OrcaSlicer/tests/libslic3r/test_arrange.cpp

#include <limits>
#include <catch2/catch_all.hpp>

#include "libslic3r/Arrange.hpp"
#include "libslic3r/BoundingBox.hpp"
#include "libslic3r/ClipperUtils.hpp"
#include "libslic3r/ExPolygon.hpp"
#include "libslic3r/Print.hpp"
#include "libslic3r/PrintConfig.hpp"

using namespace Slic3r;
using namespace Slic3r::arrangement;

namespace {

using Catch::Matchers::WithinRel;

// Square of the given (scaled) side, lower-left at the origin. bed_idx starts at
// 0 because arrange() seeds the nester's bin from it (see ModelArrange.cpp).
ArrangePolygon make_square(coord_t side)
{
    ArrangePolygon ap;
    Polygon        p;
    p.points = {Point(0, 0), Point(side, 0), Point(side, side), Point(0, side)};
    ap.poly  = ExPolygon(p);
    ap.bed_idx = 0;
    return ap;
}

ArrangePolygons squares(int n, double side_mm, double height_mm = 0.)
{
    ArrangePolygons items;
    for (int i = 0; i < n; ++i) {
        items.emplace_back(make_square(scaled(side_mm)));
        items.back().height = height_mm;
    }
    return items;
}

// Bed [0,0]..[w,h] in scaled coordinates.
BoundingBox bed(double w_mm, double h_mm)
{
    return BoundingBox(Point(0, 0), Point(scaled(w_mm), scaled(h_mm)));
}

// The default progress callback prints to stdout; silence it.
ArrangeParams quiet_params(coord_t min_dist = 0)
{
    ArrangeParams p{min_dist};
    p.progressind = [](unsigned, std::string) {};
    return p;
}

ExPolygons placed_shapes(const ArrangePolygons &items)
{
    ExPolygons out;
    out.reserve(items.size());
    for (const ArrangePolygon &ap : items)
        out.emplace_back(ap.transformed_poly());
    return out;
}

// Area double-counted across the shapes: the sum counts overlaps twice, the
// union once, so the difference is the overlapping area (0 when disjoint).
double overlap_area(const ExPolygons &shapes)
{
    double sum = 0;
    for (const ExPolygon &e : shapes)
        sum += e.area();
    double uni = 0;
    for (const ExPolygon &e : union_ex(shapes))
        uni += e.area();
    return sum - uni;
}

// Relative tolerance absorbs the area-unit rounding the clipper union introduces.
bool disjoint(const ExPolygons &shapes)
{
    double total = 0;
    for (const ExPolygon &e : shapes)
        total += e.area();
    return overlap_area(shapes) <= total * 1e-9;
}

void require_no_overlap(const ArrangePolygons &items)
{
    REQUIRE(disjoint(placed_shapes(items)));
}

// The sequential-print floor is chosen by comparing object height against the nozzle,
// so the two are defined together and every expectation is derived from them.
constexpr double NOZZLE_HEIGHT_MM = 2.5;
constexpr double CLEARANCE_MM     = 30.;
constexpr double NOZZLE_FLOOR_MM  = MAX_OUTER_NOZZLE_DIAMETER / 2.;

ArrangeParams seq_print_params(coord_t min_dist)
{
    ArrangeParams p       = quiet_params(min_dist);
    p.is_seq_print        = true;
    p.clearance_radius    = float(CLEARANCE_MM);
    p.nozzle_height       = float(NOZZLE_HEIGHT_MM);
    p.object_skirt_offset = 0.f;
    return p;
}

// update_selected_items_inflation reads the bed out of the config to cap inflation.
DynamicPrintConfig bed_config()
{
    DynamicPrintConfig c;
    c.set_key_value("printable_area", new ConfigOptionPoints{{0, 0}, {200, 0}, {200, 200}, {0, 200}});
    return c;
}

ArrangePolygons squares_of_heights(const std::vector<double> &heights_mm)
{
    ArrangePolygons items;
    for (double height_mm : heights_mm)
        items.push_back(squares(1, 20., height_mm).front());
    return items;
}

} // namespace

// Prove the overlap check the other tests rely on actually detects overlap.
TEST_CASE("overlap_area detects overlap and ignores touching edges", "[Arrange]")
{
    auto square_at = [](double x_mm) {
        ArrangePolygon ap = make_square(scaled(20.));
        ap.translation    = Vec2crd(scaled(x_mm), 0);
        return ap.transformed_poly();
    };
    ExPolygon a = square_at(0.);

    SECTION("disjoint shapes are reported disjoint") {
        REQUIRE(disjoint({a, square_at(30.)}));
    }
    SECTION("edge-touching shapes are reported disjoint") {
        REQUIRE(disjoint({a, square_at(20.)}));
    }
    SECTION("overlapping shapes are not, and the area is measured") {
        REQUIRE_FALSE(disjoint({a, square_at(10.)}));
        REQUIRE_THAT(overlap_area({a, square_at(10.)}),
                     WithinRel(double(scaled(10.)) * scaled(20.), 1e-9)); // 10x20 mm
    }
}

TEST_CASE("Arrange places every item on the physical bed", "[Arrange]")
{
    ArrangePolygons items = squares(5, 20.);
    arrange(items, bed(200, 200), quiet_params(scaled(1.)));

    for (const ArrangePolygon &ap : items)
        REQUIRE(ap.bed_idx == 0);
}

TEST_CASE("Arranged items stay within the bed", "[Arrange]")
{
    ArrangePolygons items = squares(6, 30.);
    arrange(items, bed(200, 200), quiet_params(scaled(1.)));

    for (const ArrangePolygon &ap : items) {
        REQUIRE(ap.bed_idx == 0);
        REQUIRE(bed(200, 200).contains(ap.transformed_poly().contour.bounding_box()));
    }
}

TEST_CASE("Arranged items do not overlap", "[Arrange]")
{
    ArrangePolygons items = squares(6, 40.);
    arrange(items, bed(250, 250), quiet_params(scaled(2.)));

    require_no_overlap(items);
}

TEST_CASE("Arrange spaces items by their inflation", "[Arrange]")
{
    // Per-item inflation is how the arranger enforces clearance (the GUI fills it
    // from min_obj_distance). Two items inflated 4mm each end up >= 8mm apart.
    ArrangePolygons items = squares(4, 20.);
    for (ArrangePolygon &ap : items)
        ap.inflation = scaled(4.);
    arrange(items, bed(200, 200), quiet_params());

    // Axis-aligned squares are their own bounding boxes, so the clearance between
    // a pair is the distance between their boxes (1mm slack for nester rounding).
    std::vector<BoundingBox> boxes;
    for (const ExPolygon &e : placed_shapes(items))
        boxes.push_back(e.contour.bounding_box());

    double min_gap = std::numeric_limits<double>::max();
    for (size_t i = 0; i < boxes.size(); ++i)
        for (size_t j = i + 1; j < boxes.size(); ++j) {
            coord_t sx = std::max<coord_t>(0, std::max(boxes[j].min.x() - boxes[i].max.x(),
                                                       boxes[i].min.x() - boxes[j].max.x()));
            coord_t sy = std::max<coord_t>(0, std::max(boxes[j].min.y() - boxes[i].max.y(),
                                                       boxes[i].min.y() - boxes[j].max.y()));
            min_gap = std::min(min_gap, std::sqrt(double(sx) * sx + double(sy) * sy));
        }

    REQUIRE(min_gap >= double(scaled(8.)) - double(scaled(0.5)));
}

TEST_CASE("An item larger than the bed cannot be placed", "[Arrange]")
{
    ArrangePolygons items;
    items.emplace_back(make_square(scaled(20.)));
    items.emplace_back(make_square(scaled(400.))); // far bigger than the bed

    arrange(items, bed(200, 200), quiet_params(scaled(1.)));

    REQUIRE(items[0].bed_idx == 0);
    REQUIRE(items[1].bed_idx == UNARRANGED);
}

TEST_CASE("Items overflowing one bed spill onto virtual beds", "[Arrange]")
{
    ArrangePolygons items = squares(8, 90.); // eight 90mm squares cannot share a 200x200 bed
    arrange(items, bed(200, 200), quiet_params(scaled(2.)));

    int max_bed = 0;
    for (const ArrangePolygon &ap : items) {
        REQUIRE(ap.bed_idx >= 0); // placed somewhere
        max_bed = std::max(max_bed, ap.bed_idx);
    }
    REQUIRE(max_bed >= 1); // at least one on a virtual bed
}

TEST_CASE("Arrange handles an empty input", "[Arrange]")
{
    ArrangePolygons items;
    REQUIRE_NOTHROW(arrange(items, bed(200, 200), quiet_params()));
    REQUIRE(items.empty());
}

TEST_CASE("Arrange without final alignment keeps items disjoint", "[Arrange]")
{
    // do_final_align = false selects Alignment::DONT_ALIGN (skips recentering).
    ArrangePolygons items  = squares(6, 40.);
    ArrangeParams   params = quiet_params(scaled(2.));
    params.do_final_align  = false;

    arrange(items, bed(250, 250), params);

    for (const ArrangePolygon &ap : items)
        REQUIRE(ap.bed_idx == 0);
    require_no_overlap(items);
}

TEST_CASE("Arrange aligns the pile to a custom center", "[Arrange]")
{
    // align_center != (0.5, 0.5) selects Alignment::USER_DEFINED.
    ArrangePolygons items  = squares(5, 30.);
    ArrangeParams   params = quiet_params(scaled(2.));
    params.align_center    = Vec2d(0.3, 0.7);

    arrange(items, bed(250, 250), params);

    for (const ArrangePolygon &ap : items)
        REQUIRE(ap.bed_idx == 0);
    require_no_overlap(items);
}

// A belt printer starts its parts at the leading end of the belt (best_object_pos 0.5, 0.05).
// Centring a pile on a point that close to the edge pushed everything longer than the room
// around it off the bed: four 90 mm parts on a 95 x 500 mm belt ended with one across the
// edge and one outside, with 290 mm of belt free behind them. The pile stops at the edge.
TEST_CASE("Arrange keeps a pile aligned near an edge on the bed", "[Arrange]")
{
    const BoundingBox belt   = bed(95, 500);
    ArrangePolygons   items  = squares(4, 90.);
    ArrangeParams     params = quiet_params(scaled(2.));
    params.align_center      = Vec2d(0.5, 0.05);

    arrange(items, belt, params);

    coord_t lowest = std::numeric_limits<coord_t>::max();
    for (const ArrangePolygon &ap : items) {
        REQUIRE(ap.bed_idx == 0);
        const BoundingBox bb = ap.transformed_poly().contour.bounding_box();
        CHECK(belt.contains(bb));
        lowest = std::min(lowest, bb.min.y());
    }
    // Snapped to the edge it was aimed at, less the spacing margin, not re-centred.
    CHECK(lowest < scaled(10.));
    require_no_overlap(items);
}

// On a belt the parts print in belt order, so two colours that alternate along the
// belt, or sit side by side, cost a filament change on every shared layer. Arrange
// keeps each colour together: no part shares belt length with a part of another
// colour, counting the tilted layers that run cot(angle) * height past its far edge,
// whichever end of the belt prints first.
TEST_CASE("Arrange groups the colours of a belt print along the belt", "[Arrange][belt]")
{
    const bool reversed = GENERATE(false, true);
    CAPTURE(reversed);
    const BoundingBox belt   = bed(95, 500);
    ArrangePolygons   items  = squares(6, 30., 20.);
    for (size_t i = 0; i < items.size(); ++i)
        items[i].extrude_ids = { int(i % 3) + 1 };   // three colours, two parts each
    ArrangeParams params     = quiet_params(scaled(2.));
    params.align_center      = Vec2d(0.5, 0.05);
    params.is_belt           = true;
    params.belt_axis         = 1;
    params.belt_reversed     = reversed;
    params.belt_tilt_slope   = 1.f;   // 45 degrees

    arrange(items, belt, params);
    require_no_overlap(items);

    // Belt position in print order, so the same check serves both directions.
    const coord_t dir = reversed ? -1 : 1;
    auto start = [&](const ArrangePolygon &ap) { const BoundingBox bb = ap.transformed_poly().contour.bounding_box(); return dir * (reversed ? bb.max.y() : bb.min.y()); };
    auto end   = [&](const ArrangePolygon &ap) { const BoundingBox bb = ap.transformed_poly().contour.bounding_box(); return dir * (reversed ? bb.min.y() : bb.max.y()) + scaled(ap.height * params.belt_tilt_slope); };

    for (const ArrangePolygon &ap : items) {
        REQUIRE(ap.bed_idx == 0);
        CHECK(belt.contains(ap.transformed_poly().contour.bounding_box()));
    }
    for (const ArrangePolygon &a : items)
        for (const ArrangePolygon &b : items) {
            if (a.extrude_ids == b.extrude_ids)
                continue;
            // The part printed later starts after the earlier one has finished.
            const coord_t earlier_end = start(a) <= start(b) ? end(a) : end(b);
            const coord_t later_start = std::max(start(a), start(b));
            INFO("colour " << a.extrude_ids.front() << " vs " << b.extrude_ids.front());
            CHECK(earlier_end <= later_start);
        }
}

TEST_CASE("Sequential print floors the object distance by object height", "[Arrange]")
{
    // The only place sequential-print clearance is enforced. The arrange menu offers
    // no floor of its own, so a stored 0 has to be raised here or not at all.
    struct Case
    {
        std::string         description;
        std::vector<double> heights;
        double              skirt_offset_mm;
        double              expected_floor_mm;
    };

    auto c = GENERATE(values<Case>({
        {"objects taller than the nozzle need the full clearance",     {NOZZLE_HEIGHT_MM * 2, NOZZLE_HEIGHT_MM * 2}, 0., CLEARANCE_MM},
        {"an object exactly at the nozzle height counts as tall",      {NOZZLE_HEIGHT_MM,     NOZZLE_HEIGHT_MM},     0., CLEARANCE_MM},
        {"one tall object among short ones is enough",                 {NOZZLE_HEIGHT_MM / 2, NOZZLE_HEIGHT_MM * 2}, 0., CLEARANCE_MM},
        {"objects the nozzle clears keep only the nozzle-width floor", {NOZZLE_HEIGHT_MM / 2, NOZZLE_HEIGHT_MM / 2}, 0., NOZZLE_FLOOR_MM},
        {"a wide skirt raises the floor for short objects",            {NOZZLE_HEIGHT_MM / 2, NOZZLE_HEIGHT_MM / 2}, 3., 6.},
    }));

    DYNAMIC_SECTION(c.description)
    {
        ArrangePolygons    items = squares_of_heights(c.heights);
        DynamicPrintConfig cfg   = bed_config();
        ArrangeParams      p     = seq_print_params(0);
        p.object_skirt_offset    = float(c.skirt_offset_mm);

        update_selected_items_inflation(items, &cfg, p);

        CHECK(p.min_obj_distance >= scaled(c.expected_floor_mm));
        CHECK(p.min_obj_distance <= scaled(c.expected_floor_mm + 0.01));
        // Half each, so a pair ends up a full min_obj_distance apart.
        CHECK(items.front().inflation == p.min_obj_distance / 2);
    }
}

TEST_CASE("Sequential print keeps an object distance already above the floor", "[Arrange]")
{
    const coord_t      stored = scaled(CLEARANCE_MM * 2);
    ArrangePolygons    items  = squares_of_heights({NOZZLE_HEIGHT_MM * 2, NOZZLE_HEIGHT_MM * 2});
    DynamicPrintConfig cfg    = bed_config();
    ArrangeParams      p      = seq_print_params(stored);

    update_selected_items_inflation(items, &cfg, p);
    CHECK(p.min_obj_distance == stored);
}

TEST_CASE("Layered printing does not floor the object distance", "[Arrange]")
{
    ArrangePolygons    items = squares_of_heights({NOZZLE_HEIGHT_MM * 2, NOZZLE_HEIGHT_MM * 2});
    DynamicPrintConfig cfg   = bed_config();
    ArrangeParams      p     = seq_print_params(0);
    p.is_seq_print           = false;

    update_selected_items_inflation(items, &cfg, p);
    CHECK(p.min_obj_distance == 0);
}