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Invalid File error if too many polygons are loaded
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Description

Cura LE Version: 3.6.3

Operating System: Windows 10 (fully patched) 64-bit with 32Gb or RAM

Printer: Taz 6

Tool Head: Using SL 0.25mm nozzle but it is not tied to nozzle size.

Description of issue: There seems to be a memory issue where if a model has too many polygons it will just not load and give an "Invalid File" error. The problem seems to be somehow tied to the total number of polygons loaded since Cura was started. Even if a model will load properly once all I have to do is clear the build plate and repeat (with the same model) and eventually I will get told it is an "Invalid File". This may be a known issue but searching here for "Invalid File" gave a ton of results that didn't seem to fit this bill (although I didn't check every one of them).

Steps to reproduce: Using the model p1stl.stl from https://www.thingiverse.com/thing:3479423 (I'll also upload the model) start Cura load the model, clear the build plate, reload model, clear build plate etc. Usually at the 4th load I will get the "Invalid File" error although a couple of times I got in on the 5th load. Note that I am submitted this on my office computer (with no printer attached) but the same issue will arise at home regardless of whether my printer is attached or not (I usually have it attached to a Raspberry pi and print from that).

Upload cura-lulzbot.log (attachment) :

Model used in reproducing the error (can also be found at Thingiverse link above) :

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Event Timeline

pfenrir created this task.May 9 2019, 7:31 AM
karrad assigned this task to Yahuba.May 9 2019, 12:56 PM
karrad triaged this task as Normal priority.
karrad moved this task from Restricted Project Column to Restricted Project Column on the Restricted Project board.
karrad added subscribers: Yahuba, karrad.

@Yahuba Can you try to duplicate on Win 10 with the above file?

karrad changed the edit policy from "Custom Policy" to "Restricted Project (Project)".May 9 2019, 12:56 PM
Yahuba added a comment.May 9 2019, 2:00 PM

I was just able to reproduce this in 3.6.8 as well on my Windows 10 machine using the same file. Took me 4 or 5 attempts as well.

karrad added a comment.May 9 2019, 2:01 PM

@Yahuba Thanks, can you post the error log as well?

Yahuba added a comment.May 9 2019, 2:05 PM

@karrad

karrad reassigned this task from Yahuba to victor_larchenko.May 9 2019, 2:08 PM
karrad added subscribers: victor_larchenko, alexei.

@Yahuba Thank you much! Looks like the log is showing a memory error.

@victor_larchenko @alexei Not sure what can be done here, but it may be another reason for a 64bit build?

Thank you for looking into this. I was hoping it would be something "simple" like clearing memory after a model is unloaded. While I obviously don't have a vote on what you do I'd love to see a 64-bit build. I slice/print a ton of miniatures and depending on the artist/model I end up restarting Cura every 1-6 models. Get's kind of annoying. On a side note that 0.25mm nozzle you released a while back is amazing! Don't quite get resin quality on the miniatures (supports still leave to much junk on the model) but the quality is close enough that I've shelved the idea of picking up a resin printer...

One "fix" - although not a real fix is to load the model into something like Blender and use that to reduce the number of polygons in the model. I've not done that for the example I sent you but I've got a couple (could probably track at least one done again) where the only way I could get it to load (even the first time) was to greatly reduce the polygon count on the model. As I said, not really a fix but it will at least allow models to load the first time if needed.

Thanks again for looking into this!

karrad added a comment.May 9 2019, 3:40 PM

@pfenrir Not a problem, and thank you for the report! You are set up as a follower on this ticket, and will get updates as they happen. While we dig into this, please let us know if you run into any other issues.

P.S. We automatically sync our latest builds to our development site, and if you are up to trying newer versions you can find them here: http://devel.lulzbot.com/software/cura-lulzbot/

victor_larchenko added a comment.EditedMay 10 2019, 3:39 AM

@karrad Cura using this memory to hold models for Undo\Redo can work. We can add a menu row to clear actions history and free this memory. But it won't solve issue with models that have polygons over 1.5Gb in loaded state.

@pfenrir We are going to be digging into a 64bit build, unfortunately no ETA as of yet. You can follow along with the ticket here if you would like T7220

karrad removed victor_larchenko as the assignee of this task.May 10 2019, 3:48 PM

@victor_larchenko We are going to pursue the 64bit build for this issue, going to un-assign for now. We will leave this open for now to verify the fix once available.