Dense infill does not function propertly and BREAKS the workaround to fix it

[nerys]

OK simplify 3d has had a bug since day 1. it loves printing in "mid air" when it should easily be smart enough to not do this.

see my pictures and factory file. if you try to print a cylinder on top of a cube it does NOT print a solid layer between the two objects which is NEEDED when using "low infill" settings.

S3D's answer was to use more infill which is just dumb as it wastes time and plastic for models that do not require this.

the only real solution was to use multi process to FORCE it to print a solid layer at the interface. and even that can require work arounds to forces s3d to do what you want.

now we have dense infill. PERFECT exactly what we need. it seems the "interface" and increases the infill density as I define it. SO PERFECT. except..... it completely fails. IT LEAVES THE STINKING HOLE !!!! the one thing it needs to remove (the hole) it refuses to remove !!! and now the normal work around ALSO fails (create 3 solid layers but now it prints 1 solid 1 fill 1 solid BREAKING the work around)

the "dense infill" needs to cross THE ENTIRE PLANAR SURFACE !!!! filling the "hole" at the interface "IS" the reason to use this feature.

which I can use annoying wasteful multi process to fix this on SIMPLE models. just you TRY and do this on a complex numbers model say with "stair steps" that would require you do this is dozens or more times to where you finally give up and BLOW kilo's of plastic to just increase the infill all over to avoid failures.

File 0 is the object in question.

File 01 is what S3d DOES (wrong. it LEAVES the stinking HOLE in the center)

File 02 is what is "SHOULD" do (in reality this should create the NUMBER of dense layers I specify before and AFTER the interface PLUS the number of layers for top and bottom. SO if I specify 3 dense layers on a model with 3 top and bottom layers it should create 9 dense layers. 3 before 3 during and 3 after the inferface for maximum integrity and minumum filament usage.

you need a solid monolith structure to transition or the part is weak at the interface

When I use solid diaphram and process trick to add 3 solid layers instead of does what you see in image 4

it makes 1 solid one with a hole and another solid. Grrrr WTAF is up with that??

PLEASE FIX this setting could SO easily fix this problem ENTIRELY if it did not leave the HOLE in the dense layers.

[nerys]

it would not let me add the 4th image so its here in the reply. also won't let me attach the factory file ???

[S3D-Jason]

There is a new option in V5 that might help with this. By default, the software will only add solid layers when it is near the outer boundary of your part. If you look at the bottom center of your cylindrical peg, there is a long distance between that local and the outer surface of the part, so it doesn't get solid fill. However, that behavior can now be modified in V5. Go to the Infill tab and increase the Solid Infill Extra Expansion to something in the range of 5-10mm. Now the software will expand the solid infill to completely fill the space between the cylinder and the cube.

[wirlybird]

I just tried the solid infill extra expansion! This is a great one and really needed.

I have a test model I use that is similar to the one in the post and it worked excellent.

[nerys]

There is a new option in V5 that might help with this. By default, the software will only add solid layers when it is near the outer boundary of your part. If you look at the bottom center of your cylindrical peg, there is a long distance between that local and the outer surface of the part, so it doesn't get solid fill. However, that behavior can now be modified in V5. Go to the Infill tab and increase the Solid Infill Extra Expansion to something in the range of 5-10mm. Now the software will expand the solid infill to completely fill the space between the cylinder and the cube.


Cylinder-Solid-Infill-Expansion.png

Duuuuuuuddddeeee !!!! you freaking rock that works PERFECTLY. I just set it to 500mm to make sure the layer is solid. for HUGE models it will also be nice to set it to something lower (just to reach the next infill line) and now the DENSE INFILL setting now ALSO works correctly !!!

so now if I do 5% infill then 25% dense for 4 layers and set the thresh to 500mm I get 5% then 4 SOLID layers of 25% then the proper 3 SOLID 100% layers then the rest of the model! !!!! EXACTLY as it should be. you are awesome!!

[S3D-Jason]

Yeah this was one of the 120 features that didn't even make it onto the main webpage for V5. There are lot of other small features like this that we think are really nice, but there just wasn't enough room to talk about everything.

If you want to see the reallllly long list of changes for V5, the whole list can be found here:
https://www.simplify3d.com/products/sim ... ase-notes/