The last priming area is shortened and the excess wipe is moved

into the wipe tower if there is enough space inside the wipe tower.

8 files changed, 115 insertions, 39 deletions

diff --git a/xs/src/libslic3r/BoundingBox.cpp b/xs/src/libslic3r/BoundingBox.cpp
index f268bb3fb..66beaa3d5 100644
--- a/xs/src/libslic3r/BoundingBox.cpp
+++ b/xs/src/libslic3r/BoundingBox.cpp
@@ -125,15 +125,17 @@ template void BoundingBoxBase<Pointf>::merge(const Pointfs &points);
 template <class PointClass> void
 BoundingBoxBase<PointClass>::merge(const BoundingBoxBase<PointClass> &bb)
 {
-    if (this->defined) {
-        this->min.x = std::min(bb.min.x, this->min.x);
-        this->min.y = std::min(bb.min.y, this->min.y);
-        this->max.x = std::max(bb.max.x, this->max.x);
-        this->max.y = std::max(bb.max.y, this->max.y);
-    } else {
-        this->min = bb.min;
-        this->max = bb.max;
-        this->defined = true;
+    if (bb.defined) {
+        if (this->defined) {
+            this->min.x = std::min(bb.min.x, this->min.x);
+            this->min.y = std::min(bb.min.y, this->min.y);
+            this->max.x = std::max(bb.max.x, this->max.x);
+            this->max.y = std::max(bb.max.y, this->max.y);
+        } else {
+            this->min = bb.min;
+            this->max = bb.max;
+            this->defined = true;
+        }
     }
 }
 template void BoundingBoxBase<Point>::merge(const BoundingBoxBase<Point> &bb);
@@ -160,11 +162,13 @@ template void BoundingBox3Base<Pointf3>::merge(const Pointf3s &points);
 template <class PointClass> void
 BoundingBox3Base<PointClass>::merge(const BoundingBox3Base<PointClass> &bb)
 {
-    if (this->defined) {
-        this->min.z = std::min(bb.min.z, this->min.z);
-        this->max.z = std::max(bb.max.z, this->max.z);
+    if (bb.defined) {
+        if (this->defined) {
+            this->min.z = std::min(bb.min.z, this->min.z);
+            this->max.z = std::max(bb.max.z, this->max.z);
+        }
+        BoundingBoxBase<PointClass>::merge(bb);
     }
-    BoundingBoxBase<PointClass>::merge(bb);
 }
 template void BoundingBox3Base<Pointf3>::merge(const BoundingBox3Base<Pointf3> &bb);
 
diff --git a/xs/src/libslic3r/GCode.cpp b/xs/src/libslic3r/GCode.cpp
index a2e2f5607..478864e74 100644
--- a/xs/src/libslic3r/GCode.cpp
+++ b/xs/src/libslic3r/GCode.cpp
@@ -700,15 +700,17 @@ bool GCode::_do_export(Print &print, FILE *file)
                 BoundingBoxf bbox_prime(get_wipe_tower_priming_extrusions_extents(print));
                 bbox_prime.offset(0.5f);
                 // Beep for 500ms, tone 800Hz. Yet better, play some Morse.
+                write(file, this->retract());
                 fprintf(file, "M300 S800 P500\n");
                 if (bbox_prime.overlap(bbox_print)) {
                     // Wait for the user to remove the priming extrusions, otherwise they would
                     // get covered by the print.
-                    fprintf(file, "M1 Remove priming towers and click button.\n");
+                    fprintf(file, "M1 Remove priming towers and click button.\nM117 Printing\n");
                 } else {
                     // Just wait for a bit to let the user check, that the priming succeeded.
-                    fprintf(file, "M0 S10\n");
+                    fprintf(file, "M117 Verify extruder priming\nM0 S10\nM117 Printing\n");
                 }
+                write(file, this->unretract());
             } else
                 write(file, WipeTowerIntegration::prime_single_color_print(print, initial_extruder_id, *this));
         }
diff --git a/xs/src/libslic3r/GCode/PrintExtents.cpp b/xs/src/libslic3r/GCode/PrintExtents.cpp
index 98dc59f58..db33627ec 100644
--- a/xs/src/libslic3r/GCode/PrintExtents.cpp
+++ b/xs/src/libslic3r/GCode/PrintExtents.cpp
@@ -101,7 +101,7 @@ BoundingBoxf get_print_extrusions_extents(const Print &print)
     return bbox;
 }
 
-BoundingBoxf get_print_object_extrusions_extents(const PrintObject &print_object, const coord_t max_print_z)
+BoundingBoxf get_print_object_extrusions_extents(const PrintObject &print_object, const coordf_t max_print_z)
 {
     BoundingBoxf bbox;
     for (const Layer *layer : print_object.layers) {
@@ -129,7 +129,7 @@ BoundingBoxf get_print_object_extrusions_extents(const PrintObject &print_object
 
 // Returns a bounding box of a projection of the wipe tower for the layers <= max_print_z.
 // The projection does not contain the priming regions.
-BoundingBoxf get_wipe_tower_extrusions_extents(const Print &print, const coord_t max_print_z)
+BoundingBoxf get_wipe_tower_extrusions_extents(const Print &print, const coordf_t max_print_z)
 {
     BoundingBoxf bbox;
     for (const std::vector<WipeTower::ToolChangeResult> &tool_changes : print.m_wipe_tower_tool_changes) {
diff --git a/xs/src/libslic3r/GCode/PrintExtents.hpp b/xs/src/libslic3r/GCode/PrintExtents.hpp
index 2706e2cab..db507689d 100644
--- a/xs/src/libslic3r/GCode/PrintExtents.hpp
+++ b/xs/src/libslic3r/GCode/PrintExtents.hpp
@@ -16,11 +16,11 @@ class BoundingBoxf;
 BoundingBoxf get_print_extrusions_extents(const Print &print);
 
 // Returns a bounding box of a projection of the object extrusions at z <= max_print_z.
-BoundingBoxf get_print_object_extrusions_extents(const PrintObject &print_object, const coord_t max_print_z);
+BoundingBoxf get_print_object_extrusions_extents(const PrintObject &print_object, const coordf_t max_print_z);
 
 // Returns a bounding box of a projection of the wipe tower for the layers <= max_print_z.
 // The projection does not contain the priming regions.
-BoundingBoxf get_wipe_tower_extrusions_extents(const Print &print, const coord_t max_print_z);
+BoundingBoxf get_wipe_tower_extrusions_extents(const Print &print, const coordf_t max_print_z);
 
 // Returns a bounding box of the wipe tower priming extrusions.
 BoundingBoxf get_wipe_tower_priming_extrusions_extents(const Print &print);
diff --git a/xs/src/libslic3r/GCode/WipeTower.hpp b/xs/src/libslic3r/GCode/WipeTower.hpp
index cccbe23d8..c5fa27392 100644
--- a/xs/src/libslic3r/GCode/WipeTower.hpp
+++ b/xs/src/libslic3r/GCode/WipeTower.hpp
@@ -105,7 +105,16 @@ public:
 	};
 
 	// Returns gcode to prime the nozzles at the front edge of the print bed.
-	virtual ToolChangeResult prime(float first_layer_height, std::vector<unsigned int> tools, Purpose purpose = PURPOSE_MOVE_TO_TOWER_AND_EXTRUDE) = 0;
+	virtual ToolChangeResult prime(
+		// print_z of the first layer.
+		float 						first_layer_height, 
+		// Extruder indices, in the order to be primed. The last extruder will later print the wipe tower brim, print brim and the object.
+		std::vector<unsigned int> 	tools,
+		// If true, the last priming are will be the same as the other priming areas, and the rest of the wipe will be performed inside the wipe tower.
+		// If false, the last priming are will be large enough to wipe the last extruder sufficiently.
+		bool 						last_wipe_inside_wipe_tower, 
+		// May be used by a stand alone post processor.
+		Purpose 					purpose = PURPOSE_MOVE_TO_TOWER_AND_EXTRUDE) = 0;
 
 	// Returns gcode for toolchange and the end position.
 	// if new_tool == -1, just unload the current filament over the wipe tower.
diff --git a/xs/src/libslic3r/GCode/WipeTowerPrusaMM.cpp b/xs/src/libslic3r/GCode/WipeTowerPrusaMM.cpp
index 760ff03f0..14b67936d 100644
--- a/xs/src/libslic3r/GCode/WipeTowerPrusaMM.cpp
+++ b/xs/src/libslic3r/GCode/WipeTowerPrusaMM.cpp
@@ -364,7 +364,16 @@ WipeTowerPrusaMM::material_type WipeTowerPrusaMM::parse_material(const char *nam
 }
 
 // Returns gcode to prime the nozzles at the front edge of the print bed.
-WipeTower::ToolChangeResult WipeTowerPrusaMM::prime(float first_layer_height, std::vector<unsigned int> tools, Purpose purpose)
+WipeTower::ToolChangeResult WipeTowerPrusaMM::prime(
+	// print_z of the first layer.
+	float 						first_layer_height, 
+	// Extruder indices, in the order to be primed. The last extruder will later print the wipe tower brim, print brim and the object.
+	std::vector<unsigned int> 	tools,
+	// If true, the last priming are will be the same as the other priming areas, and the rest of the wipe will be performed inside the wipe tower.
+	// If false, the last priming are will be large enough to wipe the last extruder sufficiently.
+	bool 						last_wipe_inside_wipe_tower, 
+	// May be used by a stand alone post processor.
+	Purpose 					purpose)
 {
 	this->set_layer(first_layer_height, first_layer_height, tools.size(), true, false);
 
@@ -411,6 +420,7 @@ WipeTower::ToolChangeResult WipeTowerPrusaMM::prime(float first_layer_height, st
 		  .set_extruder_trimpot(750);
 
 	if (purpose == PURPOSE_EXTRUDE || purpose == PURPOSE_MOVE_TO_TOWER_AND_EXTRUDE) {
+		float y_end = 0.f;
 		for (size_t idx_tool = 0; idx_tool < tools.size(); ++ idx_tool) {
 			unsigned int tool = tools[idx_tool];
 			// Select the tool, set a speed override for soluble and flex materials.
@@ -419,10 +429,20 @@ WipeTower::ToolChangeResult WipeTowerPrusaMM::prime(float first_layer_height, st
 			toolchange_Load(writer, cleaning_box);
 			if (idx_tool + 1 == tools.size()) {
 				// Last tool should not be unloaded, but it should be wiped enough to become of a pure color.
-				toolchange_Wipe(writer, cleaning_box);
+				if (last_wipe_inside_wipe_tower) {
+					// Shrink the last wipe area to the area of the other purge areas,
+					// remember the last initial wipe width to be purged into the 1st layer of the wipe tower.
+					this->m_initial_extra_wipe = std::max(0.f, wipe_area - (y_end + 0.5f * 0.85f * m_perimeter_width - cleaning_box.ld.y));
+					cleaning_box.lu.y -= this->m_initial_extra_wipe;
+					cleaning_box.ru.y -= this->m_initial_extra_wipe;
+				}
+				toolchange_Wipe(writer, cleaning_box, false);
 			} else {
 				// Ram the hot material out of the melt zone, retract the filament into the cooling tubes and let it cool.
+				writer.travel(writer.x(), writer.y() + m_perimeter_width, 7200);
 				toolchange_Unload(writer, cleaning_box, m_material[m_current_tool], m_first_layer_temperature[tool]);
+				// Save the y end of the non-last priming area.
+				y_end = writer.y();
 			    cleaning_box.translate(m_wipe_tower_width, 0.f);
 				writer.travel(cleaning_box.ld, 7200);
 			}
@@ -546,7 +566,7 @@ WipeTower::ToolChangeResult WipeTowerPrusaMM::tool_change(unsigned int tool, boo
 			toolchange_Change(writer, tool, m_material[tool]);
 			toolchange_Load(writer, cleaning_box);
 			// Wipe the newly loaded filament until the end of the assigned wipe area.
-			toolchange_Wipe(writer, cleaning_box);
+			toolchange_Wipe(writer, cleaning_box, false);
 			// Draw a perimeter around cleaning_box and wipe.
 			box_coordinates box = cleaning_box;
 			if (m_current_shape == SHAPE_REVERSED) {
@@ -647,6 +667,21 @@ WipeTower::ToolChangeResult WipeTowerPrusaMM::toolchange_Brim(Purpose purpose, b
 			}
 		}
 
+		if (m_initial_extra_wipe > m_perimeter_width * 1.9f) {
+			box_coordinates cleaning_box(
+				m_wipe_tower_pos + xy(0.f, 0.5f * m_perimeter_width),
+				m_wipe_tower_width, 
+				m_initial_extra_wipe - m_perimeter_width);
+		    writer.travel(cleaning_box.ld + xy(m_perimeter_width, 0.5f * m_perimeter_width), 6000);
+			// Wipe the newly loaded filament until the end of the assigned wipe area.
+			toolchange_Wipe(writer, cleaning_box, true);
+			// Draw a perimeter around cleaning_box.
+			writer.travel(cleaning_box.lu, 7000)
+				  .extrude(cleaning_box.ld, 3200).extrude(cleaning_box.rd)
+				  .extrude(cleaning_box.ru).extrude(cleaning_box.lu);
+		    m_current_wipe_start_y = m_initial_extra_wipe;
+		}
+
 		// Move to the front left corner.
 		writer.travel(wipeTower_box.ld, 7000);
 
@@ -786,6 +821,9 @@ void WipeTowerPrusaMM::toolchange_Load(
 {
 	float xl = cleaning_box.ld.x + m_perimeter_width;
 	float xr = cleaning_box.rd.x - m_perimeter_width;
+	//FIXME flipping left / right side, so that the following toolchange_Wipe will start
+	// where toolchange_Load ends. 
+	std::swap(xl, xr);
 
 	writer.append("; CP TOOLCHANGE LOAD\n")
 	// Load the filament while moving left / right,
@@ -819,7 +857,8 @@ void WipeTowerPrusaMM::toolchange_Load(
 // Wipe the newly loaded filament until the end of the assigned wipe area.
 void WipeTowerPrusaMM::toolchange_Wipe(
 	PrusaMultiMaterial::Writer &writer,
-	const box_coordinates  &cleaning_box)
+	const box_coordinates  &cleaning_box,
+	bool skip_initial_y_move)
 {
 	// Increase flow on first layer, slow down print.
 	writer.set_extrusion_flow(m_extrusion_flow * (m_is_first_layer ? 1.18f : 1.f))
@@ -833,23 +872,27 @@ void WipeTowerPrusaMM::toolchange_Wipe(
 	float wipe_speed_max = 4800.f;
 	// Y increment per wipe line.
 	float dy = ((m_current_shape == SHAPE_NORMAL) ? 1.f : -1.f) * m_perimeter_width * 0.8f;
-	for (bool p = true; ; p = ! p) {
-		wipe_speed = std::min(wipe_speed_max, wipe_speed + wipe_speed_inc);
-		if (p) {
-			writer.extrude(xl - m_perimeter_width / 2, writer.y() + dy, wipe_speed * wipe_coeff);
-			writer.extrude(xr + m_perimeter_width,     writer.y());
-		} else {
-			writer.extrude(xl - m_perimeter_width,     writer.y() + dy, wipe_speed * wipe_coeff);
-			writer.extrude(xr + m_perimeter_width * 2, writer.y());
-		}
+	for (bool p = true; 
+		// Next wipe line fits the cleaning box.
+		((m_current_shape == SHAPE_NORMAL) ?
+			(writer.y() <= cleaning_box.lu.y - m_perimeter_width) :
+			(writer.y() >= cleaning_box.ld.y + m_perimeter_width));
+		p = ! p)
+	{
 		wipe_speed = std::min(wipe_speed_max, wipe_speed + wipe_speed_inc);
-		writer.extrude(xr + m_perimeter_width, writer.y() + dy, wipe_speed * wipe_coeff);
-		writer.extrude(xl - m_perimeter_width, writer.y());
+		if (skip_initial_y_move)
+			skip_initial_y_move = false;
+		else
+			writer.extrude(xl - (p ? m_perimeter_width / 2 : m_perimeter_width), writer.y() + dy, wipe_speed * wipe_coeff);
+		writer.extrude(xr + (p ? m_perimeter_width : m_perimeter_width * 2), writer.y(), wipe_speed * wipe_coeff);
+		// Next wipe line fits the cleaning box.
 		if ((m_current_shape == SHAPE_NORMAL) ?
 			(writer.y() > cleaning_box.lu.y - m_perimeter_width) :
 			(writer.y() < cleaning_box.ld.y + m_perimeter_width))
-			// Next wipe line does not fit the cleaning box.
 			break;
+		wipe_speed = std::min(wipe_speed_max, wipe_speed + wipe_speed_inc);
+		writer.extrude(xr + m_perimeter_width, writer.y() + dy, wipe_speed * wipe_coeff);
+		writer.extrude(xl - m_perimeter_width, writer.y());
 	}
 	// Reset the extrusion flow.
 	writer.set_extrusion_flow(m_extrusion_flow);
diff --git a/xs/src/libslic3r/GCode/WipeTowerPrusaMM.hpp b/xs/src/libslic3r/GCode/WipeTowerPrusaMM.hpp
index c21c62486..15a96d367 100644
--- a/xs/src/libslic3r/GCode/WipeTowerPrusaMM.hpp
+++ b/xs/src/libslic3r/GCode/WipeTowerPrusaMM.hpp
@@ -108,7 +108,16 @@ public:
 	virtual bool 	  		 finished() const { return m_max_color_changes == 0; }
 
 	// Returns gcode to prime the nozzles at the front edge of the print bed.
-	virtual ToolChangeResult prime(float first_layer_height, std::vector<unsigned int> tools, Purpose purpose = PURPOSE_MOVE_TO_TOWER_AND_EXTRUDE);
+	virtual ToolChangeResult prime(
+		// print_z of the first layer.
+		float 						first_layer_height, 
+		// Extruder indices, in the order to be primed. The last extruder will later print the wipe tower brim, print brim and the object.
+		std::vector<unsigned int> 	tools,
+		// If true, the last priming are will be the same as the other priming areas, and the rest of the wipe will be performed inside the wipe tower.
+		// If false, the last priming are will be large enough to wipe the last extruder sufficiently.
+		bool 						last_wipe_inside_wipe_tower, 
+		// May be used by a stand alone post processor.
+		Purpose 					purpose = PURPOSE_MOVE_TO_TOWER_AND_EXTRUDE);
 
 	// Returns gcode for a toolchange and a final print head position.
 	// On the first layer, extrude a brim around the future wipe tower first.
@@ -176,6 +185,9 @@ private:
 	unsigned int 	m_current_tool  = 0;
 	// Current y position at the wipe tower.
 	float 		 	m_current_wipe_start_y = 0.f;
+	// How much to wipe the 1st extruder over the wipe tower at the 1st layer
+	// after the wipe tower brim has been extruded?
+	float  			m_initial_extra_wipe = 0.f;
 
 	struct box_coordinates
 	{
@@ -230,7 +242,8 @@ private:
 	
 	void toolchange_Wipe(
 		PrusaMultiMaterial::Writer &writer,
-		const box_coordinates  &cleaning_box);
+		const box_coordinates  &cleaning_box,
+		bool skip_initial_y_move);
 	
 	void toolchange_Perimeter();
 };
diff --git a/xs/src/libslic3r/Print.cpp b/xs/src/libslic3r/Print.cpp
index 766acbe9b..667a3b4ea 100644
--- a/xs/src/libslic3r/Print.cpp
+++ b/xs/src/libslic3r/Print.cpp
@@ -992,8 +992,13 @@ void Print::_make_wipe_tower()
             this->config.temperature.get_at(i),
             this->config.first_layer_temperature.get_at(i));
 
+    // When printing the first layer's wipe tower, the first extruder is expected to be active and primed.
+    // Therefore the number of wipe sections at the wipe tower will be (m_tool_ordering.front().extruders-1) at the 1st layer.
+    // The following variable is true if the last priming section cannot be squeezed inside the wipe tower.
+    bool last_priming_wipe_full = m_tool_ordering.front().extruders.size() > m_tool_ordering.front().wipe_tower_partitions;
+
     m_wipe_tower_priming = Slic3r::make_unique<WipeTower::ToolChangeResult>(
-        wipe_tower.prime(this->skirt_first_layer_height(), m_tool_ordering.all_extruders(), WipeTower::PURPOSE_EXTRUDE));
+        wipe_tower.prime(this->skirt_first_layer_height(), m_tool_ordering.all_extruders(), ! last_priming_wipe_full, WipeTower::PURPOSE_EXTRUDE));
 
     // Generate the wipe tower layers.
     m_wipe_tower_tool_changes.reserve(m_tool_ordering.layer_tools().size());