[CURA-13251] variable wall thickness for tree support

include/SupportInfillPart.h

@@ -31,15 +31,17 @@ struct SupportInfillPart
     std::optional<Shape> base_inside_contour_; //!< If an inside base is generated, contains the inner contour
     AABB outline_boundary_box_; //!< The boundary box for the infill area
     coord_t support_line_width_; //!< The support line width
-    int inset_count_to_generate_; //!< The number of insets need to be generated from the outline. This is not the actual insets that will be generated.
+    coord_t inset_width_to_generate_; //!< The width of insets need to be generated from the outline. This is not the actual insets that will be generated.
     std::vector<std::vector<Shape>> infill_area_per_combine_per_density_; //!< a list of separated sub-areas which requires different infill densities and combined thicknesses
                                                                           //   for infill_areas[x][n], x means the density level and n means the thickness
     std::vector<VariableWidthLines> wall_toolpaths_; //!< Any walls go here, not in the areas, where they could be combined vertically (don't combine walls). Binned by inset_idx.
 
     coord_t custom_line_distance_; //!< The distance between support infill lines. 0 means use the default line distance instead.
     bool use_fractional_config_; //!< Request to use the configuration used to fill a partial layer height here, instead of the normal full layer height configuration.
 
-    SupportInfillPart(const SingleShape& outline, coord_t support_line_width, bool use_fractional_config, int inset_count_to_generate = 0, coord_t custom_line_distance = 0);
+    SupportInfillPart(const SingleShape& outline, coord_t support_line_width, bool use_fractional_config, coord_t inset_width_to_generate = 0, coord_t custom_line_distance = 0);
+
+    const Shape& getInfillArea() const;
 };
 
 } // namespace cura

include/TreeSupport.h

@@ -1,9 +1,11 @@
-// Copyright (c) 2021 Ultimaker B.V.
+// Copyright (c) 2026 UltiMaker
 // CuraEngine is released under the terms of the AGPLv3 or higher.
 
 #ifndef TREESUPPORT_H
 #define TREESUPPORT_H
 
+#include <utility>
+
 #include "TreeModelVolumes.h"
 #include "TreeSupportBaseCircle.h"
 #include "TreeSupportElement.h"
@@ -15,6 +17,7 @@
 #include "settings/EnumSettings.h"
 #include "sliceDataStorage.h"
 #include "utils/Coord_t.h"
+#include "utils/SparsePointGridInclusive.h"
 
 namespace cura
 {
@@ -291,6 +294,7 @@ class TreeSupport
 
     void filterFloatingLines(std::vector<Shape>& support_layer_storage);
 
+    using CenterGrid = std::vector<std::unique_ptr<SparsePointGridInclusive<std::pair<coord_t, float>>>>;
     /*!
      * \brief Generates Support Floor, ensures Support Roof can not cut of branches, and saves the branches as support to storage
      *
@@ -302,6 +306,7 @@ class TreeSupport
         std::vector<Shape>& support_layer_storage,
         std::vector<Shape>& support_roof_storage,
         std::vector<Shape>& support_layer_storage_fractional,
+        const CenterGrid& center_locator_per_layer,
         SliceDataStorage& storage);
 
     /*!

include/TreeSupportSettings.h

@@ -68,7 +68,8 @@ struct TreeSupportSettings
         , support_roof_line_width(mesh_group_settings.get<coord_t>("support_roof_line_width"))
         , support_line_distance(mesh_group_settings.get<coord_t>("support_line_distance"))
         , support_bottom_offset(mesh_group_settings.get<coord_t>("support_bottom_offset"))
-        , support_wall_count(mesh_group_settings.get<int>("support_wall_count"))
+        , support_wall_thickness(mesh_group_settings.get<coord_t>("support_wall_thickness"))
+        , support_enlarged_wall_thickness(mesh_group_settings.get<coord_t>("support_enlarged_wall_thickness"))
         , support_roof_wall_count(mesh_group_settings.get<int>("support_roof_wall_count"))
         , zig_zaggify_support(mesh_group_settings.get<bool>("zig_zaggify_support"))
         , maximum_deviation(mesh_group_settings.get<coord_t>("meshfix_maximum_deviation"))
@@ -82,6 +83,9 @@ struct TreeSupportSettings
         , min_feature_size(mesh_group_settings.get<coord_t>("min_feature_size"))
         , min_wall_line_width(settings.get<coord_t>("min_wall_line_width"))
         , fill_outline_gaps(settings.get<bool>("fill_outline_gaps"))
+        , support_wall_thickness_bottom_layers(settings.get<int>("support_wall_thickness_bottom_layers"))
+        , support_wall_thickness_top_layers(settings.get<int>("support_wall_thickness_top_layers"))
+        , support_wall_thickness_layer_smooth(settings.get<int>("support_wall_thickness_layer_smooth"))
         , simplifier(Simplify(mesh_group_settings))
     {
         layer_start_bp_radius = (bp_radius - branch_radius) / (branch_radius * diameter_scale_bp_radius);
@@ -313,9 +317,14 @@ struct TreeSupportSettings
     coord_t support_bottom_offset;
 
     /*!
-     * \brief Amount of walls the support area will have.
+     * \brief Nominal width of walls the support area will have (see also below).
      */
-    int support_wall_count;
+    coord_t support_wall_thickness;
+
+    /*!
+     * \brief Width of walls the support areas that need to be sturdier will have.
+     */
+    coord_t support_enlarged_wall_thickness;
 
     /*!
      * \brief Amount of walls the support roof area will have.
@@ -383,6 +392,21 @@ struct TreeSupportSettings
      */
     bool fill_outline_gaps;
 
+    /*!
+     * \brief The number of lines from the build-plate at which the nominal line-width switches to the enlarged line-width. (But see also support_line_width_layer_smooth.)
+     */
+    coord_t support_wall_thickness_bottom_layers;
+
+    /*!
+     * \brief The number of lines from the top of the support at which the nominal line-width switches to the enlarged line-width. (But see also support_line_width_layer_smooth.)
+     */
+    coord_t support_wall_thickness_top_layers;
+
+    /*!
+     * \brief The number of lines that can be used to smooth out the transition from the nominal line-width to the enlarged line-width.
+     */
+    coord_t support_wall_thickness_layer_smooth;
+
     /*!
      * \brief Simplifier to simplify polygons.
      */
@@ -402,8 +426,8 @@ struct TreeSupportSettings
             && support_line_width == other.support_line_width && support_overrides == other.support_overrides && support_line_distance == other.support_line_distance
             && support_roof_line_width == other.support_roof_line_width
             && // can not be set on a per-mesh basis currently, so code to enable processing different roof line width in the same iteration seems useless.
-               support_bottom_offset == other.support_bottom_offset && support_wall_count == other.support_wall_count && support_pattern == other.support_pattern
-            && roof_pattern == other.roof_pattern
+               support_bottom_offset == other.support_bottom_offset && support_wall_thickness == other.support_wall_thickness
+            && support_enlarged_wall_thickness == other.support_enlarged_wall_thickness && support_pattern == other.support_pattern && roof_pattern == other.roof_pattern
             && // can not be set on a per-mesh basis currently, so code to enable processing different roof patterns in the same iteration seems useless.
                support_roof_angles == other.support_roof_angles && support_infill_angles == other.support_infill_angles
             && increase_radius_until_radius == other.increase_radius_until_radius && support_bottom_layers == other.support_bottom_layers && layer_height == other.layer_height
@@ -412,7 +436,8 @@ struct TreeSupportSettings
             && zag_skip_count == other.zag_skip_count && connect_zigzags == other.connect_zigzags && interface_preference == other.interface_preference
             && min_feature_size == other.min_feature_size && // interface_preference should be identical to ensure the tree will correctly interact with the roof.
                support_rest_preference == other.support_rest_preference && max_radius == other.max_radius && min_wall_line_width == other.min_wall_line_width
-            && fill_outline_gaps == other.fill_outline_gaps &&
+            && fill_outline_gaps == other.fill_outline_gaps && support_wall_thickness_bottom_layers == other.support_wall_thickness_bottom_layers
+            && support_wall_thickness_top_layers == other.support_wall_thickness_top_layers && support_wall_thickness_layer_smooth == other.support_wall_thickness_layer_smooth &&
                // The infill class now wants the settings object and reads a lot of settings, and as the infill class is used to calculate support roof lines for
                // interface-preference. Not all of these may be required to be identical, but as I am not sure, better safe than sorry
                (interface_preference == InterfacePreference::INTERFACE_AREA_OVERWRITES_SUPPORT || interface_preference == InterfacePreference::SUPPORT_AREA_OVERWRITES_INTERFACE

include/TreeSupportUtils.h

@@ -120,7 +120,7 @@ class TreeSupportUtils
         constexpr coord_t support_roof_overlap = 0;
         constexpr size_t infill_multiplier = 1;
         const int support_shift = roof ? 0 : support_infill_distance / 2;
-        const size_t wall_line_count = include_walls ? (! roof ? config.support_wall_count : config.support_roof_wall_count) : 0;
+        const size_t wall_line_count = include_walls ? (! roof ? config.support_wall_thickness : config.support_roof_wall_count) : 0;
         constexpr coord_t narrow_area_width = 0;
         const Point2LL infill_origin;
         constexpr bool skip_stitching = false;

include/infill.h

@@ -48,7 +48,7 @@ class Infill
     coord_t shift_{}; //!< shift of the scanlines in the direction perpendicular to the fill_angle
     coord_t max_resolution_{}; //!< Min feature size of the output
     coord_t max_deviation_{}; //!< Max deviation fro the original poly when enforcing max_resolution
-    size_t wall_line_count_{}; //!< Number of walls to generate at the boundary of the infill region, spaced \ref infill_line_width apart
+    coord_t wall_thickness_{}; //!< Thickness of walls to generate at the boundary of the infill region
     coord_t small_area_width_{}; //!< Maximum width of a small infill region to be filled with walls
     Point2LL infill_origin_{}; //!< origin of the infill pattern
     bool skip_line_stitching_{ false }; //!< Whether to bypass the line stitching normally performed for polyline type infills
@@ -116,7 +116,7 @@ class Infill
         coord_t shift,
         coord_t max_resolution,
         coord_t max_deviation,
-        size_t wall_line_count,
+        std::variant<size_t, coord_t> walls,
         coord_t small_area_width,
         Point2LL infill_origin,
         bool skip_line_stitching) noexcept
@@ -133,7 +133,7 @@ class Infill
         , shift_{ shift }
         , max_resolution_{ max_resolution }
         , max_deviation_{ max_deviation }
-        , wall_line_count_{ wall_line_count }
+        , wall_thickness_{ std::holds_alternative<coord_t>(walls) ? std::get<coord_t>(walls) : static_cast<coord_t>(std::get<size_t>(walls) * infill_line_width) }
         , small_area_width_{ small_area_width }
         , infill_origin_{ infill_origin }
         , skip_line_stitching_{ skip_line_stitching }
@@ -154,7 +154,7 @@ class Infill
         coord_t shift,
         coord_t max_resolution,
         coord_t max_deviation,
-        size_t wall_line_count,
+        std::variant<size_t, coord_t> walls,
         coord_t small_area_width,
         Point2LL infill_origin,
         bool skip_line_stitching,
@@ -177,7 +177,7 @@ class Infill
         , shift_{ shift }
         , max_resolution_{ max_resolution }
         , max_deviation_{ max_deviation }
-        , wall_line_count_{ wall_line_count }
+        , wall_thickness_{ std::holds_alternative<coord_t>(walls) ? std::get<coord_t>(walls) : static_cast<coord_t>(std::get<size_t>(walls) * infill_line_width) }
         , small_area_width_{ small_area_width }
         , infill_origin_{ infill_origin }
         , skip_line_stitching_{ skip_line_stitching }
@@ -229,7 +229,7 @@ class Infill
      *
      * \param toolpaths [out] The generated toolpaths. Binned by inset_idx.
      * \param outer_contour [in] the outer contour
-     * \param wall_line_count [in] The number of walls that needs to be generated
+     * \param wall_thickness [in] The thickness of walls that needs to be generated
      * \param line_width [in] The optimum wall line width of the walls
      * \param settings [in] A settings storage to use for generating variable-width walls.
      * \param generator The generator to use for outer "walls"
@@ -238,7 +238,7 @@ class Infill
     static Shape generateWallToolPaths(
         std::vector<VariableWidthLines>& toolpaths,
         const Shape& outer_contour,
-        const size_t wall_line_count,
+        const coord_t wall_thickness,
         const coord_t line_width,
         const Settings& settings,
         int layer_idx,

include/infill/LightningGenerator.h

@@ -72,7 +72,7 @@ class LightningGenerator // "Just like Nicola used to make!"
      * Generate the lightning infill for the given areas with the given settings
      * @param layer_thickness The actual layer thickness
      * @param line_width The extrusion line width
-     * @param wall_line_count The number of external walls in the infill areas
+     * @param wall_thickness The thickness of external walls in the infill areas
      * @param line_distance The base "line distance", which represents the density of the infill
      * @param overhang_angle The angle at which we consider overhanging areas
      * @param prune_angle The angle of the generated lines overhang
@@ -82,7 +82,7 @@ class LightningGenerator // "Just like Nicola used to make!"
     void generate(
         const coord_t layer_thickness,
         const coord_t line_width,
-        const coord_t wall_line_count,
+        const coord_t wall_thickness,
         const coord_t line_distance,
         const AngleRadians& overhang_angle,
         const AngleRadians& prune_angle,
@@ -97,12 +97,12 @@ class LightningGenerator // "Just like Nicola used to make!"
      * only when support is generated. For this pattern, we also need to
      * generate overhang areas for the inside of the model.
      */
-    void generateInitialInternalOverhangs(const coord_t infill_line_width, const coord_t infill_wall_line_count, const std::vector<Shape>& areas_per_layer);
+    void generateInitialInternalOverhangs(const coord_t infill_wall_thickness, const std::vector<Shape>& areas_per_layer);
 
     /*!
      * Calculate the tree structure of all layers.
      */
-    void generateTrees(const coord_t infill_line_width, const coord_t infill_wall_line_count, const std::vector<Shape>& areas_per_layer);
+    void generateTrees(const coord_t infill_wall_thickness, const std::vector<Shape>& areas_per_layer);
 
     /*!
      * How far each piece of infill can support skin in the layer above.

include/sliceDataStorage.h

@@ -236,22 +236,22 @@ class SupportLayer
      * \param area The support polygon to fill up with infill parts.
      * \param support_fill_per_layer The support polygons to fill up with infill parts.
      * \param support_line_width Line width of the support extrusions.
-     * \param wall_line_count Wall-line count around the fill.
+     * \param wall_thickness Wall-line thickness around the fill.
      * \param use_fractional_config (optional, default to false) If the area should be added as fractional support.
      * \param unionAll (optional, default to false) Wether to 'union all' for the split into parts bit.
      * \param custom_line_distance (optional, default to 0) Distance between lines of the infill pattern. custom_line_distance of 0 means use the default instead.
      */
     void fillInfillParts(
         const Shape& area,
         const coord_t support_line_width,
-        const coord_t wall_line_count,
+        const coord_t wall_thickness,
         const bool use_fractional_config = false,
         const bool unionAll = false,
         const coord_t custom_line_distance = 0)
     {
         for (const SingleShape& island_outline : area.splitIntoParts(unionAll))
         {
-            support_infill_parts.emplace_back(island_outline, support_line_width, use_fractional_config, wall_line_count, custom_line_distance);
+            support_infill_parts.emplace_back(island_outline, support_line_width, use_fractional_config, wall_thickness, custom_line_distance);
         }
     }
 
@@ -263,7 +263,7 @@ class SupportLayer
      * \param infill_layer_height The layer height of the support-fill.
      * \param meshes The model meshes to be supported, needed here to handle fractional support layer height.
      * \param support_line_width Line width of the support extrusions.
-     * \param wall_line_count Wall-line count around the fill.
+     * \param wall_thickness Wall-line thickness around the fill.
      * \param grow_layer_above (optional, default to 0) In cases where support shrinks per layer up, an appropriate offset may be nescesary.
      * \param unionAll (optional, default to false) Wether to 'union all' for the split into parts bit.
      * \param custom_line_distance (optional, default to 0) Distance between lines of the infill pattern. custom_line_distance of 0 means use the default instead.
@@ -274,7 +274,7 @@ class SupportLayer
         const coord_t infill_layer_height,
         const std::vector<std::shared_ptr<SliceMeshStorage>>& meshes,
         const coord_t support_line_width,
-        const coord_t wall_line_count,
+        const coord_t wall_thickness,
         const coord_t grow_layer_above = 0,
         const bool unionAll = false,
         const coord_t custom_line_distance = 0);

src/FffGcodeWriter.cpp

@@ -3629,7 +3629,7 @@ bool FffGcodeWriter::processSupportInfill(const SliceDataStorage& storage, Layer
         infill_density_multiplier = infill_extruder.settings_.get<size_t>("support_infill_density_multiplier_initial_layer");
     }
 
-    const size_t wall_line_count = infill_extruder.settings_.get<size_t>("support_wall_count");
+    const size_t wall_thickness = infill_extruder.settings_.get<size_t>("support_wall_thickness");
     const coord_t max_resolution = infill_extruder.settings_.get<coord_t>("meshfix_maximum_resolution");
     const coord_t max_deviation = infill_extruder.settings_.get<coord_t>("meshfix_maximum_deviation");
     coord_t default_support_line_width = infill_extruder.settings_.get<coord_t>("support_line_width");
@@ -3679,7 +3679,7 @@ bool FffGcodeWriter::processSupportInfill(const SliceDataStorage& storage, Layer
         const auto& configs = part.use_fractional_config_ ? gcode_layer.configs_storage_.support_fractional_infill_config : gcode_layer.configs_storage_.support_infill_config;
 
         // always process the wall overlap if walls are generated
-        const int current_support_infill_overlap = (part.inset_count_to_generate_ > 0) ? default_support_infill_overlap : 0;
+        const int current_support_infill_overlap = (part.inset_width_to_generate_ > 0) ? default_support_infill_overlap : 0;
 
         // The support infill walls were generated separately, first. Always add them, regardless of how many densities we have.
         std::vector<VariableWidthLines> wall_toolpaths = part.wall_toolpaths_;
@@ -3787,7 +3787,7 @@ bool FffGcodeWriter::processSupportInfill(const SliceDataStorage& storage, Layer
                     area,
                     support_line_width,
                     support_line_distance_here,
-                    current_support_infill_overlap - (density_idx == max_density_idx ? 0 : wall_line_count * support_line_width),
+                    current_support_infill_overlap - (density_idx == max_density_idx ? 0 : wall_thickness),
                     infill_multiplier,
                     support_infill_angle,
                     gcode_layer.z_ + configs[combine_idx].z_offset,
@@ -3890,7 +3890,7 @@ bool FffGcodeWriter::processSupportInfill(const SliceDataStorage& storage, Layer
 
             // If we're printing with a support wall, that support wall generates gap filling as well.
             // If not, the pattern may still generate gap filling (if it's connected infill or zigzag). We still want to print those.
-            if (wall_line_count == 0 || ! wall_toolpaths_here.empty())
+            if (wall_thickness == 0 || ! wall_toolpaths_here.empty())
             {
                 const GCodePathConfig& config = configs[0];
                 constexpr coord_t wipe_dist = 0;