Pcbnew, export Solder masks in Gerber Format: fix not working export when the solder mask minimal width is not 0 (the exported shapes were the same as if the vule = 0) with boost version >= 1.56

This is due to the fact the boost::pylygon function resize ( a inflate/deflate function) used for calculations does not work with boost version >= 1.56.
Use Clipper  inflate/deflate function instead. It is faster and works fine.

pcbnew/board_items_to_polygon_shape_transform.cpp

@@ -580,7 +580,10 @@ void D_PAD:: TransformShapeWithClearanceToPolygon( CPOLYGONS_LIST& aCornerBuffer
         ClipperLib::Paths shapeWithClearance;
 
         for( int ii = 0; ii < 4; ii++ )
+        {
+            corners[ii] += PadShapePos;
             outline << ClipperLib::IntPoint( corners[ii].x, corners[ii].y );
+        }
 
         ClipperLib::ClipperOffset offset_engine;
         // Prepare an offset (inflate) transform, with edges connected by arcs
@@ -600,19 +603,7 @@ void D_PAD:: TransformShapeWithClearanceToPolygon( CPOLYGONS_LIST& aCornerBuffer
         offset_engine.Execute( shapeWithClearance, rounding_radius );
 
         // get new outline (only one polygon is expected)
-        // For info, ClipperLib uses long long to handle integer coordinates
-        ClipperLib::Path& polygon = shapeWithClearance[0];
-
-        for( unsigned jj = 0; jj < polygon.size(); jj++ )
-        {
-            corner_position.x = int( polygon[jj].X );
-            corner_position.y = int( polygon[jj].Y );
-            corner_position += PadShapePos;
-            CPolyPt polypoint( corner_position.x, corner_position.y );
-            aCornerBuffer.Append( polypoint );
-        }
-
-        aCornerBuffer.CloseLastContour();
+        aCornerBuffer.ImportFrom( shapeWithClearance );
     }
         break;
     }

pcbnew/class_zone.cpp

@@ -898,3 +898,14 @@ wxString ZONE_CONTAINER::GetSelectMenuText() const
 
     return msg;
 }
+
+
+/* Copy polygons stored in aKiPolyList to m_FilledPolysList
+ * The previous m_FilledPolysList contents is replaced.
+ */
+void ZONE_CONTAINER::CopyPolygonsFromClipperPathsToFilledPolysList(
+                            ClipperLib::Paths& aClipperPolyList )
+{
+    m_FilledPolysList.RemoveAllContours();
+    m_FilledPolysList.ImportFrom( aClipperPolyList );
+}

pcbnew/class_zone.h

@@ -305,6 +305,14 @@ public:
      */
     void CopyPolygonsFromKiPolygonListToFilledPolysList( KI_POLYGON_SET& aKiPolyList );
 
+    /**
+     * Function CopyPolygonsFromClipperPathsToFilledPolysList
+     * Copy polygons stored in aKiPolyList to m_FilledPolysList
+     * The previous m_FilledPolysList contents is replaced.
+     * @param aClipperPolyList = a ClipperLib::Paths containing polygons.
+     */
+    void CopyPolygonsFromClipperPathsToFilledPolysList( ClipperLib::Paths& aClipperPolyList );
+
     /**
      * Function CopyPolygonsFromFilledPolysListToKiPolygonList
      * Copy polygons from m_FilledPolysList to aKiPolyList

pcbnew/event_handlers_tracks_vias_sizes.cpp

@@ -41,9 +41,7 @@
 #include <class_module.h>
 
 
-/**
- * Function Tracks_and_Vias_Size_Event
- * Event handler for tracks and vias size selection (and some options)
+/* Event handler for tracks and vias size selection (and some options)
  * relative to toolbars and popup events
  */
 void PCB_EDIT_FRAME::Tracks_and_Vias_Size_Event( wxCommandEvent& event )
@@ -51,11 +49,11 @@ void PCB_EDIT_FRAME::Tracks_and_Vias_Size_Event( wxCommandEvent& event )
     int ii;
     int id = event.GetId();
 
-/* Note: none of these events require aborting the current command (if any)
- * (like move, edit or block command)
- * so we do not test for a current command in progress and call
- *  m_canvas->m_endMouseCaptureCallback( m_canvas, &dc );
- */
+    /* Note: none of these events require aborting the current command (if any)
+     * (like move, edit or block command)
+     * so we do not test for a current command in progress and call
+     *  m_canvas->m_endMouseCaptureCallback( m_canvas, &dc );
+     */
     switch( id )
     {
     case ID_AUX_TOOLBAR_PCB_SELECT_AUTO_WIDTH:
@@ -142,5 +140,7 @@ void PCB_EDIT_FRAME::Tracks_and_Vias_Size_Event( wxCommandEvent& event )
     }*/
     //+hp
     //Refresh canvas, that we can see changes instantly. I use this because it dont,t throw  mouse up-left corner.
-    m_canvas->Refresh();
+
+    if( m_canvas->IsMouseCaptured() )
+        m_canvas->Refresh();
 }

pcbnew/plot_board_layers.cpp

@@ -773,12 +773,25 @@ void PlotSolderMaskLayer( BOARD *aBoard, PLOTTER* aPlotter,
 
         zone->TransformOutlinesShapeWithClearanceToPolygon( bufferPolys,
                     inflate, true );
+        zone->TransformOutlinesShapeWithClearanceToPolygon( initialPolys,
+                    0, true );
     }
 
+    // To avoid a lot of code, use a ZONE_CONTAINER
+    // to handle and plot polygons, because our polygons look exactly like
+    // filled areas in zones
+    // Note, also this code is not optimized: it creates a lot of copy/duplicate data
+    // However it is not complex, and fast enough for plot purposes (copy/convert data
+    // is only a very small calculation time for these calculations)
+    ZONE_CONTAINER zone( aBoard );
+    zone.SetArcSegmentCount( 32 );
+    zone.SetMinThickness( 0 );      // trace polygons only
+    zone.SetLayer ( layer );
+
     // Now:
-    // 1 - merge areas which are intersecting, i.e. remove gaps
+    // 1 - merge polygons which are intersecting, i.e. remove gaps
     //     having a thickness < aMinThickness
-    // 2 - deflate resulting areas by aMinThickness/2
+    // 2 - deflate resulting polygons by aMinThickness/2
     KI_POLYGON_SET areasToMerge;
     bufferPolys.ExportTo( areasToMerge );
     KI_POLYGON_SET initialAreas;
@@ -788,29 +801,44 @@ void PlotSolderMaskLayer( BOARD *aBoard, PLOTTER* aPlotter,
     // = aMinThickness/2, shapes too close ( dist < aMinThickness )
     // will be merged, because they are overlapping
     KI_POLYGON_SET areas;
-    areas |= areasToMerge;
+    areas |= areasToMerge;      // Populates with merged polygons
 
     // Deflate: remove the extra margin, to create the actual shapes
     // Here I am using polygon:resize, because this function creates better shapes
     // than deflate algo.
-    // Use here deflate with arc creation and 18 segments per circle to create arcs
-    // In boost polygon (at least v 1.54 and previous) in very rare cases resize crashes
-    // with 16 segments (perhaps related to 45 degrees pads). So using 18 segments
-    // is a workaround to try to avoid these crashes
-    areas = resize( areas, -inflate , true, 18 );
+    // Use here deflate made by Clipper, because:
+    // Clipper is (by far) faster and better, event using arcs to deflate shapes
+    // boost::polygon < 1.56 polygon resize function sometimes crashes when deflating using arcs
+    // boost::polygon >=1.56 polygon resize function just does not work
+    // Note also we combine polygons using boost::polygon, which works better than Clipper,
+    // especially with zones using holes linked to main outlines by overlapping segments
+    CPOLYGONS_LIST tmp;
+    tmp.ImportFrom( areas );
 
-    // Resize slightly changes shapes. So *ensure* initial shapes are kept
+    // Deflate area using Clipper, better than boost::polygon
+    ClipperLib::Paths areasDeflate;
+    tmp.ExportTo( areasDeflate );
+
+    // Deflate areas: they will have the right size after deflate
+    ClipperLib::ClipperOffset offset_engine;
+    circleToSegmentsCount = 16;
+    offset_engine.ArcTolerance = (double)inflate / 3.14 / circleToSegmentsCount;
+    offset_engine.AddPaths( areasDeflate, ClipperLib::jtRound, ClipperLib::etClosedPolygon );
+    offset_engine.Execute( areasDeflate, -inflate );
+
+    // Combine the current areas to initial areas. This is mandatory because
+    // inflate/deflate transform is not perfect, and we want the initial areas perfectly kept
+    tmp.RemoveAllContours();
+    tmp.ImportFrom( areasDeflate );
+    areas.clear();
+    tmp.ExportTo( areas );
+
+    // Resize slightly changes shapes (the transform is not perfect).
+    // So *ensure* initial shapes are kept
     areas |= initialAreas;
 
-    // To avoid a lot of code, use a ZONE_CONTAINER
-    // to plot polygons, because they are exactly like
-    // filled areas in zones
-    ZONE_CONTAINER zone( aBoard );
-    zone.SetArcSegmentCount( 32 );
-    zone.SetMinThickness( 0 );      // trace polygons only
-    zone.SetLayer ( layer );
-
     zone.CopyPolygonsFromKiPolygonListToFilledPolysList( areas );
+
     itemplotter.PlotFilledAreas( &zone );
 }