Got Fill? Even seems to do the right thing adding bridges and capping…

… local maxima.

AreaWriter.pde

@@ -136,10 +136,6 @@ class AreaWriter {
     for(int SliceNum=0;SliceNum<SliceAreaList.size();SliceNum++)
     {
       SSArea thisArea;
-      if(SliceAreaList.size()>0) {
-        thisArea = (SSArea) SliceAreaList.get(SliceNum);
-        if(!thisArea.isEmpty()) GCodeWriteArea(SliceNum, thisArea);
-      }
       if(ShellAreaList.size()>0) {
         thisArea = (SSArea) ShellAreaList.get(SliceNum);
         if(!thisArea.isEmpty()) GCodeWriteArea(SliceNum, thisArea);
@@ -148,6 +144,10 @@ class AreaWriter {
         thisArea = (SSArea) FillAreaList.get(SliceNum);
         if(!thisArea.isEmpty()) GCodeWriteArea(SliceNum, thisArea);
       }
+      if(SliceAreaList.size()>0) {
+        thisArea = (SSArea) SliceAreaList.get(SliceNum);
+        if(!thisArea.isEmpty()) GCodeWriteArea(SliceNum, thisArea);
+      }
     }
   }
 

Extruder.pde

@@ -0,0 +1,58 @@
+// Extruder Class
+import java.lang.Math;
+
+class Extruder {
+  int ToolNum;
+  Material Filament;
+  float ZThick;
+  float Diameter;
+  float FlowRate;
+
+  Extruder() {
+    ToolNum=0;
+    Filament=new Material("ABS");
+    Diameter=0.6;
+    ZThick=0.37;
+  }
+
+  Extruder(int anInt) {
+    ToolNum=anInt;
+    Filament=new Material("ABS");
+    Diameter=0.6;
+    ZThick=0.37;
+  }
+
+  Extruder(int anInt, String aString) {
+    ToolNum=anInt;
+    Filament=new Material(aString);
+    Diameter=0.6;
+    ZThick=0.37;
+  }
+
+  void setDiameter(float aFloat) {
+    Diameter=aFloat;
+    if(ZThick>Diameter) {
+      println("Z thickness greater than extruded diameter. Setting Z thickness to half diameter.");
+      ZThick=Diameter/2;
+    }
+  }
+
+  void setZThick(float aFloat) {
+    if(aFloat<Diameter) {
+      ZThick=aFloat;
+    } else {
+      println("Z thickness greater than extruded diameter. Setting Z thickness to half diameter.");
+      ZThick=Diameter/2;
+    }
+  }
+
+  void setFlowRate(float aFloat) {
+    FlowRate=aFloat;
+  }
+
+  float calcWallWidth() {
+    float freespace_area=PI*pow(Diameter/2,2);
+    return(freespace_area/ZThick);
+  }
+}
+

Fill.pde

@@ -0,0 +1,101 @@
+// Fill Generation
+import java.awt.geom.Rectangle2D;
+
+class Fill {
+
+  boolean debugFlag;
+  int Width;
+  int Height;
+  Extruder ExtruderProperties;
+  float SparseFillDensity;
+  float RotateFillAngle;
+  SSArea SparseFill;
+  SSArea BridgeFill;
+
+  Fill(boolean bFlag, int iWidth, int iHeight, float fillDensity) {
+    RotateFillAngle=45.0;
+    debugFlag=bFlag;
+    Width=iWidth;
+    Height=iHeight;
+    if(fillDensity<0 || fillDensity>1.0) {
+      println("Sparse Fill Density out of 0 to 1.0 range. Setting to 0.5");
+      SparseFillDensity=0.5;
+    } else {
+      SparseFillDensity=fillDensity;
+    }
+    ExtruderProperties = new Extruder();
+    SparseFill = new SSArea();
+    SparseFill.setGridScale(0.01);
+    float wallWidth=ExtruderProperties.calcWallWidth();
+    for(float dx=0;dx<Width; dx+=2*wallWidth/fillDensity) {
+      Rectangle2D thisRect=new Rectangle2D.Float(dx,0,wallWidth/fillDensity,Height);
+      Area thisRectArea=new Area(thisRect);
+      AffineTransform centerAreaTransform = new AffineTransform();
+      centerAreaTransform.setToTranslation(-Width/2,-Height/2);
+      thisRectArea.transform(centerAreaTransform);
+      SparseFill.add(thisRectArea);
+    }
+    BridgeFill = new SSArea();
+    BridgeFill.setGridScale(0.01);
+    for(float dx=0;dx<Width; dx+=2*wallWidth) {
+      Rectangle2D thisRect=new Rectangle2D.Float(dx,0,wallWidth,Height);
+      Area thisRectArea=new Area(thisRect);
+      AffineTransform centerAreaTransform = new AffineTransform();
+      centerAreaTransform.setToTranslation(-Width/2,-Height/2);
+      thisRectArea.transform(centerAreaTransform);
+      BridgeFill.add(thisRectArea);
+    }
+  }
+
+  ArrayList GenerateFill(ArrayList SliceList) {
+    ArrayList FillAreaList = new ArrayList();
+    float wallWidth=ExtruderProperties.calcWallWidth();
+    for(int LayerNum=0; LayerNum<SliceList.size();LayerNum++) {
+      SSArea thisArea = (SSArea) SliceList.get(LayerNum);
+      // Shell area to subtract off slice.
+      SSArea thisShell = new SSArea();
+      thisShell.setGridScale(thisArea.getGridScale());
+      thisShell.add(thisArea);
+      thisShell.makeShell(wallWidth);
+      // Fill mask area
+      SSArea thisFill = new SSArea();
+      thisFill.setGridScale(thisArea.getGridScale());
+      thisFill.add(thisArea);
+      thisFill.subtract(thisShell);
+      // Identify bridge areas for special treatment.
+      SSArea thisBridge = new SSArea();
+      thisBridge.setGridScale(thisFill.getGridScale());
+      thisBridge.add(thisFill);
+      AffineTransform rotateFill = new AffineTransform();
+      rotateFill.setToRotation(2*PI*RotateFillAngle/360.0);
+      BridgeFill.transform(rotateFill);
+      SparseFill.transform(rotateFill);
+      if(LayerNum==0 || LayerNum==SliceList.size()-1) {
+	// Bottom and Top layer special case.
+	thisFill.intersect(BridgeFill);
+      } else {
+	SSArea prevArea = (SSArea) SliceList.get(LayerNum-1);
+	thisBridge.subtract(prevArea);
+	// Identify cap areas for special treatment.
+	SSArea nextArea = (SSArea) SliceList.get(LayerNum+1);
+	SSArea thisCap = new SSArea();
+	thisCap.setGridScale(thisFill.getGridScale());
+	thisCap.add(thisArea);
+	thisCap.subtract(nextArea);
+	thisBridge.add(thisCap);
+	if(!thisBridge.isEmpty()) {
+	  thisFill.subtract(thisBridge);
+	  thisBridge.intersect(BridgeFill);
+	  thisFill.intersect(SparseFill);
+	  thisFill.add(thisBridge);
+	} else {
+	  thisFill.intersect(SparseFill);
+	}
+      }
+      // Subtract bridge areas from fill mask
+      FillAreaList.add(LayerNum,thisFill);
+    }
+    return(FillAreaList);
+  }
+}
+

Material.pde

@@ -0,0 +1,27 @@
+// Material Class
+
+class Material {
+  String TypeName;
+  float MeltTemp;
+  float ExtrudeTemp;
+
+  Material(String aString) {
+    if(aString == "ABS") {
+      TypeName=aString;
+      MeltTemp=100.0;
+      ExtrudeTemp=220.0;
+    } else {
+      TypeName=aString;
+      MeltTemp=0;
+      ExtrudeTemp=0;
+    }
+  }
+
+  void setMeltTemp(float aFloat) {
+    MeltTemp=aFloat;
+  }
+  void setExtrudeTemp(float aFloat) {
+    ExtrudeTemp=aFloat;
+  }
+
+}

SuperSkein.pde

@@ -247,7 +247,10 @@ void mousePressed()
   if(GUIPage==0)STLName.checkFocus(mouseX,mouseY);
   if(GUIPage==0)STLScale.checkFocus(mouseX,mouseY);
   if(GUIPage==0)STLXRotate.checkFocus(mouseX,mouseY);
-  if(GUIPage==0 && STLName.Focus) STLName.Text=selectInput();
+  if(GUIPage==0 && STLName.Focus) {
+    String newName=selectInput("Select STL to Load");
+    STLName.Text=newName;
+  }
 
   if(LeftButton.over(mouseX,mouseY))GUIPage--;
   if(RightButton.over(mouseX,mouseY))GUIPage++;
@@ -354,20 +357,22 @@ class FileWriteProc implements Runnable{
 	thisSubArea.subtract(thisShell);
         ShellAreaList.add(ShellNum,thisSubArea);
       }
+      Fill areaFill=new Fill(true,round(BuildPlatformWidth),round(BuildPlatformHeight),0.2);
+      ArrayList FillAreaList = areaFill.GenerateFill(ShellAreaList);
 
       String GCodeFileName = selectOutput("Save G-Code to This File");
       if(GCodeFileName == null) {
         println("No file was selected; using STL File as G-Code file prefix.");
         GCodeFileName=STLName.Text+".gcode";
       }
 
-      AreaWriter gcodeOut=new AreaWriter(false,round(BuildPlatformWidth),round(BuildPlatformHeight));
+      AreaWriter gcodeOut=new AreaWriter(debugFlag,round(BuildPlatformWidth),round(BuildPlatformHeight));
       gcodeOut.setOperatingTemp(OperatingTemp);
       gcodeOut.setFlowRate(FlowRate);
       gcodeOut.setLayerThickness(LayerThickness);
       gcodeOut.setPrintHeadSpeed(PrintHeadSpeed);
 
-      gcodeOut.ArrayList2GCode(GCodeFileName,SliceAreaList,ShellAreaList,new ArrayList());
+      gcodeOut.ArrayList2GCode(GCodeFileName,SliceAreaList,ShellAreaList,FillAreaList);
 
       FileWriteFraction=1.5;
       print("\nFinished Slicing!  Bounding Box is:\n");
@@ -398,6 +403,7 @@ class DXFWriteProc implements Runnable{
       }
       String DXFSliceFileName;
       String DXFShellFileName;
+      String DXFFillFileName;
       // int DXFSliceNum;
 
       String OpenSCADFileName = DXFSliceFilePrefix + "_" + LayerThickness + ".scad";
@@ -429,6 +435,7 @@ class DXFWriteProc implements Runnable{
         thisArea.Slice2Area(ThisSlice);
         SliceAreaList.add(SliceNum, thisArea);
       }
+
       ArrayList ShellAreaList = new ArrayList();
       for(int ShellNum=0;ShellNum<SliceAreaList.size();ShellNum++) {
         SSArea thisArea = (SSArea) SliceAreaList.get(ShellNum);
@@ -451,6 +458,9 @@ class DXFWriteProc implements Runnable{
         ShellAreaList.add(ShellNum,thisShell);
       }
 
+      Fill areaFill=new Fill(true,round(BuildPlatformWidth),round(BuildPlatformHeight),0.2);
+      ArrayList FillAreaList = areaFill.GenerateFill(SliceAreaList);
+
       DXFSliceFileName = DXFSliceFilePrefix + "_slices_" + LayerThickness + ".dxf";
       print("DXF Slice File Name: " + DXFSliceFileName + "\n");
       AreaWriter dxfOut = new AreaWriter(false,round(BuildPlatformWidth),round(BuildPlatformHeight));
@@ -460,6 +470,10 @@ class DXFWriteProc implements Runnable{
       print("DXF Shell File Name: " + DXFShellFileName + "\n");
       dxfOut.ArrayList2DXF(DXFShellFileName,ShellAreaList);
 
+      DXFFillFileName = DXFSliceFilePrefix + "_fill_" + LayerThickness + ".dxf";
+      print("DXF Fill File Name: " + DXFFillFileName + "\n");
+      dxfOut.ArrayList2DXF(DXFFillFileName,FillAreaList);
+
       for(int DXFSliceNum=0;DXFSliceNum<SliceAreaList.size();DXFSliceNum++) {
         output.println(" if(index>="+DXFSliceNum+"&&index<(1+"+DXFSliceNum+")) {");
         output.println("  echo(\"  Instantiating slice "+DXFSliceNum+".\");");

config.txt

@@ -1,6 +1,6 @@
 CONFIG_SCALE	1.0
 CONFIG_XROTATE	0.0
-CONFIG_STLFILE	Z_Bracket.stl
+CONFIG_STLFILE	sculpt_dragon.stl
 MACHINE_OPTEMP	220
 MACHINE_FLOWRATE	190
 CONFIG_SINK	0.0