Slic3r/lib/Slic3r/Print.pm

package Slic3r::Print;
use Moo;

use Math::ConvexHull 1.0.4 qw(convex_hull);
use Slic3r::Geometry qw(X Y Z PI MIN MAX scale);
use Slic3r::Geometry::Clipper qw(explode_expolygons safety_offset diff_ex intersection_ex
    union_ex offset JT_ROUND JT_MITER);
use XXX;

has 'x_length' => (
    is          => 'ro',
    required    => 1,
);

has 'y_length' => (
    is          => 'ro',
    required    => 1,
);

has 'layers' => (
    traits  => ['Array'],
    is      => 'rw',
    #isa     => 'ArrayRef[Slic3r::Layer]',
    default => sub { [] },
);

has 'total_extrusion_length' => (is => 'rw');

sub new_from_mesh {
    my $class = shift;
    my ($mesh) = @_;
    
    $mesh->rotate($Slic3r::rotate);
    $mesh->scale($Slic3r::scale / $Slic3r::resolution);
    
    # calculate the displacements needed to 
    # have lowest value for each axis at coordinate 0
    {
        my @extents = $mesh->bounding_box;
        my @shift = map -$extents[$_][MIN], X,Y,Z;
        $mesh->move(@shift);
    }
    
    # duplicate object
    {
        my @size = $mesh->size;
        my @duplicate_offset = map +($size[$_] + scale $Slic3r::duplicate_distance), (X,Y);
        $mesh->duplicate(map [$duplicate_offset[X] * ($_-1), 0], 2..$Slic3r::duplicate_x);
        $mesh->duplicate(map [0, $duplicate_offset[Y] * ($_-1)], 2..$Slic3r::duplicate_y);
    }
    
    # initialize print job
    my @size = $mesh->size;
    my $print = $class->new(
        x_length => $size[X],
        y_length => $size[Y],
    );
    
    $mesh->make_edge_table;
        
    # process facets
    for (my $i = 0; $i <= $#{$mesh->facets}; $i++) {
        my $facet = $mesh->facets->[$i];
        
        # transform vertex coordinates
        my ($normal, @vertices) = @$facet;
        $mesh->_facet($print, $i, $normal, @vertices);
    }
    
    die "Invalid input file\n" if !@{$print->layers};
    
    # remove last layer if empty
    # (we might have created it because of the $max_layer = ... + 1 code below)
    pop @{$print->layers} if !@{$print->layers->[-1]->surfaces} && !@{$print->layers->[-1]->lines};
    
    print "\n==> PROCESSING SLICES:\n";
    foreach my $layer (@{ $print->layers }) {
        printf "Making surfaces for layer %d:\n", $layer->id;
        
        # layer currently has many lines representing intersections of
        # model facets with the layer plane. there may also be lines
        # that we need to ignore (for example, when two non-horizontal
        # facets share a common edge on our plane, we get a single line;
        # however that line has no meaning for our layer as it's enclosed
        # inside a closed polyline)
        
        # build surfaces from sparse lines
        $layer->make_surfaces($mesh->make_loops($layer));
    }
    
    # detect slicing errors
    my $warning_thrown = 0;
    for (my $i = 0; $i <= $#{$print->layers}; $i++) {
        my $layer = $print->layers->[$i];
        next unless $layer->slicing_errors;
        if (!$warning_thrown) {
            warn "The model has overlapping or self-intersecting facets. I tried to repair it, "
                . "however you might want to check the results or repair the input file and retry.\n";
            $warning_thrown = 1;
        }
        
        # try to repair the layer surfaces by merging all contours and all holes from
        # neighbor layers
        Slic3r::debugf "Attempting to repair layer %d\n", $i;
        
        my (@upper_surfaces, @lower_surfaces);
        for (my $j = $i+1; $j <= $#{$print->layers}; $j++) {
            if (!$print->layers->[$j]->slicing_errors) {
                @upper_surfaces = @{$print->layers->[$j]->slices};
                last;
            }
        }
        for (my $j = $i-1; $j >= 0; $j--) {
            if (!$print->layers->[$j]->slicing_errors) {
                @lower_surfaces = @{$print->layers->[$j]->slices};
                last;
            }
        }
        
        my $union = union_ex([
            map $_->expolygon->contour, @upper_surfaces, @lower_surfaces,
        ]);
        my $diff = diff_ex(
            [ map @$_, @$union ],
            [ map $_->expolygon->holes, @upper_surfaces, @lower_surfaces, ],
        );
        
        @{$layer->slices} = map Slic3r::Surface->cast_from_expolygon
            ($_, surface_type => 'internal'),
            @$diff;
    }
    
    # remove empty layers from bottom
    while (@{$print->layers} && !@{$print->layers->[0]->slices} && !@{$print->layers->[0]->thin_walls}) {
        shift @{$print->layers};
        for (my $i = 0; $i <= $#{$print->layers}; $i++) {
            $print->layers->[$i]->id($i);
        }
    }
    
    return $print;
}

sub layer_count {
    my $self = shift;
    return scalar @{ $self->layers };
}

sub max_length {
    my $self = shift;
    return ($self->x_length > $self->y_length) ? $self->x_length : $self->y_length;
}

sub layer {
    my $self = shift;
    my ($layer_id) = @_;
    
    # extend our print by creating all necessary layers
    
    if ($self->layer_count < $layer_id + 1) {
        for (my $i = $self->layer_count; $i <= $layer_id; $i++) {
            push @{ $self->layers }, Slic3r::Layer->new(id => $i);
        }
    }
    
    return $self->layers->[$layer_id];
}

sub detect_surfaces_type {
    my $self = shift;
    
    # prepare a reusable subroutine to make surface differences
    my $surface_difference = sub {
        my ($subject_surfaces, $clip_surfaces, $result_type) = @_;
        my $expolygons = diff_ex(
            [ map { ref $_ eq 'ARRAY' ? $_ : ref $_ eq 'Slic3r::ExPolygon' ? @$_ : $_->p } @$subject_surfaces ],
            [ map { ref $_ eq 'ARRAY' ? $_ : ref $_ eq 'Slic3r::ExPolygon' ? @$_ : $_->p } @$clip_surfaces ],
            1,
        );
        return grep $_->contour->is_printable,
            map Slic3r::Surface->cast_from_expolygon($_, surface_type => $result_type), 
            @$expolygons;
    };
    
    for (my $i = 0; $i < $self->layer_count; $i++) {
        my $layer = $self->layers->[$i];
        Slic3r::debugf "Detecting solid surfaces for layer %d\n", $layer->id;
        my $upper_layer = $self->layers->[$i+1];
        my $lower_layer = $i > 0 ? $self->layers->[$i-1] : undef;
        
        my (@bottom, @top, @internal) = ();
        
        # find top surfaces (difference between current surfaces
        # of current layer and upper one)
        if ($upper_layer) {
            @top = $surface_difference->($layer->slices, $upper_layer->slices, 'top');
        } else {
            # if no upper layer, all surfaces of this one are solid
            @top = @{$layer->slices};
            $_->surface_type('top') for @top;
        }
        
        # find bottom surfaces (difference between current surfaces
        # of current layer and lower one)
        if ($lower_layer) {
            @bottom = $surface_difference->($layer->slices, $lower_layer->slices, 'bottom');
        } else {
            # if no lower layer, all surfaces of this one are solid
            @bottom = @{$layer->slices};
            $_->surface_type('bottom') for @bottom;
        }
        
        # now, if the object contained a thin membrane, we could have overlapping bottom
        # and top surfaces; let's do an intersection to discover them and consider them
        # as bottom surfaces (to allow for bridge detection)
        if (@top && @bottom) {
            my $overlapping = intersection_ex([ map $_->p, @top ], [ map $_->p, @bottom ]);
            Slic3r::debugf "  layer %d contains %d membrane(s)\n", $layer->id, scalar(@$overlapping);
            @top = $surface_difference->([@top], $overlapping, 'top');
        }
        
        # find internal surfaces (difference between top/bottom surfaces and others)
        @internal = $surface_difference->($layer->slices, [@top, @bottom], 'internal');
        
        # save surfaces to layer
        $layer->slices([ @bottom, @top, @internal ]);
        
        Slic3r::debugf "  layer %d has %d bottom, %d top and %d internal surfaces\n",
            $layer->id, scalar(@bottom), scalar(@top), scalar(@internal);
    }
    
    # clip surfaces to the fill boundaries
    foreach my $layer (@{$self->layers}) {
        @{$layer->surfaces} = ();
        foreach my $surface (@{$layer->slices}) {
            my $intersection = intersection_ex(
                [ $surface->p ],
                [ map $_->p, @{$layer->fill_boundaries} ],
            );
            push @{$layer->surfaces}, map Slic3r::Surface->cast_from_expolygon
                ($_, surface_type => $surface->surface_type),
                @$intersection;
        }
    }
}

sub discover_horizontal_shells {
    my $self = shift;
    
    Slic3r::debugf "==> DISCOVERING HORIZONTAL SHELLS\n";
    
    for (my $i = 0; $i < $self->layer_count; $i++) {
        my $layer = $self->layers->[$i];
        foreach my $type (qw(top bottom)) {
            # find surfaces of current type for current layer
            my @surfaces = grep $_->surface_type eq $type, @{$layer->fill_surfaces} or next;
            my $surfaces_p = [ map $_->p, @surfaces ];
            Slic3r::debugf "Layer %d has %d surfaces of type '%s'\n",
                $i, scalar(@surfaces), $type;
            
            for (my $n = $type eq 'top' ? $i-1 : $i+1; 
                    abs($n - $i) <= $Slic3r::solid_layers-1; 
                    $type eq 'top' ? $n-- : $n++) {
                
                next if $n < 0 || $n >= $self->layer_count;
                Slic3r::debugf "  looking for neighbors on layer %d...\n", $n;
                
                my @neighbor_surfaces = @{$self->layers->[$n]->surfaces};
                my @neighbor_fill_surfaces = @{$self->layers->[$n]->fill_surfaces};
                
                # find intersection between neighbor and current layer's surfaces
                # intersections have contours and holes
                my $new_internal_solid = intersection_ex(
                    $surfaces_p,
                    [ map $_->p, grep $_->surface_type =~ /internal/, @neighbor_surfaces ],
                    undef, 1,
                );
                next if !@$new_internal_solid;
                
                # internal-solid are the union of the existing internal-solid surfaces
                # and new ones
                my $internal_solid = union_ex([
                    ( map $_->p, grep $_->surface_type eq 'internal-solid', @neighbor_fill_surfaces ),
                    ( map @$_, @$new_internal_solid ),
                ]);
                
                # subtract intersections from layer surfaces to get resulting inner surfaces
                my $internal = diff_ex(
                    [ map $_->p, grep $_->surface_type eq 'internal', @neighbor_fill_surfaces ],
                    [ map @$_, @$internal_solid ],
                );
                Slic3r::debugf "    %d internal-solid and %d internal surfaces found\n",
                    scalar(@$internal_solid), scalar(@$internal);
                
                # Note: due to floating point math we're going to get some very small
                # polygons as $internal; they will be removed by removed_small_features()
                
                # assign resulting inner surfaces to layer
                my $neighbor_fill_surfaces = $self->layers->[$n]->fill_surfaces;
                @$neighbor_fill_surfaces = ();
                push @$neighbor_fill_surfaces, Slic3r::Surface->cast_from_expolygon
                    ($_, surface_type => 'internal')
                    for @$internal;
                
                # assign new internal-solid surfaces to layer
                push @$neighbor_fill_surfaces, Slic3r::Surface->cast_from_expolygon
                    ($_, surface_type => 'internal-solid')
                    for @$internal_solid;
                
                # assign top and bottom surfaces to layer
                foreach my $s (Slic3r::Surface->group(grep $_->surface_type =~ /top|bottom/, @neighbor_fill_surfaces)) {
                    my $solid_surfaces = diff_ex(
                        [ map $_->p, @$s ],
                        [ map @$_, @$internal_solid, @$internal ],
                    );
                    push @$neighbor_fill_surfaces, Slic3r::Surface->cast_from_expolygon
                        ($_, surface_type => $s->[0]->surface_type, bridge_angle => $s->[0]->bridge_angle)
                        for @$solid_surfaces;
                }
            }
        }
    }
}

sub extrude_skirt {
    my $self = shift;
    return unless $Slic3r::skirts > 0;
    
    # collect points from all layers contained in skirt height
    my $skirt_height = $Slic3r::skirt_height;
    $skirt_height = $self->layer_count if $skirt_height > $self->layer_count;
    my @layers = map $self->layer($_), 0..($skirt_height-1);
    my @points = map @$_, map $_->p, map +(@{$_->slices}, @{$_->thin_walls}), @layers;
    return if !@points;
    
    # find out convex hull
    my $convex_hull = convex_hull(\@points);
    
    # draw outlines from outside to inside
    my @skirts = ();
    for (my $i = $Slic3r::skirts - 1; $i >= 0; $i--) {
        my $distance = scale ($Slic3r::skirt_distance + ($Slic3r::flow_spacing * $i));
        my $outline = offset([$convex_hull], $distance, $Slic3r::resolution * 100, JT_ROUND);
        push @skirts, Slic3r::ExtrusionLoop->cast([ @{$outline->[0]} ], role => 'skirt');
    }
    
    # apply skirts to all layers
    push @{$_->skirts}, @skirts for @layers;
}

# combine fill surfaces across layers
sub infill_every_layers {
    my $self = shift;
    return unless $Slic3r::infill_every_layers > 1 && $Slic3r::fill_density > 0;
    
    printf "==> COMBINING INFILL\n";
    
    # start from bottom, skip first layer
    for (my $i = 1; $i < $self->layer_count; $i++) {
        my $layer = $self->layer($i);
        
        # skip layer if no internal fill surfaces
        next if !grep $_->surface_type eq 'internal', @{$layer->fill_surfaces};
        
        # for each possible depth, look for intersections with the lower layer
        # we do this from the greater depth to the smaller
        for (my $d = $Slic3r::infill_every_layers - 1; $d >= 1; $d--) {
            next if ($i - $d) < 0;
            my $lower_layer = $self->layer($i - 1);
            
            # select surfaces of the lower layer having the depth we're looking for
            my @lower_surfaces = grep $_->depth_layers == $d && $_->surface_type eq 'internal',
                @{$lower_layer->fill_surfaces};
            next if !@lower_surfaces;
            
            # calculate intersection between our surfaces and theirs
            my $intersection = intersection_ex(
                [ map $_->p, grep $_->depth_layers <= $d, @lower_surfaces ],
                [ map $_->p, grep $_->surface_type eq 'internal', @{$layer->fill_surfaces} ],
            );
            next if !@$intersection;
            
            # new fill surfaces of the current layer are:
            # - any non-internal surface
            # - intersections found (with a $d + 1 depth)
            # - any internal surface not belonging to the intersection (with its original depth)
            {
                my @new_surfaces = ();
                push @new_surfaces, grep $_->surface_type ne 'internal', @{$layer->fill_surfaces};
                push @new_surfaces, map Slic3r::Surface->cast_from_expolygon
                    ($_, surface_type => 'internal', depth_layers => $d + 1), @$intersection;
                
                foreach my $depth (reverse $d..$Slic3r::infill_every_layers) {
                    push @new_surfaces, map Slic3r::Surface->cast_from_expolygon
                        ($_, surface_type => 'internal', depth_layers => $depth),
                        
                        # difference between our internal layers with depth == $depth
                        # and the intersection found
                        @{diff_ex(
                            [
                                map $_->p, grep $_->surface_type eq 'internal' && $_->depth_layers == $depth, 
                                    @{$layer->fill_surfaces},
                            ],
                            [ map @$_, @$intersection ],
                            1,
                        )};
                }
                @{$layer->fill_surfaces} = @new_surfaces;
            }
            
            # now we remove the intersections from lower layer
            {
                my @new_surfaces = ();
                push @new_surfaces, grep $_->surface_type ne 'internal', @{$lower_layer->fill_surfaces};
                foreach my $depth (1..$Slic3r::infill_every_layers) {
                    push @new_surfaces, map Slic3r::Surface->cast_from_expolygon
                        ($_, surface_type => 'internal', depth_layers => $depth),
                        
                        # difference between internal layers with depth == $depth
                        # and the intersection found
                        @{diff_ex(
                            [
                                map $_->p, grep $_->surface_type eq 'internal' && $_->depth_layers == $depth, 
                                    @{$lower_layer->fill_surfaces},
                            ],
                            [ map @$_, @$intersection ],
                            1,
                        )};
                }
                @{$lower_layer->fill_surfaces} = @new_surfaces;
            }
        }
    }
}

sub export_gcode {
    my $self = shift;
    my ($file) = @_;
    
    printf "Exporting GCODE file...\n";
    
    # open output gcode file
    open my $fh, ">", $file
        or die "Failed to open $file for writing\n";
    
    # write some information
    my @lt = localtime;
    printf $fh "; generated by Slic3r $Slic3r::VERSION on %02d-%02d-%02d at %02d:%02d:%02d\n\n",
        $lt[5] + 1900, $lt[4]+1, $lt[3], $lt[2], $lt[1], $lt[0];
    
    for (qw(layer_height perimeters solid_layers fill_density nozzle_diameter filament_diameter
        perimeter_speed infill_speed travel_speed extrusion_width_ratio scale)) {
        printf $fh "; %s = %s\n", $_, Slic3r::Config->get($_);
    }
    print  $fh "\n";
    
    # write start commands to file
    printf $fh "M104 S%d ; set temperature\n", $Slic3r::temperature if $Slic3r::temperature;
    print  $fh "$Slic3r::start_gcode\n";
    printf $fh "M109 S%d ; wait for temperature to be reached\n", $Slic3r::temperature if $Slic3r::temperature;
    print  $fh "G90 ; use absolute coordinates\n";
    print  $fh "G21 ; set units to millimeters\n";
    printf $fh "G92 %s0 ; reset extrusion distance\n", $Slic3r::extrusion_axis if $Slic3r::extrusion_axis;
    if ($Slic3r::use_relative_e_distances) {
        print $fh "M83 ; use relative distances for extrusion\n";
    } else {
        print $fh "M82 ; use absolute distances for extrusion\n";
    }
    
    # set up our extruder object
    my $extruder = Slic3r::Extruder->new(
        # calculate X,Y shift to center print around specified origin
        shift_x => $Slic3r::print_center->[X] - ($self->x_length * $Slic3r::resolution / 2),
        shift_y => $Slic3r::print_center->[Y] - ($self->y_length * $Slic3r::resolution / 2),
    );
    
    # write gcode commands layer by layer
    foreach my $layer (@{ $self->layers }) {
        # go to layer
        printf $fh $extruder->change_layer($layer);
        
        # extrude skirts
        printf $fh $extruder->extrude_loop($_, 'skirt') for @{ $layer->skirts };
        
        # extrude perimeters
        printf $fh $extruder->extrude($_, 'perimeter') for @{ $layer->perimeters };
        
        # extrude fills
        for my $fill (@{ $layer->fills }) {
            printf $fh $extruder->extrude_path($_, 'fill') 
                for $fill->shortest_path($extruder->last_pos);
        }
    }
    
    # save statistic data
    $self->total_extrusion_length($extruder->total_extrusion_length);
    
    # write end commands to file
    print $fh "$Slic3r::end_gcode\n";
    
    printf $fh "; filament used = %.1fmm (%.1fcm3)\n",
        $self->total_extrusion_length, $self->total_extrusion_volume;
    
    # close our gcode file
    close $fh;
}

sub total_extrusion_volume {
    my $self = shift;
    return $self->total_extrusion_length * ($Slic3r::filament_diameter**2) * PI/4 / 1000;
}

1;