Allow using tool path angle on laser fill (#3137)

Author: breiler

ugs-designer/src/main/java/com/willwinder/ugs/designer/io/gcode/toolpaths/LaserFillToolPath.java

@@ -6,15 +6,15 @@
 import com.willwinder.ugs.designer.io.gcode.path.Segment;
 import com.willwinder.ugs.designer.io.gcode.path.SegmentType;
 import com.willwinder.ugs.designer.model.Settings;
+import static com.willwinder.ugs.designer.utils.GeometryUtils.generateLineString;
 import com.willwinder.universalgcodesender.model.PartialPosition;
-import org.locationtech.jts.geom.Coordinate;
-import org.locationtech.jts.geom.CoordinateXY;
 import org.locationtech.jts.geom.Envelope;
 import org.locationtech.jts.geom.Geometry;
 import org.locationtech.jts.geom.LineString;
 import org.locationtech.jts.geom.MultiPoint;
 
 import java.awt.geom.Area;
+import java.util.Arrays;
 import java.util.List;
 
 public class LaserFillToolPath extends AbstractToolPath {
@@ -37,30 +37,57 @@ private List<Geometry> getGeometries() {
     public void appendGcodePath(GcodePath gcodePath, Settings settings) {
         gcodePath.addSegment(new Segment(SegmentType.SEAM, null, null, (int) Math.round(settings.getMaxSpindleSpeed() * (source.getSpindleSpeed() / 100d)), source.getFeedRate()));
 
+        double toolPathAngle = source.getToolPathAngle();
         List<Geometry> geometries = getGeometries();
         geometries.forEach(g -> {
             Envelope envelope = g.getEnvelopeInternal();
+            double[] offsetRange = getOffsetRange(envelope, toolPathAngle);
 
             int currentPass = 0;
             while (currentPass < source.getPasses()) {
                 currentPass++;
 
                 boolean reverse = false;
-                double currentY = envelope.getMinY();
-                while (currentY <= envelope.getMaxY()) {
-                    LineString lineString = getGeometryFactory().createLineString(new Coordinate[]{
-                            new CoordinateXY(envelope.getMinX(), currentY),
-                            new CoordinateXY(envelope.getMaxX(), currentY),
-                    });
-
-                    addLineIntersectionSegments(gcodePath, g, lineString, reverse);
-                    currentY += settings.getLaserDiameter();
+                double currentOffset = offsetRange[0];
+                while (currentOffset <= offsetRange[1]) {
+                    LineString lineString = generateLineString(envelope, currentOffset, toolPathAngle);
+                    if (lineString != null) {
+                        addLineIntersectionSegments(gcodePath, g, lineString, reverse);
+                    }
+                    currentOffset += settings.getLaserDiameter();
                     reverse = !reverse;
                 }
             }
         });
     }
 
+    /**
+     * Returns the range of offsets along the pass normal that covers the whole envelope for the given angle.
+     * The offset is measured from the envelope's minimum corner, matching {@link com.willwinder.ugs.designer.utils.GeometryUtils#generateLineString}.
+     */
+    private static double[] getOffsetRange(Envelope envelope, double angleInDegrees) {
+        double radians = Math.toRadians(-angleInDegrees);
+        double dx = Math.cos(radians);
+        double dy = Math.sin(radians);
+
+        double normalX = -dy;
+        double normalY = dx;
+
+        double width = envelope.getWidth();
+        double height = envelope.getHeight();
+
+        double[] projections = {
+                0,
+                width * normalX,
+                height * normalY,
+                width * normalX + height * normalY
+        };
+
+        double min = Arrays.stream(projections).min().orElse(0);
+        double max = Arrays.stream(projections).max().orElse(0);
+        return new double[]{min, max};
+    }
+
     private static void addLineIntersectionSegments(GcodePath gcodePath, Geometry geometry, LineString lineString, boolean reverse) {
         Geometry intersection = geometry.intersection(lineString);
 

ugs-designer/src/test/java/com/willwinder/ugs/designer/io/gcode/toolpaths/LaserFillToolPathTest.java

@@ -13,6 +13,7 @@
 import static com.willwinder.ugs.designer.io.gcode.path.SegmentType.MOVE;
 import static com.willwinder.ugs.designer.io.gcode.path.SegmentType.SEAM;
 import static org.junit.Assert.assertEquals;
+import static org.junit.Assert.assertFalse;
 
 public class LaserFillToolPathTest {
 
@@ -44,6 +45,42 @@ public void fillToolPathShouldNotConnectThePointEdgesWithALineSegment() {
         assertSegment(segments.get(4), LINE, 0.0, 0.2);
     }
 
+    @Test
+    public void fillToolPathShouldFillAlongToolPathAngle() {
+        Path path = new Path();
+        path.setPasses(1);
+        path.setToolPathAngle(90);
+        path.moveTo(0, 0);
+        path.lineTo(0, 1);
+        path.lineTo(1, 1);
+        path.lineTo(1, 0);
+        path.lineTo(0, 0);
+        path.close();
+
+        Settings settings = new Settings();
+        settings.setMaxSpindleSpeed(10000);
+
+        LaserFillToolPath toolPath = new LaserFillToolPath(settings, path);
+        toolPath.setStartDepth(0);
+        toolPath.setTargetDepth(0);
+
+        GcodePath gcodePath = toolPath.toGcodePath();
+        List<Segment> segments = gcodePath.getSegments();
+        assertEquals(SEAM, segments.get(0).type);
+
+        List<Segment> lineSegments = segments.stream().filter(s -> s.type == LINE).toList();
+        assertFalse("Expected the fill to produce line segments", lineSegments.isEmpty());
+
+        // A 90 degree angle fills with vertical passes, so every line moves along Y while keeping X constant
+        lineSegments.forEach(segment ->
+                assertEquals(segment.getPoint().getX(), findMovePreceding(segments, segment).getPoint().getX(), 0.01));
+    }
+
+    private Segment findMovePreceding(List<Segment> segments, Segment lineSegment) {
+        int index = segments.indexOf(lineSegment);
+        return segments.get(index - 1);
+    }
+
     private void assertSegment(Segment segment, SegmentType segmentType, double x, double y) {
         assertEquals(segmentType, segment.getType());
         assertEquals(x, segment.getPoint().getX(), 0.01);