Incorrect infill generation with Ensure Vertical Shell Thickness

Nemernemer commented 1 month ago

Is there an existing issue for this problem?

[X] I have searched the existing issues

OrcaSlicer Version

2.2.0-beta

Operating System (OS)

Windows

OS Version

Windows 11 (Atlas OS)

Additional system information

No response

Printer

Custom Voron 2.4

How to reproduce

Import any model that has a vertical wall adjacent to a horizontal surface. Slice with "Ensure vertical shell thickness" set to anything other than "All"

Actual results

The last layer for the adjacent top surface incorrectly skews the walls for the next layer in, filling the new space between shell and solid infill with sparse infill.

This causes a very weak layer bond on these intersections, and even gaps in the printed model.

Expected results

I would expect the same result as with the setting on "All":

Project file & Debug log uploads

Assembly.zip

Checklist of files to include

[ ] Log file
[X] Project file

Anything else?

This is not a recent issue for me, but I only recently discovered why it was happening. Repeats on multiple installs between different computers (all Win11).

xokahag commented 4 weeks ago

This issue is present since pre-2.0 versions (I tested 1.9), but because it was only an on/off option it wasn't as obvious.

Most of the times this does not present significant strength and or cosmetic problems, but the additional holes can make the slicer and printer unpredictable at times. I don't need extra material on the inside of slated walls, but I do want it to support structures printed directly on top. For me, 100% vertical support counts as "critical only" and should therefore be included in the moderate/critical options. (easier said then done, i know)

Here is another example with the benchy:

Vertical shell thickness: ALL vertical_shell_thickness_all

Vertical shell thickness: other modes vertical_shell_thinkness_other

Nemernemer commented 4 weeks ago

I would have to disagree on strength not being significantly affected. In the case of staggered features, such as a cylinder sticking out of a flat surface, the entire protruding feature is only bonded to the previous layers through sparse infill:

Had a couple parts like this break, which led to me investigating what was causing this defect to begin with.

xokahag commented 3 weeks ago

Because most models print just fine, there is not more people besides us complaining about this issue.

I posted screenshot exactly because it is a real issue, and it needs the attention to get it fixed.

SoftFever / OrcaSlicer