spacing);
+					: config.ironing_spacing.value);
                 ironing_params.inset = (!config.filament_ironing_inset.is_nil(extruder_idx)
 					? config.filament_ironing_inset.get_at(extruder_idx)
 					: config.ironing_inset);

src/libslic3r/Fill/FillConcentric.cpp

@@ -22,6 +22,9 @@ void FillConcentric::_fill_surface_single(
     
     coord_t min_spacing = scale_(this->spacing) * params.multiline;
     coord_t distance = coord_t(min_spacing / params.density);
+    // A non-positive step never shrinks the region, so the inset loop below would not end.
+    if (min_spacing <= 0 || distance <= 0)
+        return;
     
     if (params.density > 0.9999f && !params.dont_adjust) {
         distance = this->_adjust_solid_spacing(bounding_box.size()(0), distance);
@@ -108,6 +111,8 @@ void FillConcentric::_fill_surface_single(const FillParams& params,
     // no rotation is supported for this infill pattern
     Point   bbox_size = expolygon.contour.bounding_box().size();
     coord_t min_spacing = scaled<coord_t>(this->spacing);
+    if (min_spacing <= 0)
+        return;
 
     if (params.density > 0.9999f && !params.dont_adjust) {
         coord_t                loops_count = std::max(bbox_size.x(), bbox_size.y()) / min_spacing + 1;

src/libslic3r/PrintConfig.hpp

@@ -180,6 +180,10 @@ enum class IroningType {
     Count,
 };
 
+// Smallest usable ironing line spacing. Anything tighter yields an unprintable number of lines,
+// and zero stops the fillers from making progress.
+constexpr double IRONING_SPACING_MIN = 0.05;
+
 //BBS
 enum class WallInfillOrder {
     InnerOuterInfill,

src/libslic3r/Support/SupportParameters.hpp

@@ -64,7 +64,7 @@ struct SupportParameters {
 
         this->ironing = object_config.support_ironing;
         this->ironing_flow = support_material_interface_flow.with_height(support_material_interface_flow.height() * 0.01 * object_config.support_ironing_flow.value);
-        this->ironing_spacing = object_config.support_ironing_spacing;
+        this->ironing_spacing = std::max(IRONING_SPACING_MIN, object_config.support_ironing_spacing.value);
         this->ironing_pattern = object_config.support_ironing_pattern;
 
         // Calculate a minimum support layer height as a minimum over all extruders, but not smaller than 10um.

src/slic3r/GUI/ConfigManipulation.cpp

@@ -212,6 +212,30 @@ void ConfigManipulation::check_filament_max_volumetric_speed(DynamicPrintConfig
 
 }
 
+void ConfigManipulation::check_filament_ironing_spacing(DynamicPrintConfig *config)
+{
+    const auto *opt = config->option<ConfigOptionFloatsNullable>("filament_ironing_spacing");
+    if (opt == nullptr)
+        return;
+    std::vector<double> values = opt->values;
+    bool                reset  = false;
+    for (size_t i = 0; i < values.size(); ++i)
+        if (!opt->is_nil(i) && values[i] < IRONING_SPACING_MIN) {
+            values[i] = 0.1;
+            reset     = true;
+        }
+    if (!reset)
+        return;
+    const wxString     msg_text = _(L("Ironing spacing too small\nIt has been reset to 0.1"));
+    MessageDialog      dialog(nullptr, msg_text, "", wxICON_WARNING | wxOK);
+    DynamicPrintConfig new_conf = *config;
+    is_msg_dlg_already_exist    = true;
+    dialog.ShowModal();
+    new_conf.set_key_value("filament_ironing_spacing", new ConfigOptionFloatsNullable(values));
+    apply(config, &new_conf);
+    is_msg_dlg_already_exist = false;
+}
+
 void ConfigManipulation::check_chamber_temperature(DynamicPrintConfig* config)
 {
    bool support_chamber_temp_control=GUI::wxGetApp().preset_bundle->printers.get_selected_preset().config.opt_bool("support_chamber_temp_control");
@@ -334,7 +358,7 @@ void ConfigManipulation::update_print_fff_config(DynamicPrintConfig* config, con
     }
 
     //BBS: ironing_spacing shouldn't be too small or equal to zero
-    if (config->opt_float("ironing_spacing") < 0.05)
+    if (config->opt_float("ironing_spacing") < IRONING_SPACING_MIN)
     {
         const wxString msg_text = _(L("Ironing spacing too small\nIt has been reset to 0.1"));
         MessageDialog dialog(nullptr, msg_text, "", wxICON_WARNING | wxOK);
@@ -345,7 +369,7 @@ void ConfigManipulation::update_print_fff_config(DynamicPrintConfig* config, con
         apply(config, &new_conf);
         is_msg_dlg_already_exist = false;
     }
-    if (config->opt_float("support_ironing_spacing") < 0.05)
+    if (config->opt_float("support_ironing_spacing") < IRONING_SPACING_MIN)
     {
         const wxString msg_text = _(L("Ironing spacing too small\nIt has been reset to 0.1"));
         MessageDialog dialog(nullptr, msg_text, "", wxICON_WARNING | wxOK);

src/slic3r/GUI/ConfigManipulation.hpp

@@ -84,6 +84,7 @@ public:
     void    check_nozzle_temperature_initial_layer_range(DynamicPrintConfig* config, unsigned int variant_index);
     void    check_adaptive_pressure_advance_model(DynamicPrintConfig* config);
     void    check_filament_max_volumetric_speed(DynamicPrintConfig *config);
+    void    check_filament_ironing_spacing(DynamicPrintConfig *config);
     void    check_chamber_temperature(DynamicPrintConfig* config);
     void    check_chamber_minimal_temperature(DynamicPrintConfig* config);
     bool    check_layer_height(DynamicPrintConfig* config);

src/slic3r/GUI/Tab.cpp

@@ -4911,6 +4911,7 @@ void TabFilament::update()
         return; // ys_FIXME
 
     m_config_manipulation.check_filament_max_volumetric_speed(m_config);
+    m_config_manipulation.check_filament_ironing_spacing(m_config);
 
     m_update_cnt++;
 

tests/fff_print/test_fill.cpp

@@ -748,6 +748,61 @@ TEST_CASE("A region with ironing turned off is never ironed", "[Fill]")
     REQUIRE(Layer::choose_ironing_extruder(cfg, spiral_mode, /*is_topmost_layer=*/true) == -1);
 }
 
+// Ironing path count and total length in mm, over the whole object.
+static std::pair<size_t, double> ironing_extent(const Print &print)
+{
+    size_t paths  = 0;
+    double length = 0.;
+    for (const Layer *layer : print.objects().front()->layers())
+        for (const LayerRegion *region : layer->regions())
+            for (const ExtrusionEntity *entity : region->fills.flatten().entities)
+                if (ironing_role(entity->role())) {
+                    ++paths;
+                    length += unscale<double>(entity->length());
+                }
+    return {paths, length};
+}
+
+TEST_CASE("Ironing spacing below the minimum irons at the minimum spacing", "[Fill]")
+{
+    const std::string pattern      = GENERATE("rectilinear", "concentric");
+    const bool        via_filament = GENERATE(false, true);
+    const double      spacing      = GENERATE(0., 0.001);
+    CAPTURE(pattern, via_filament, spacing);
+
+    auto ironing_for = [&pattern, via_filament](double spacing) {
+        DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+        config.set_deserialize_strict({{"ironing_type", "top"},
+                                       {"ironing_pattern", pattern},
+                                       {"layer_height", 0.2}});
+        // The filament override replaces the process spacing, which stays at a usable value.
+        if (via_filament)
+            config.set_deserialize_strict({{"ironing_spacing", 0.1}, {"filament_ironing_spacing", spacing}});
+        else
+            config.set_deserialize_strict({{"ironing_spacing", spacing}});
+        Print print;
+        Slic3r::Test::init_and_process_print({Slic3r::Test::cube(20)}, print, config);
+        return ironing_extent(print);
+    };
+
+    const std::pair<size_t, double> clamped = ironing_for(spacing);
+    const std::pair<size_t, double> minimum = ironing_for(IRONING_SPACING_MIN);
+    REQUIRE(minimum.first > 0);
+    CHECK(clamped.first == minimum.first);
+    CHECK_THAT(clamped.second, Catch::Matchers::WithinRel(minimum.second, 1e-9));
+}
+
+TEST_CASE("Concentric fill at zero spacing returns without paths", "[Fill]")
+{
+    std::unique_ptr<Fill> filler(Fill::new_from_type(ipConcentric));
+    filler->spacing      = 0.;
+    filler->bounding_box = BoundingBox(Point(0, 0), Point::new_scale(10, 10));
+    FillParams params;
+    params.density = 1.f;
+    Surface surface(stTop, ExPolygon({Point(0, 0), Point::new_scale(10, 0), Point::new_scale(10, 10), Point::new_scale(0, 10)}));
+    CHECK(filler->fill_surface(&surface, params).empty());
+}
+
 TEST_CASE("Solid infill direction offsets every layer when no template is set", "[Fill]")
 {
     auto angles_for = [](int direction) {