add laser stacking stl reconstruction option

src/geo/polygon.js

@@ -2403,6 +2403,7 @@ export class Polygon {
     }
 
     // extrude poly (with inner voids) into 3d mesh
+    // todo: zadd broken when poly Z is not 0
     extrude(z = 1, opt = {}) {
         let earcut = this.earcut(); // array of 3-point polygons
 

src/kiri/core/conf.js

@@ -647,7 +647,11 @@ export const conf = {
                 ctSliceHeight: 1,
                 ctSliceHeightMin: 0,
                 ctSliceSingle: true,
+                ctOmitInner: false,
                 ctOutTileSpacing: 1,
+                ctOutClean: false,
+                ctOutFilter: 1,
+                ctOutSmooth: 0.1,
                 ctOutPower: 100,
                 ctOutSpeed: 1000,
                 ctOutGroup: true,
@@ -690,6 +694,7 @@ export const conf = {
                 ctSliceHeight: 1,
                 ctSliceHeightMin: 0,
                 ctSliceSingle: true,
+                ctOmitInner: false,
                 ctOutTileSpacing: 1,
                 ctOutPower: 100,
                 ctOutSpeed: 1000,
@@ -734,6 +739,7 @@ export const conf = {
                 ctSliceHeight: 1,
                 ctSliceHeightMin: 0,
                 ctSliceSingle: true,
+                ctOmitInner: false,
                 ctOutTileSpacing: 1,
                 ctOutPower: 100,
                 ctOutSpeed: 1000,

src/kiri/core/export.js

@@ -99,6 +99,12 @@ function exportLaserDialog(data, names) {
     const filename = `${fileroot}-${(printSeq.toString().padStart(3,"0"))}`;
     const settings = api.conf.get();
     const driver = laser_driver;
+    const { process } = settings;
+    if (process.ctOutStack) {
+        $('print-stl').classList.remove('hide');
+    } else {
+        $('print-stl').classList.add('hide');
+    }
 
     function download_svg() {
         api.util.download(
@@ -114,6 +120,13 @@ function exportLaserDialog(data, names) {
         );
     }
 
+    function download_stl() {
+        api.util.download(
+            driver.exportSTL(settings, data),
+            $('print-filename-laser').value + ".stl"
+        );
+    }
+
     function download_gcode() {
         api.util.download(
             driver.exportGCode(settings, data),
@@ -130,6 +143,7 @@ function exportLaserDialog(data, names) {
     $('print-lines').value = util.comma(segments);
     $('print-svg').onclick = download_svg;
     $('print-dxf').onclick = download_dxf;
+    $('print-stl').onclick = download_stl;
     $('print-lg').onclick = download_gcode;
 }
 

src/kiri/core/widget.js

@@ -872,8 +872,9 @@ class Widget {
         return shadows[z] = POLY.setZ(shadow, z);
     }
 
+    // create a stack of faces in 1mm increments
+    // the stacks are then used to produce shadowlines
     #ensureShadowCache() {
-        // cache faces with normals up
         if (this.cache.shadow) {
             return;
         }
@@ -881,7 +882,6 @@ class Widget {
         const length = geo.length;
         const bounds = this.getBoundingBox();
         const stack = {};
-        // const faces = [];
         for (let i = Math.floor(bounds.min.z); i <= Math.ceil(bounds.max.z); i++) {
             stack[i] = [];
         }
@@ -892,7 +892,6 @@ class Widget {
             const n = THREE.computeFaceNormal(a, b, c);
             if (n.z < 0.001) {
                 continue;
-                // faces.push(a, b, c);
             }
             const minZ = Math.floor(Math.min(a.z, b.z, c.z));
             const maxZ = Math.ceil(Math.max(a.z, b.z, c.z));
@@ -904,6 +903,7 @@ class Widget {
     }
 
     // union triangles > z (opt cap < ztop) into polygon(s)
+    // slice the triangle stack matchingg z then union the results
     #computeShadowAt(z, ztop) {
         this.#ensureShadowCache();
         const found = [];

src/kiri/mode/laser/driver.js

@@ -10,6 +10,8 @@ import { polygons as POLY } from '../../../geo/polygons.js';
 import { render } from '../../core/render.js';
 import { slicer } from '../../../geo/slicer.js';
 import { newSlice } from '../../core/slice.js';
+import { newPolygon } from '../../../geo/polygon.js';
+import { STL } from '../../../load/stl.js';
 
 export const TYPE = {
     LASER: 0,
@@ -228,9 +230,28 @@ function laser_slice(settings, widget, onupdate, ondone) {
         widget.slices = output.slices.map(data => {
             let { z, lines, groups } = data;
             let tops = POLY.nest(groups);
+            let { ctOutClean, ctOutFilter, ctOutSmooth } = proc;
+            // optional cleaning, smoothing, filtering steps
+            // if we're going to re-export an stl
+            if (ctOutClean) {
+                tops.map(top => top.clean(true));
+                POLY.setZ(tops, z);
+            }
+            // running this here vs at output time seems to cause manifold issues ?!?
+            // if (ctOutSmooth) {
+            //     console.log({ ctOutSmooth });
+            //     tops = POLY.offset(tops, ctOutSmooth);
+            //     tops = POLY.offset(tops, -ctOutSmooth);
+            //     POLY.setZ(tops, z);
+            // }
+            if (ctOutFilter) {
+                tops = tops.filter(top => top.area() > ctOutFilter);
+            }
             // for WireEDM, we commonly omit inner polys because we can't
             // navigate to cut them separately unlike laser, water, drag
-            if (ctOmitInner) tops.forEach(top => delete top.inner);
+            if (ctOmitInner) {
+                tops.forEach(top => delete top.inner);
+            }
             let slice = newSlice(z).addTops(tops);
             slice.index = indices.indexOf(z);
             // create top offsets (even if 0)
@@ -269,6 +290,7 @@ async function laser_prepare(widgets, settings, update) {
         { ctOutStack, ctOutMerged, ctOutKnifeTip, ctOutShaper } = process;
 
     ctOutStack = ctOutStack && isLaser;
+    print.widgets = widgets;
 
     // shim to adapt older code -- should be refactored
     // let pppo = [];
@@ -588,6 +610,49 @@ function exportElements(settings, output, onpre, onpoly, onpost, onpoint, onlaye
     onpost();
 };
 
+function exportSTL(settings, data) {
+    let { ctSliceHeight, ctOutSmooth } = settings.process;
+    let polys = [];
+    for (let array of data) {
+        let poly;
+        for (let el of array) {
+            let { emit, point } = el;
+            if (emit === 0) {
+                poly = newPolygon().addObj(point);
+                polys.push(poly);
+            } else {
+                poly.addObj(point);
+            }
+        }
+    }
+    if (ctOutSmooth) {
+        polys = polys.map(poly => {
+            let pump = POLY.offset([ poly ], ctOutSmooth);
+            pump = POLY.offset(pump, -ctOutSmooth);
+            return POLY.setZ(pump, poly.getZ());
+        }).flat().filter(v => v);
+    }
+    let layers = {};
+    let mesh = [];
+    for (let poly of polys) {
+        let z = poly.getZ();
+        let layer = layers[z];
+        if (!layer) {
+            layer = layers[z] = [];
+        }
+        layer.push(poly);
+    }
+    for (let rec of Object.entries(layers)) {
+        let [ z, polys ] = rec;
+        polys = POLY.nest(polys);
+        for (let poly of polys) {
+            let ext = poly.setZ(0).extrude(ctSliceHeight, { zadd: parseFloat(z) });
+            mesh = mesh.concat(ext);
+        }
+    }
+    return new STL().encode(mesh);
+}
+
 /**
  *
  */
@@ -867,5 +932,6 @@ export const LASER = {
     export: laser_export,
     exportGCode,
     exportDXF,
-    exportSVG
+    exportSVG,
+    exportSTL
 };

src/kiri/mode/laser/init-menu.js

@@ -35,7 +35,7 @@ export function menu() {
     ctSliceHeightMin:    newInput(LANG.ls_lahm_s, {title:LANG.ls_lahm_l, convert:toFloat, show:() => ui.ctSliceHeight.value == 0 && !ui.ctSliceSingle.checked }),
     separator:           newBlank({ class:"set-sep", driven }),
     ctSliceSingle:       newBoolean(LANG.ls_sngl_s, onBooleanClick, {title:LANG.ls_sngl_l}),
-    ctOmitInner:         newBoolean(LANG.we_omit_s, onBooleanClick, {title:LANG.we_omit_l, modes:WEDM}),
+    ctOmitInner:         newBoolean(LANG.we_omit_s, onBooleanClick, {title:LANG.we_omit_l}),
     _____:               newGroup('surfaces', $('lzr-surface'), { modes:[-1], driven, separator }),
     ctSurfaces: newRow([
         (ui.faceAdd = newButton(undefined, onButtonClick, {icon:'<i class="fas fa-plus"></i>'})),
@@ -68,6 +68,10 @@ export function menu() {
     ctOutInches:         newBoolean(LANG.ou_inch_s, onBooleanClick, { title:LANG.ou_inch_l, modes:LASER }),
     ctOutStack:          newBoolean(LANG.ou_stak_s, onBooleanClick, { title:LANG.ou_stak_l, modes:LASER }),
     ctOutShaper:         newBoolean(LANG.ou_shap_s, onBooleanClick, { title:LANG.ou_shap_l, modes:LASER, show:() => ui.ctOutStack.checked }),
+    separator:           newBlank({ class:"set-sep", driven, modes:LASER, show: () => ui.ctOutStack.checked }),
+    ctOutClean:          newBoolean('clean', onBooleanClick, { title:'clean', modes:LASER, show:() => ui.ctOutStack.checked }),
+    ctOutFilter:         newInput('filter', { title:'filter', modes:LASER, convert:toFloat, show:() => ui.ctOutStack.checked }),
+    ctOutSmooth:         newInput('smooth', { title:'smooth', modes:LASER, convert:toFloat, show:() => ui.ctOutStack.checked }),
 
     };
 

web/kiri/index.html

@@ -691,6 +691,7 @@
             <div class="f-row box">
                 <button id="print-svg" class="grow">svg</button>
                 <button id="print-dxf" class="grow">dxf</button>
+                <button id="print-stl" class="grow">stl</button>
                 <button id="print-lg" class="grow">gcode</button>
             </div>
         </div>