#include #include "libslic3r/AABBTreeLines.hpp" #include "libslic3r/GCode/ExtrusionProcessor.hpp" #include "libslic3r/GCodeReader.hpp" #include "libslic3r/TriangleMesh.hpp" #include "test_helpers.hpp" #include #include #include #include using namespace Slic3r; using namespace Slic3r::Test; namespace { // Print settings the assertions below are derived from. constexpr double caged_layer_height = 0.2; // mm constexpr double caged_wall_width = 0.42; // mm, outer wall line width constexpr double caged_outer_wall_speed = 200.; // mm/s constexpr double caged_slow_speed = 100.; // mm/s, between every configured overhang speed (<= 50) and the wall speed // A wall running 0.2mm out over a previous layer whose edge dishes 0.03mm away from it in the middle, // standing in for the endpoint readings a caged overhang perimeter takes: enough of a difference to // print at another speed, but only a fraction of the distance at which slowdown begins. constexpr double dished_wall_gap = 0.2; // mm, how far the wall runs out past the previous layer's edge constexpr double dished_layer_depth = 0.03; // mm, how much further out the middle of it reads constexpr double dished_min_distance = 0.042; // mm, the reading at which the configured speeds begin to slow down // Every reading here is past that, so the whole wall is slowed and only the amount is in question. constexpr float dished_end_reading = float(dished_wall_gap + 0.5 * caged_wall_width); constexpr float dished_mid_reading = float(dished_end_reading + dished_layer_depth); // The two readings are dished_layer_depth apart, so half of that tells them apart while still allowing // for the points the passes after sampling add, which read a little further out than the ends do. constexpr double dished_reading_tolerance = 0.5 * dished_layer_depth; // A 40 x 20 x 20 mm box with a 45 degree overhang cut into the y = 0 side. The sloped face spans // x = 5.086 .. 34.914 only, so the full-height walls of the box cage both ends of every overhang // perimeter: the endpoints look supported even though the span between them is not. TriangleMesh caged_overhang_mesh() { return TriangleMesh( { {5.0859987f, 10.167065f, 5.711731f}, {34.914257f, 10.167065f, 5.711731f}, {34.914257f, 0.f, 15.878796f}, {5.0859995f, 0.f, 15.878796f}, {0.f, 0.f, 0.f}, {0.f, 0.f, 20.f}, {0.f, 20.f, 20.f}, {0.f, 20.f, 0.f}, {40.f, 20.f, 20.f}, {40.f, 20.f, 0.f}, {40.f, 0.f, 20.f}, {40.f, 0.f, 0.f}, {34.914257f, 0.f, 0.f}, {5.0859995f, 0.f, 0.f}, {34.914257f, 10.167065f, 0.f}, {5.0859995f, 10.167065f, 0.f}, }, { {0, 1, 2}, {0, 2, 3}, {4, 5, 6}, {4, 6, 7}, {7, 6, 8}, {7, 8, 9}, {9, 8, 10}, {9, 10, 11}, {12, 11, 10}, {5, 4, 13}, {5, 13, 3}, {2, 12, 10}, {5, 3, 2}, {10, 5, 2}, {9, 11, 12}, {9, 12, 14}, {13, 4, 7}, {9, 14, 15}, {15, 13, 7}, {7, 9, 15}, {8, 6, 5}, {8, 5, 10}, {14, 1, 0}, {14, 0, 15}, {2, 1, 14}, {2, 14, 12}, {15, 0, 3}, {15, 3, 13}, }); } // Mesh geometry the wall filters below are derived from. constexpr double caged_box_depth = 20.; // mm, the box spans y = 0 .. 20 constexpr double caged_slope_face_sum = 15.878796; // mm, y + z of the sloped face, from its corners // The sloped face spans this x range; outside it the box walls run full height. constexpr double caged_slope_x_min = 5.0859995; constexpr double caged_slope_x_max = 34.914257; constexpr double caged_slope_span = caged_slope_x_max - caged_slope_x_min; // ~29.8 mm // The z range the sloped face occupies, from the same fixture vertices. constexpr double caged_slope_z_min = 5.711731; constexpr double caged_slope_z_max = 15.878796; // The lowest slope layer still sits on the solid body below the notch, so it is fully supported and // runs at the outer wall speed by design. The caged span proper begins one layer above it. constexpr double caged_span_z_min = caged_slope_z_min + caged_layer_height; // A layer printed at z is sliced at z - layer_height / 2, and the outer wall centreline sits half a // line width inside the contour, so the wall on the slope satisfies y + z = 16.189. constexpr double caged_slope_wall_sum = caged_slope_face_sum + 0.5 * caged_layer_height + 0.5 * caged_wall_width; // Same inset on the fully supported y = 20 face, vertical over the whole height. constexpr double caged_back_wall_y = caged_box_depth - 0.5 * caged_wall_width; // And on the y = 0 face, which runs full height only outside the slope's x range. constexpr double caged_front_wall_y = 0.5 * caged_wall_width; // Arachne varies the wall width along a face, and the centreline inset is half that width, so a // wall sits within about half a line width of where the nominal inset alone would put it. The // faces being selected are millimetres apart, so this stays far from ambiguous. constexpr double caged_wall_tolerance = 0.5 * caged_wall_width; // Feed rates in mm/min of the long outer wall extrusions `keep_line` selects. template std::vector outer_wall_feed_rates(const std::string& gcode, KeepLine keep_line) { std::vector feed_rates; bool outer_wall = false; GCodeReader parser; parser.parse_buffer(gcode, [&feed_rates, &outer_wall, &keep_line](GCodeReader& self, const GCodeReader::GCodeLine& line) { const std::string_view comment = line.comment(); if (comment.find("FEATURE:") != std::string_view::npos || comment.find("TYPE:") != std::string_view::npos) outer_wall = comment.find("Outer wall") != std::string_view::npos || comment.find("External perimeter") != std::string_view::npos; if (outer_wall && line.extruding(self) && line.dist_XY(self) > 1.0 && keep_line(self, line)) feed_rates.push_back(line.new_F(self)); }); return feed_rates; } // The caged 45 degree overhang: outer walls crossing the sloped face for most of its width, on the // layers where the face genuinely overhangs. // Both ends are tested against the slope plane rather than requiring a constant Y. Arachne's // variable-width walls drift slightly in Y along the same slope (Y6.186 -> Y6.189 on one move), so // a constant-Y filter matches almost nothing under Arachne and silently reduces its coverage. // The length test excludes the cage walls: they are only as wide as the box is either side of the // slope, but being vertical their y + z sweeps through the slope plane as z rises, so a couple of // their fully supported moves would otherwise be counted as part of the span. std::vector caged_slope_feed_rates(const std::string& gcode) { return outer_wall_feed_rates(gcode, [](const GCodeReader& self, const GCodeReader::GCodeLine& line) { const double z = line.new_Z(self); return z > caged_span_z_min && z < caged_slope_z_max && line.dist_XY(self) > 0.5 * caged_slope_span && std::abs(self.y() + z - caged_slope_wall_sum) < caged_wall_tolerance && std::abs(line.new_Y(self) + z - caged_slope_wall_sum) < caged_wall_tolerance; }); } // The opposite, fully supported face, skipping the initial layer and its own speed settings. std::vector back_wall_feed_rates(const std::string& gcode) { return outer_wall_feed_rates(gcode, [](const GCodeReader& self, const GCodeReader::GCodeLine& line) { return line.new_Z(self) > 1.5 * caged_layer_height && std::abs(self.y() - caged_back_wall_y) < caged_wall_tolerance && std::abs(line.new_Y(self) - caged_back_wall_y) < caged_wall_tolerance; }); } // The first layer printed entirely above the slope. Its y = 0 wall runs the full width of the box. const double caged_layer_above_slope_z = std::ceil(caged_slope_z_max / caged_layer_height) * caged_layer_height; // The parts of that wall standing on the cage rather than the slope, so on a contour identical to their own. // Where the support changes is found by bisection, which stops at spans of 2mm, so the move spanning each end of // the slope reaches a little way into the cage. Taking only the moves lying wholly outside the slope's x range // leaves the wall that is unambiguously supported, without asserting how closely the bisection converged. std::vector cage_shoulder_feed_rates(const std::string& gcode) { return outer_wall_feed_rates(gcode, [](const GCodeReader& self, const GCodeReader::GCodeLine& line) { return std::abs(line.new_Z(self) - caged_layer_above_slope_z) < 0.5 * caged_layer_height && std::abs(self.y() - caged_front_wall_y) < caged_wall_tolerance && std::abs(line.new_Y(self) - caged_front_wall_y) < caged_wall_tolerance && (std::max(self.x(), line.new_X(self)) <= caged_slope_x_min || std::min(self.x(), line.new_X(self)) >= caged_slope_x_max); }); } // The readings a 40mm wall takes over a previous layer whose edge falls away by 0.03mm towards the // middle: both ends read the same, and the middle reads slightly further out over air. Whether that // middle reading survives is what decides the speed the wall is printed at. std::vector> sampled_wall_over_dished_layer(const std::function& distance_to_speed) { const AABBTreeLines::LinesDistancer prev_layer(std::vector{ {{0., 0.}, {20., -dished_layer_depth}}, {{20., -dished_layer_depth}, {40., 0.}}, {{40., 0.}, {40., -10.}}, {{40., -10.}, {0., -10.}}, {{0., -10.}, {0., 0.}}, }); const Points wall{Point::new_scale(0., dished_wall_gap), Point::new_scale(40., dished_wall_gap)}; return estimate_points_properties(wall, prev_layer, caged_wall_width, -1.f, dished_min_distance, distance_to_speed); } // A straight, otherwise supported wall over a previous-layer boundary with a 2mm-wide pocket. Moving the // pocket between x = 10 and x = 20 covers both discovery away from the wall's midpoint and refinement around // a midpoint that has already been discovered. The current wall is inset half its width from the flat boundary, // so its supported readings are zero after the estimator applies its boundary offset. constexpr double narrow_pocket_wall_length = 40.; constexpr double narrow_pocket_width = 2.; constexpr double narrow_pocket_depth = 0.3; std::vector> sampled_wall_over_narrow_pocket( double pocket_center, const std::function& distance_to_speed) { const double pocket_left = pocket_center - 0.5 * narrow_pocket_width; const double pocket_right = pocket_center + 0.5 * narrow_pocket_width; const AABBTreeLines::LinesDistancer prev_layer(std::vector{ {{0., 0.}, {pocket_left, 0.}}, {{pocket_left, 0.}, {pocket_left, -narrow_pocket_depth}}, {{pocket_left, -narrow_pocket_depth}, {pocket_right, -narrow_pocket_depth}}, {{pocket_right, -narrow_pocket_depth}, {pocket_right, 0.}}, {{pocket_right, 0.}, {narrow_pocket_wall_length, 0.}}, {{narrow_pocket_wall_length, 0.}, {narrow_pocket_wall_length, -10.}}, {{narrow_pocket_wall_length, -10.}, {0., -10.}}, {{0., -10.}, {0., 0.}}, }); const double wall_y = -0.5 * caged_wall_width; const Points wall{Point::new_scale(0., wall_y), Point::new_scale(narrow_pocket_wall_length, wall_y)}; return estimate_points_properties(wall, prev_layer, caged_wall_width, -1.f, dished_min_distance, distance_to_speed); } // A cross section that grows a layer's worth on the two faces meeting at either end of a wall, as any // 45 degree overhang does. The wall itself stands on a contour identical to its own, but its ends sit // where the growing faces cut the corners off, and the previous layer's edge there is nearer than the // half line width the centreline is inset by. Both ends therefore read an overhang while everything // between them reads supported: the reverse of the caged span, and the case the sampling above must // leave to the passes after it. constexpr double stepped_wall_inset = 0.5 * caged_wall_width; // mm, centreline inset from the contour constexpr double stepped_end_gap = stepped_wall_inset - caged_layer_height; // mm, how far inside the corner ends up constexpr double stepped_wall_span = 30.; // mm, the length of the wall std::vector> sampled_wall_between_growing_corners(const std::function& distance_to_speed) { const AABBTreeLines::LinesDistancer prev_layer(std::vector{ {{0., 0.}, {32., 0.}}, {{32., 0.}, {32., -stepped_wall_span}}, {{32., -stepped_wall_span}, {0., -stepped_wall_span}}, {{0., -stepped_wall_span}, {0., 0.}}, }); const Points wall{Point::new_scale(stepped_wall_inset, -stepped_end_gap), Point::new_scale(stepped_wall_inset, stepped_end_gap - stepped_wall_span)}; return estimate_points_properties(wall, prev_layer, caged_wall_width, -1.f, dished_min_distance, distance_to_speed); } // How much of a path is printed below the speed a fully supported reading gives. A segment is printed // at the lower of the speeds its ends read. double slowed_length(const std::vector>& points, const std::function& distance_to_speed) { double length = 0.; for (size_t i = 0; i + 1 < points.size(); ++i) if (std::min(distance_to_speed(points[i].distance), distance_to_speed(points[i + 1].distance)) < distance_to_speed(0.f)) length += (points[i + 1].position - points[i].position).norm(); return length; } float furthest_reading(const std::vector>& points) { return std::max_element(points.begin(), points.end(), [](const ExtendedPoint<2>& l, const ExtendedPoint<2>& r) { return l.distance < r.distance; })->distance; } DynamicPrintConfig caged_overhang_config(const char* wall_generator){ DynamicPrintConfig config = DynamicPrintConfig::full_print_config(); config.set_deserialize_strict({ {"nozzle_diameter", "0.4"}, {"initial_layer_print_height", caged_layer_height}, {"layer_height", caged_layer_height}, {"line_width", caged_wall_width}, {"outer_wall_line_width", caged_wall_width}, {"inner_wall_line_width", "0.45"}, {"wall_loops", "2"}, {"wall_generator", wall_generator}, {"wall_sequence", "inner wall/outer wall"}, {"sparse_infill_density", "15%"}, {"detect_overhang_wall", "1"}, {"enable_overhang_speed", "1"}, {"slowdown_for_curled_perimeters", "0"}, {"zaa_enabled", "0"}, {"outer_wall_speed", caged_outer_wall_speed}, {"inner_wall_speed", "300"}, {"overhang_1_4_speed", "0"}, {"overhang_2_4_speed", "50"}, {"overhang_3_4_speed", "30"}, {"overhang_4_4_speed", "10"}, {"bridge_speed", "50"}, {"filament_max_volumetric_speed", "22"}, {"slow_down_for_layer_cooling", "0"}, {"slow_down_layers", "0"}, // Nothing but the overhang settings may lower a wall speed }); return config; } std::string caged_overhang_gcode(const char* wall_generator) { Print print; Model model; init_print(std::vector{caged_overhang_mesh()}, print, model, caged_overhang_config(wall_generator), nullptr, false); return gcode(print); } // Reports the matched move count alongside the extremes, so a filter that selected nothing is // distinguishable from a span that simply was not slowed. void info_feed_rates(const char* span, const std::vector& feed_rates) { UNSCOPED_INFO("matched " << feed_rates.size() << " " << span << " moves"); if (!feed_rates.empty()) { const auto extremes = std::minmax_element(feed_rates.begin(), feed_rates.end()); UNSCOPED_INFO("slowest " << *extremes.first / MM_PER_MIN << " mm/s, fastest " << *extremes.second / MM_PER_MIN << " mm/s"); } } } // namespace // Classic reproduces the endpoint-sampling bug: it emits the span as one long move whose endpoints // both read as supported, so endpoint-only sampling never slows it. Arachne's endpoints already read // as overhanging, but their placement near the cage makes the inferred support vary by layer. Arachne // parity is therefore part of this regression's scope: both generators must classify the unsupported // interior of the same 45-degree span consistently. TEST_CASE("Caged external overhangs are slowed along their span", "[ExtrusionProcessor][Regression]") { const char* wall_generator = GENERATE("classic", "arachne"); INFO("wall generator: " << wall_generator); const std::vector feed_rates = caged_slope_feed_rates(caged_overhang_gcode(wall_generator)); info_feed_rates("caged slope", feed_rates); REQUIRE_FALSE(feed_rates.empty()); // The endpoint bug left Classic at the full wall speed, while Arachne's cage-adjacent endpoint // samples selected much faster bands on some layers. The whole span must stay in the slowed range // for both generators, without requiring their different path segmentations to match. const double fastest = *std::max_element(feed_rates.begin(), feed_rates.end()); REQUIRE(fastest < caged_slow_speed * MM_PER_MIN); } // The other side of the fix: the midpoint probe fires on every long external perimeter, so a // regression that over-slows would leave the test above green. A fully supported wall must keep the // speed it was configured with. TEST_CASE("Supported vertical walls keep their normal speed", "[ExtrusionProcessor][Regression]") { const char* wall_generator = GENERATE("classic", "arachne"); INFO("wall generator: " << wall_generator); const std::vector feed_rates = back_wall_feed_rates(caged_overhang_gcode(wall_generator)); info_feed_rates("back wall", feed_rates); REQUIRE_FALSE(feed_rates.empty()); const double slowest = *std::min_element(feed_rates.begin(), feed_rates.end()); REQUIRE(slowest >= caged_slow_speed * MM_PER_MIN); } // The slope's top edge falls mid layer, so the first layer above it still stands 0.179mm proud of the layer // below wherever that layer was still on the slope. That is a real overhang and is slowed, but it ends with the // slope: outside the slope's x range the box runs full height, so the same wall stands on a contour identical to // its own. Sampling the interior of that wall at a single point reported one support reading for all of it and // slowed these fully supported ends along with the rest. TEST_CASE("Wall sections beside a caged overhang keep their normal speed", "[ExtrusionProcessor][Regression]") { const char* wall_generator = GENERATE("classic", "arachne"); INFO("wall generator: " << wall_generator); const std::vector feed_rates = cage_shoulder_feed_rates(caged_overhang_gcode(wall_generator)); info_feed_rates("cage shoulder", feed_rates); REQUIRE_FALSE(feed_rates.empty()); const double slowest = *std::min_element(feed_rates.begin(), feed_rates.end()); REQUIRE_THAT(slowest / MM_PER_MIN, Catch::Matchers::WithinRel(caged_outer_wall_speed, 0.01)); } // A wall is printed at the lower of the speeds its ends read, so a reading only earns a point in the // path where it prints at a different speed from the readings around it. Judging that on the readings // themselves rather than the speeds they produce was too coarse: the configured speeds interpolate // between their sections, so readings a fraction of the slowdown threshold apart still print more than // 10% apart, and a real 45 degree overhang had its true reading dropped as if it agreed with its ends. // The ends then chose the speed on their own, and being next to the walls either side of the overhang // they read differently from layer to layer, banding an overhang that should have been uniform. TEST_CASE("An overhang reading is kept whenever it changes the speed", "[ExtrusionProcessor][Regression]") { // A steep speed curve, of the kind the configured overhang speeds interpolate across. const std::vector> points = sampled_wall_over_dished_layer([](float distance) { return std::round(200.f - 400.f * distance); }); REQUIRE_THAT(furthest_reading(points), Catch::Matchers::WithinAbs(dished_mid_reading, dished_reading_tolerance)); } // The complement, and why the readings alone were tempting: a reading that prints at the same speed as // its neighbours cannot change the G-code, so sampling must leave the path alone however far out it is. TEST_CASE("An overhang reading is dropped when the speed is unchanged", "[ExtrusionProcessor]") { // A flat speed curve, of the kind a single configured overhang speed produces. const std::vector> points = sampled_wall_over_dished_layer([](float) { return 50.f; }); REQUIRE_THAT(furthest_reading(points), Catch::Matchers::WithinAbs(dished_end_reading, dished_reading_tolerance)); } TEST_CASE("Coarse probing detects an unsupported pocket away from the wall midpoint", "[ExtrusionProcessor][Regression]") { const std::function distance_to_speed = [](float distance) { return distance <= 0.2f ? 100.f : 50.f; }; const std::vector> points = sampled_wall_over_narrow_pocket(0.25 * narrow_pocket_wall_length, distance_to_speed); const double slowed = slowed_length(points, distance_to_speed); REQUIRE(slowed > 0.); REQUIRE(slowed < 5.); } TEST_CASE("Coarse probing brackets a narrow slowdown at the wall midpoint", "[ExtrusionProcessor][Regression]") { // Half of the pocket reading still maps to full speed. A matching probe in either half therefore must not // prune that half before a supported point has been found close enough to bracket the slow midpoint. const std::function distance_to_speed = [](float distance) { return distance <= 0.2f ? 100.f : 50.f; }; const std::vector> points = sampled_wall_over_narrow_pocket(0.5 * narrow_pocket_wall_length, distance_to_speed); const double slowed = slowed_length(points, distance_to_speed); REQUIRE(slowed > 0.); REQUIRE(slowed < 5.); } // Sampling probes the interior, so it must not answer for the ends. On a supported wall between two // corners that read an overhang, the reading that differs is the end's own, and the pass that ends a // slowdown an end reads places its point from how far out that end is. Sampling took the difference as // its own to report and put a point at the nearest position bisection had reached instead, which both // sits further along the wall and leaves too little of it for that pass to run on, so the corner // slowdown ran millimetres up an otherwise supported wall. Its length grows with the wall, so on a // model whose cross section keeps growing it reads as a stair stepped band up the corner. TEST_CASE("A supported wall between overhanging corners is slowed no further than its ends require", "[ExtrusionProcessor][Regression]") { // A steep speed curve, so the ends and the interior between them print at clearly different speeds. const std::function distance_to_speed = [](float distance) { return std::round(float(caged_outer_wall_speed) - 400.f * distance); }; const double sampled = slowed_length(sampled_wall_between_growing_corners(distance_to_speed), distance_to_speed); // The same wall with sampling switched off: what the endpoint driven passes alone make of the corners. const double unsampled = slowed_length(sampled_wall_between_growing_corners({}), distance_to_speed); // The corners do read an overhang, so there is a slowdown for sampling to have lengthened. REQUIRE(unsampled > 0.); REQUIRE(sampled <= unsampled); } TEST_CASE("Benchmark caged overhang interior sampling", "[ExtrusionProcessor][!benchmark]"){ const char* wall_generator = GENERATE("classic", "arachne"); BENCHMARK(wall_generator) { return caged_overhang_gcode(wall_generator); }; }