From 7d4f090786d93963723aba130250706773d9c373 Mon Sep 17 00:00:00 2001
From: supermerill <merill@fr.fr>
Date: Mon, 11 Feb 2019 14:02:13 +0100
Subject: [PATCH] medial_axis width bugfix (at least enough for the outer
 "lobes") assert bugfix in thin walls (edge case) 2 bugfix in overlap

---
 src/libslic3r/Layer.cpp              |  3 ++-
 src/libslic3r/MedialAxis.cpp         | 13 ++++++++-----
 src/libslic3r/PerimeterGenerator.cpp |  5 +++--
 3 files changed, 13 insertions(+), 8 deletions(-)

diff --git a/src/libslic3r/Layer.cpp b/src/libslic3r/Layer.cpp
index fdf4e1c0c..91170ecdd 100644
--- a/src/libslic3r/Layer.cpp
+++ b/src/libslic3r/Layer.cpp
@@ -20,7 +20,7 @@ Layer::~Layer()
 // Test whether whether there are any slices assigned to this layer.
 bool Layer::empty() const
 {
-	for (const LayerRegion *layerm : m_regions)
+    for (const LayerRegion *layerm : m_regions)
         if (layerm != nullptr && ! layerm->slices.empty())
             // Non empty layer.
             return false;
@@ -149,6 +149,7 @@ void Layer::make_perimeters()
                     // Separate the fill surfaces.
                     ExPolygons expp = intersection_ex(to_polygons(fill_surfaces), (*l)->slices);
                     (*l)->fill_expolygons = expp;
+                    (*l)->fill_no_overlap_expolygons = (*layerm)->fill_no_overlap_expolygons;
                     (*l)->fill_surfaces.set(std::move(expp), fill_surfaces.surfaces.front());
                 }
             }
diff --git a/src/libslic3r/MedialAxis.cpp b/src/libslic3r/MedialAxis.cpp
index 2fc9476b7..0a3a3a8de 100644
--- a/src/libslic3r/MedialAxis.cpp
+++ b/src/libslic3r/MedialAxis.cpp
@@ -1513,7 +1513,7 @@ MedialAxis::grow_to_nozzle_diameter(ThickPolylines& pp, const ExPolygons& anchor
 
 void
 MedialAxis::taper_ends(ThickPolylines& pp) {
-    const coord_t min_size = this->nozzle_diameter * 0.1;
+    const coord_t min_size = std::min(this->nozzle_diameter * 0.1, this->height * (1. - 0.25 * PI));
     const coordf_t length = std::min(this->anchor_size, (this->nozzle_diameter - min_size) / 2);
     if (length <= SCALED_RESOLUTION) return;
     //ensure the width is not lower than 0.4.
@@ -1623,12 +1623,15 @@ ExtrusionEntityCollection thin_variable_width(const ThickPolylines &polylines, E
             if (path.polyline.points.empty()) {
                 path.polyline.append(line.a);
                 path.polyline.append(line.b);
-                if (role == erGapFill){
+                if (role == erGapFill) {
                     // Convert from spacing to extrusion width based on the extrusion model
                     // of a square extrusion ended with semi circles.
-                    flow.width = (float)unscaled(line.a_width) + flow.height * (1. - 0.25 * PI);
-                }else{
-                    flow.width = (float)unscaled(line.a_width);
+                    flow.width = unscale<coordf_t>(line.a_width) + flow.height * (1. - 0.25 * PI);
+                } else if (unscale<coordf_t>(line.a_width) < 2 * flow.height * (1. - 0.25 * PI)) {
+                    double percent = unscale<coordf_t>(line.a_width) / (2 * flow.height * (1. - 0.25 * PI));
+                    flow.width = unscale<coordf_t>(line.a_width)/2 + flow.height * (1. - 0.25 * PI);
+                } else {
+                    flow.width = unscale<coordf_t>(line.a_width);
                 }
 #ifdef SLIC3R_DEBUG
                 printf("  filling %f gap\n", flow.width);
diff --git a/src/libslic3r/PerimeterGenerator.cpp b/src/libslic3r/PerimeterGenerator.cpp
index ef1330e5a..31cb83a01 100644
--- a/src/libslic3r/PerimeterGenerator.cpp
+++ b/src/libslic3r/PerimeterGenerator.cpp
@@ -282,7 +282,8 @@ void PerimeterGenerator::process()
                         for (ExPolygon &half_thin : half_thins) {
                             //growing back the polygon
                             ExPolygons thin = offset_ex(half_thin, (float)(min_width / 2));
-                            assert(thin.size() == 1);
+                            assert(thin.size() <= 1);
+                            if (thin.empty()) continue;
                             coord_t overlap = (coord_t)scale_(this->config->thin_walls_overlap.get_abs_value(this->ext_perimeter_flow.nozzle_diameter));
                             ExPolygons anchor = intersection_ex(offset_ex(half_thin, (float)(min_width / 2) +
                                 (float)(overlap), jtSquare), no_thin_zone, true);
@@ -514,7 +515,7 @@ void PerimeterGenerator::process()
         // only apply infill overlap if we actually have one perimeter
         coord_t overlap = 0;
         if (inset > 0) {
-            overlap = scale_(this->config->get_abs_value("infill_overlap", unscale<coord_t>(inset + solid_infill_spacing / 2)));
+            overlap = scale_(this->config->get_abs_value("infill_overlap", unscale<coordf_t>(inset + solid_infill_spacing / 2)));
         }
         // simplify infill contours according to resolution
         Polygons pp;