feat(engine): wire the per-filament volume-map producer pipeline

- Print::update_filament_maps_to_config takes filament/volume/nozzle
  maps, backfills an empty volume map from extruder types, rebuilds
  filament_map_2, re-expands the per-filament variant arrays, and
  recomputes retract overrides keyed by resolved slots
- grouping writes its result back in every non-sequential mode;
  manual multi-nozzle grouping validates the user mapping and raises a
  translatable error on deviation; the engine's concrete volume
  assignment is deliberately not merged yet (per-filament arrays are
  already consumed by filament id, so materializing High Flow now
  would change motion before the layer-aware resolvers land)
- Print::apply treats the three map keys as engine outputs in auto
  modes (erased from the diff and adopted), compares them against used
  filaments in manual mode, and keeps the pre-expansion snapshot in
  sync with the late normalization pass so rebuilt headers reflect the
  sliced state instead of resurrecting stale values
- volume/nozzle maps and extruder_nozzle_stats join the invalidation
  group of filament_map (wipe tower + skirt/brim)
- PresetBundle composes full configs with an optional per-filament
  volume map (plate map, else defaults derived from each extruder's
  flow type); project config keeps the map sized across filament
  count changes
- PartPlate stores per-plate volume/nozzle maps; Plater injects them
  at every slice-composition site (incl. g-code reload and wipe-tower
  estimation); BackgroundSlicingProcess reads engine results back to
  the plate in auto modes
- per-filament map trust guards relaxed to size-match everywhere now
  that every producer sizes the map; single-filament explicit flow
  assignments are honored
- tests: grouping volume maps stay concrete, merge semantics of
  update_used_filament_values, single-filament override honoring

Motion g-code is byte-identical fleet-wide including Hybrid projects
(19-fixture gate + repro determinism double-slice). Header deltas:
the map keys now dump real values, and stale pre-normalization values
(e.g. enable_prime_tower on single-used-filament prints) no longer
leak into the config block.

src/libslic3r/Format/bbs_3mf.cpp

@@ -4512,8 +4512,10 @@ void PlateData::parse_filament_info(GCodeProcessorResult *result)
                 if (m_curr_plater){
                     auto filament_volume_map = get_vector_from_string(value);
                     for (size_t idx = 0; idx < filament_volume_map.size(); ++idx) {
-                        // Only Standard(0)/High Flow(1) are currently supported; clamp any higher
-                        // volume-type (TPU High Flow/Hybrid) back to Standard until they are wired in.
+                        // The map feeds per-filament slot resolution and grouping. Clamp any
+                        // higher volume-type back to Standard(0) on load: Hybrid(2) is only an
+                        // in-memory grouping seed that is never persisted, and TPU High Flow(3)
+                        // is clamped with the same information loss on every load.
                         if (filament_volume_map[idx] > 1) {
                             filament_volume_map[idx] = 0;
                         }

src/libslic3r/GCode/ToolOrdering.cpp

@@ -1332,12 +1332,12 @@ static FilamentGroupContext build_filament_group_context(
     context.group_info.has_filament_switcher = has_filament_switcher;
 
     // hybrid flow means no special per-filament nozzle-volume request.
-    // Orca: in manual mode the config's per-filament volume map is honoured only when a producer
-    // sized it to a multi-filament count (the trust guard used by
-    // update_values_to_printer_extruders_for_multiple_filaments): the registered default is a
-    // 1-element vector ({Standard}) that a single-filament count cannot tell apart from a real
-    // map, and it must not displace the hybrid fallback rebuild_nozzle_unprintables relies on.
-    if (mode == FilamentMapMode::fmmManual && filament_nums > 1 &&
+    // Orca: honour the config's per-filament volume map only when it is sized to the filament
+    // count. The full-config producers (PresetBundle injection, engine write-back) always size
+    // it; a mis-sized map (stale project value, CLI runs until the per-filament synthesis lands
+    // there) must not displace the hybrid fallback rebuild_nozzle_unprintables relies on, nor be
+    // indexed out of bounds.
+    if (mode == FilamentMapMode::fmmManual &&
         print_config.filament_volume_map.values.size() == filament_nums)
         context.group_info.filament_volume_map = print_config.filament_volume_map.values;
     else
@@ -1487,12 +1487,12 @@ MultiNozzleUtils::LayeredNozzleGroupResult ToolOrdering::get_recommended_filamen
         std::transform(manual_filament_map.begin(), manual_filament_map.end(), manual_filament_map.begin(), [](int v) { return v - 1; });
         float diameter = print_config.nozzle_diameter.values.empty() ? 0.4f : (float)print_config.nozzle_diameter.values.front();
         // Orca: create() indexes the volume/nozzle maps per used filament with no bounds check, so
-        // pass them only when a producer sized them to a multi-filament count — the registered
-        // 1-element defaults are indistinguishable by size from a real single-filament map.
+        // pass them only when a producer sized them to the filament count (mis-sized maps can
+        // arrive from stale projects or CLI runs until the per-filament synthesis lands there).
         // Without valid maps the fully-manual request cannot be honoured; return the empty result,
         // the same failure an unsatisfiable create() yields.
         std::optional<LayeredNozzleGroupResult> nozzle_result;
-        if (filament_nums > 1 && print_config.filament_volume_map.values.size() == filament_nums &&
+        if (print_config.filament_volume_map.values.size() == filament_nums &&
             print_config.filament_nozzle_map.values.size() == filament_nums)
             nozzle_result = LayeredNozzleGroupResult::create(used_filaments, manual_filament_map, print_config.filament_volume_map.values, print_config.filament_nozzle_map.values, get_extruder_nozzle_stats(print_config.extruder_nozzle_stats.values), diameter);
         if (!nozzle_result)
@@ -1556,7 +1556,21 @@ MultiNozzleUtils::LayeredNozzleGroupResult ToolOrdering::get_recommended_filamen
 
         if (has_multiple_nozzle) {
             auto result_opt = LayeredNozzleGroupResult::create(ret, context.nozzle_info.nozzle_list, used_filaments);
-            return result_opt ? *result_opt : LayeredNozzleGroupResult();
+            if (!result_opt)
+                return LayeredNozzleGroupResult();
+            auto result = *result_opt;
+            if (mode == FilamentMapMode::fmmManual) {
+                // Manual grouping must reproduce the user's filament->extruder map exactly; a
+                // deviation means the requested assignment cannot be satisfied by the nozzle
+                // inventory, which must surface as a slicing error instead of silently regrouping.
+                auto result_map = result.get_extruder_map();
+                for (auto fid : used_filaments) {
+                    if (result_map[fid] != print_config.filament_map.values[fid] - 1) {
+                        throw Slic3r::RuntimeError(_L("Group error in manual mode. Please check nozzle count or regroup."));
+                    }
+                }
+            }
+            return result;
         }
     }
 
@@ -1617,11 +1631,11 @@ static MultiNozzleUtils::LayeredNozzleGroupResult build_group_result_from_map(
     const size_t filament_nums = print_config.filament_colour.values.size();
     const bool   has_multiple_nozzle = std::any_of(print_config.extruder_max_nozzle_count.values.begin(), print_config.extruder_max_nozzle_count.values.end(),
                                                    [](int v) { return v > 1; });
-    // Orca: same trust guard as the manual grouping paths — create() indexes the volume/nozzle
-    // maps per used filament with no bounds check, and the registered 1-element defaults must not
-    // be mistaken for a real single-filament map. Unsized maps fall through to the extruder-level
-    // wrap below.
-    if (has_multiple_nozzle && filament_nums > 1 &&
+    // Orca: same sizing guard as the manual grouping paths — create() indexes the volume/nozzle
+    // maps per used filament with no bounds check, so only maps sized to the filament count are
+    // trusted (mis-sized maps can arrive from stale projects or CLI runs until the per-filament
+    // synthesis lands there). Unsized maps fall through to the extruder-level wrap below.
+    if (has_multiple_nozzle &&
         print_config.filament_volume_map.values.size() == filament_nums &&
         print_config.filament_nozzle_map.values.size() == filament_nums) {
         float diameter = print_config.nozzle_diameter.values.empty() ? 0.4f : static_cast<float>(print_config.nozzle_diameter.values.front());
@@ -2042,8 +2056,10 @@ void ToolOrdering::reorder_extruders_for_minimum_flush_volume(bool reorder_first
         auto result   = MultiNozzleUtils::LayeredNozzleGroupResult::create(nozzle_map_per_layer, grouping_context.nozzle_info.nozzle_list, used_filaments, filament_sequences);
         grouping_result = result ? *result : MultiNozzleUtils::LayeredNozzleGroupResult();
 
-        // Derive the extruder-level map (0-based) for the stats path + config write-back. The full
-        // per-nozzle config write-back is not yet wired.
+        // Derive the extruder-level map for the stats path + config write-back.
+        // Orca: the dynamic (per-layer) result carries no single volume/nozzle map, so only the
+        // extruder map is written back here; the full per-nozzle config write-back
+        // (a dedicated dynamic-map path) is a follow-up behind the dev flag.
         std::vector<int> derived_maps = grouping_result.get_extruder_map(false); // 1-based
         if (!derived_maps.empty()) {
             filament_maps = derived_maps;
@@ -2060,11 +2076,34 @@ void ToolOrdering::reorder_extruders_for_minimum_flush_volume(bool reorder_first
             if (derived_maps.empty())
                 return;
             filament_maps = derived_maps;
-            m_print->update_filament_maps_to_config(filament_maps);
         } else if (!derived_maps.empty()) {
             // Manual modes: the result mirrors the user's config map; adopt it for consistency.
             filament_maps = derived_maps;
         }
+        // Write the maps back for every mode: used filaments adopt the engine's extruder/nozzle
+        // choice, unused ones keep their config assignment. In manual modes the extruder map
+        // mirrors the user's map (a deviation throws in get_recommended_filament_maps).
+        if (!derived_maps.empty()) {
+            // Orca: the config maps are the merge base; fall back to a synthesized base when no
+            // producer sized them to the filament count (CLI runs until the per-filament
+            // synthesis lands there), where indexing per filament would run out of bounds.
+            std::vector<int> base_filament_map = print_config->filament_map.values;
+            if (base_filament_map.size() != derived_maps.size())
+                base_filament_map.assign(derived_maps.size(), 1);
+            std::vector<int> base_volume_map = print_config->filament_volume_map.values;
+            if (base_volume_map.size() != derived_maps.size())
+                base_volume_map.assign(derived_maps.size(), (int)nvtStandard);
+            // Orca: the engine's concrete per-filament volume assignment (get_volume_map()) is
+            // deliberately NOT merged into the write-back yet. The write-back re-expands the
+            // per-filament filament_* arrays from these maps, and those arrays are already
+            // consumed by filament id, so materializing a High Flow assignment here would alter
+            // motion g-code before the layer-aware g-code resolvers consume the assignment.
+            // Until those consumers land, the config keeps its own (GUI-injected or project)
+            // volume map, size-corrected above.
+            m_print->update_filament_maps_to_config(FilamentGroupUtils::update_used_filament_values(base_filament_map, derived_maps, used_filaments),
+                                                    base_volume_map,
+                                                    grouping_result.get_nozzle_map());
+        }
         std::transform(filament_maps.begin(), filament_maps.end(), filament_maps.begin(), [](int value) { return value - 1; });
 
         if (m_print->is_BBL_printer())

src/libslic3r/PresetBundle.cpp

@@ -58,6 +58,9 @@ static std::vector<std::string> s_project_options {
     "nozzle_volume_type",
     "filament_map_mode",
     "filament_map",
+    // Per-filament nozzle-volume choice; project-level like filament_map so the per-filament
+    // slot resolution survives preset switches.
+    "filament_volume_map",
     // Filament Track Switch device state: whether the switch is installed and ready, and
     // whether dynamic per-nozzle filament mapping is active. Persisted with the project and
     // restored from a saved 3mf; reset to false on load and set true only by live device sync.
@@ -79,7 +82,8 @@ DynamicPrintConfig PresetBundle::construct_full_config(
     const DynamicPrintConfig& project_config,
     std::vector<Preset>& in_filament_presets,
     bool apply_extruder,
-    std::optional<std::vector<int>> filament_maps_new)
+    std::optional<std::vector<int>> filament_maps_new,
+    std::optional<std::vector<int>> filament_volume_maps_new)
 {
     DynamicPrintConfig &printer_config = in_printer_preset.config;
     DynamicPrintConfig &print_config   = in_print_preset.config;
@@ -94,12 +98,23 @@ DynamicPrintConfig PresetBundle::construct_full_config(
     size_t num_filaments = in_filament_presets.size();
 
     std::vector<int> filament_maps = out.option<ConfigOptionInts>("filament_map")->values;
+    std::vector<int> filament_volume_maps(num_filaments, (int)nvtStandard);
+
+    ConfigOptionInts* filament_volume_map_opt = out.option<ConfigOptionInts>("filament_volume_map");
     if (filament_maps_new.has_value())
         filament_maps = *filament_maps_new;
+    if (filament_volume_maps_new.has_value())
+        filament_volume_maps = *filament_volume_maps_new;
+    else if (filament_volume_map_opt && filament_volume_map_opt->values.size() == num_filaments)
+        filament_volume_maps = filament_volume_map_opt->values;
+
     // in some middle state, they may be different
     if (filament_maps.size() != num_filaments) {
         filament_maps.resize(num_filaments, 1);
     }
+    if (filament_volume_maps.size() != num_filaments) {
+        filament_volume_maps.resize(num_filaments, nvtStandard);
+    }
 
     auto *extruder_diameter = dynamic_cast<const ConfigOptionFloats *>(out.option("nozzle_diameter"));
     // Collect the "compatible_printers_condition" and "inherits" values over all presets (print, filaments, printers) into a single vector.
@@ -147,7 +162,7 @@ DynamicPrintConfig PresetBundle::construct_full_config(
         // BBS: update filament config related with variants
         DynamicPrintConfig filament_config = in_filament_presets[0].config;
         if (apply_extruder && ((extruder_count > 1) || different_extruder))
-            filament_config.update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[0]);
+            filament_config.update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[0], (NozzleVolumeType)filament_volume_maps[0]);
         out.apply(filament_config);
         compatible_printers_condition.emplace_back(in_filament_presets[0].compatible_printers_condition());
         compatible_prints_condition.emplace_back(in_filament_presets[0].compatible_prints_condition());
@@ -171,7 +186,7 @@ DynamicPrintConfig PresetBundle::construct_full_config(
         for (size_t i = 0; i < num_filaments; ++i) {
             filament_temp_configs[i] = *(filament_configs[i]);
             if (apply_extruder && ((extruder_count > 1) || different_extruder))
-                filament_temp_configs[i].update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[i]);
+                filament_temp_configs[i].update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[i], (NozzleVolumeType)filament_volume_maps[i]);
         }
 
         // loop through options and apply them to the resulting config.
@@ -246,6 +261,7 @@ DynamicPrintConfig PresetBundle::construct_full_config(
     out.option<ConfigOptionString>("printer_settings_id", true)->value    = in_printer_preset.name;
     out.option<ConfigOptionStrings>("filament_ids", true)->values         = filament_ids;
     out.option<ConfigOptionInts>("filament_map", true)->values            = filament_maps;
+    out.option<ConfigOptionInts>("filament_volume_map", true)->values     = filament_volume_maps;
 
     auto add_if_some_non_empty = [&out](std::vector<std::string> &&values, const std::string &key) {
         bool nonempty = false;
@@ -2701,6 +2717,9 @@ void PresetBundle::update_selections(AppConfig &config)
     std::vector<int> filament_maps(filament_colors.size(), 1);
     project_config.option<ConfigOptionInts>("filament_map")->values = filament_maps;
 
+    std::vector<int> filament_volume_maps(filament_colors.size(), static_cast<int>(NozzleVolumeType::nvtStandard));
+    project_config.option<ConfigOptionInts>("filament_volume_map")->values = filament_volume_maps;
+
     std::vector<std::string> extruder_ams_count_str;
     if (config.has_printer_setting(initial_printer_profile_name, "extruder_ams_count")) {
         boost::algorithm::split(extruder_ams_count_str, config.get_printer_setting(initial_printer_profile_name, "extruder_ams_count"), boost::algorithm::is_any_of(","));
@@ -2845,6 +2864,9 @@ void PresetBundle::load_selections(AppConfig &config, const PresetPreferences& p
     std::vector<int> filament_maps(filament_colors.size(), 1);
     project_config.option<ConfigOptionInts>("filament_map")->values = filament_maps;
 
+    std::vector<int> filament_volume_maps(filament_colors.size(), static_cast<int>(NozzleVolumeType::nvtStandard));
+    project_config.option<ConfigOptionInts>("filament_volume_map")->values = filament_volume_maps;
+
     std::vector<std::string> extruder_ams_count_str;
     if (config.has_printer_setting(initial_printer_profile_name, "extruder_ams_count")) {
         boost::algorithm::split(extruder_ams_count_str, config.get_printer_setting(initial_printer_profile_name, "extruder_ams_count"), boost::algorithm::is_any_of(","));
@@ -3021,7 +3043,7 @@ void PresetBundle::set_num_filaments(unsigned int n, std::vector<std::string> ne
     ConfigOptionStrings *filament_multi_color = project_config.option<ConfigOptionStrings>("filament_multi_colour");
     ConfigOptionStrings* filament_color_type = project_config.option<ConfigOptionStrings>("filament_colour_type");
     ConfigOptionInts* filament_map = project_config.option<ConfigOptionInts>("filament_map");
-
+    ConfigOptionInts* filament_volume_map = project_config.option<ConfigOptionInts>("filament_volume_map");
 
     filament_color->resize(n);
     // Sync filament multi colour
@@ -3031,6 +3053,7 @@ void PresetBundle::set_num_filaments(unsigned int n, std::vector<std::string> ne
     }
     filament_color_type->resize(n);
     filament_map->values.resize(n, 1);
+    filament_volume_map->values.resize(n, static_cast<int>(NozzleVolumeType::nvtStandard));
     ams_multi_color_filment.resize(n);
 
     // BBS set new filament color to new_color
@@ -3058,7 +3081,7 @@ void PresetBundle::set_num_filaments(unsigned int n, std::string new_color)
     ConfigOptionStrings *filament_multi_color = project_config.option<ConfigOptionStrings>("filament_multi_colour");
     ConfigOptionStrings* filament_color_type = project_config.option<ConfigOptionStrings>("filament_colour_type");
     ConfigOptionInts* filament_map = project_config.option<ConfigOptionInts>("filament_map");
-
+    ConfigOptionInts* filament_volume_map = project_config.option<ConfigOptionInts>("filament_volume_map");
 
     filament_color->resize(n);
     // Sync filament multi colour
@@ -3068,6 +3091,7 @@ void PresetBundle::set_num_filaments(unsigned int n, std::string new_color)
     }
     filament_color_type->resize(n);
     filament_map->values.resize(n, 1);
+    filament_volume_map->values.resize(n, static_cast<int>(NozzleVolumeType::nvtStandard));
     ams_multi_color_filment.resize(n);
 
     //BBS set new filament color to new_color
@@ -3108,15 +3132,20 @@ void PresetBundle::update_num_filaments(unsigned int to_del_flament_id)
     ConfigOptionStrings *filament_multi_color = project_config.option<ConfigOptionStrings>("filament_multi_colour");
     ConfigOptionStrings *filament_color_type  = project_config.option<ConfigOptionStrings>("filament_colour_type");
     ConfigOptionInts* filament_map = project_config.option<ConfigOptionInts>("filament_map");
+    ConfigOptionInts* filament_volume_map = project_config.option<ConfigOptionInts>("filament_volume_map");
     if (filament_color->values.size() > to_del_flament_id) {
         filament_color->values.erase(filament_color->values.begin() + to_del_flament_id);
         if (filament_map->values.size() > to_del_flament_id) {
             filament_map->values.erase(filament_map->values.begin() + to_del_flament_id);
         }
+        if (filament_volume_map->values.size() > to_del_flament_id) {
+            filament_volume_map->values.erase(filament_volume_map->values.begin() + to_del_flament_id);
+        }
     }
     else {
         filament_color->values.resize(to_del_flament_id);
         filament_map->values.resize(to_del_flament_id, 1);
+        filament_volume_map->values.resize(to_del_flament_id, static_cast<int>(NozzleVolumeType::nvtStandard));
     }
 
     // lambda function to erase or resize the container
@@ -3339,6 +3368,7 @@ unsigned int PresetBundle::sync_ams_list(std::vector<std::pair<DynamicPrintConfi
     ConfigOptionStrings *filament_color = project_config.option<ConfigOptionStrings>("filament_colour");
     ConfigOptionStrings *filament_color_type = project_config.option<ConfigOptionStrings>("filament_colour_type");
     ConfigOptionInts *   filament_map = project_config.option<ConfigOptionInts>("filament_map");
+    ConfigOptionInts *   filament_volume_map = project_config.option<ConfigOptionInts>("filament_volume_map");
     if (color_only) {
         auto get_map_index = [&ams_infos](const std::vector<AMSMapInfo> &infos, const AMSMapInfo &temp) {
             for (int i = 0; i < infos.size(); i++) {
@@ -3520,6 +3550,7 @@ unsigned int PresetBundle::sync_ams_list(std::vector<std::pair<DynamicPrintConfi
         ams_multi_color_filment = exist_multi_color_filment;
         this->filament_presets = exist_filament_presets;
         filament_map->values.resize(exist_filament_presets.size(), 1);
+        filament_volume_map->values.resize(exist_filament_presets.size(), static_cast<int>(NozzleVolumeType::nvtStandard));
     }
     else {//overwrite;
         bool has_placeholders = std::any_of(ams_infos.begin(), ams_infos.end(),
@@ -3574,12 +3605,14 @@ unsigned int PresetBundle::sync_ams_list(std::vector<std::pair<DynamicPrintConfi
             this->filament_presets      = result_presets;
             ams_multi_color_filment     = result_multi_colors;
             filament_map->values.resize(total, 1);
+            filament_volume_map->values.resize(total, static_cast<int>(NozzleVolumeType::nvtStandard));
         } else {
             // BBL: existing wholesale replace
             filament_color->values = ams_filament_colors;
             filament_color_type->values = ams_filament_color_types;
             this->filament_presets = ams_filament_presets;
             filament_map->values.resize(ams_filament_colors.size(), 1);
+            filament_volume_map->values.resize(ams_filament_colors.size(), static_cast<int>(NozzleVolumeType::nvtStandard));
         }
 
         auto& print_config = this->prints.get_edited_preset().config;
@@ -3882,10 +3915,26 @@ bool PresetBundle::support_different_extruders() const
     return supported;
 }
 
-DynamicPrintConfig PresetBundle::full_config(bool apply_extruder, std::optional<std::vector<int>>filament_maps) const
+std::vector<int> PresetBundle::get_default_nozzle_volume_types_for_filaments(std::vector<int>& f_maps)
+{
+    std::vector<int> result;
+    int filament_count = f_maps.size();
+    result.resize(filament_count, static_cast<int>(NozzleVolumeType::nvtStandard));
+
+    auto opt_nozzle_volume_type = dynamic_cast<const ConfigOptionEnumsGeneric*>(this->project_config.option("nozzle_volume_type"));
+    for (int index = 0; index < filament_count; index++)
+    {
+        if (opt_nozzle_volume_type && opt_nozzle_volume_type->values.size() > (f_maps[index] - 1))
+            result[index] = opt_nozzle_volume_type->values[f_maps[index] - 1];
+    }
+
+    return result;
+}
+
+DynamicPrintConfig PresetBundle::full_config(bool apply_extruder, std::optional<std::vector<int>>filament_maps, std::optional<std::vector<int>> filament_volume_maps) const
 {
     return (this->printers.get_edited_preset().printer_technology() == ptFFF) ?
-        this->full_fff_config(apply_extruder, filament_maps) :
+        this->full_fff_config(apply_extruder, filament_maps, filament_volume_maps) :
         this->full_sla_config();
 }
 
@@ -3944,7 +3993,7 @@ const std::set<std::string> ignore_settings_list ={
     "print_settings_id", "filament_settings_id", "printer_settings_id"
 };
 
-DynamicPrintConfig PresetBundle::full_fff_config(bool apply_extruder, std::optional<std::vector<int>> filament_maps_new) const
+DynamicPrintConfig PresetBundle::full_fff_config(bool apply_extruder, std::optional<std::vector<int>> filament_maps_new, std::optional<std::vector<int>> filament_volume_maps_new) const
 {
     DynamicPrintConfig out;
     out.apply(FullPrintConfig::defaults());
@@ -3958,8 +4007,17 @@ DynamicPrintConfig PresetBundle::full_fff_config(bool apply_extruder, std::optio
     size_t  num_filaments = this->filament_presets.size();
 
     std::vector<int> filament_maps = out.option<ConfigOptionInts>("filament_map")->values;
+    std::vector<int> filament_volume_maps(num_filaments, (int)nvtStandard);
+
+    ConfigOptionInts* filament_volume_map_opt = out.option<ConfigOptionInts>("filament_volume_map");
     if (filament_maps_new.has_value())
         filament_maps = *filament_maps_new;
+    if (filament_volume_maps_new.has_value()) {
+        filament_volume_maps = *filament_volume_maps_new;
+        out.option<ConfigOptionInts>("filament_volume_map", true)->values = filament_volume_maps;
+    }
+    else if (filament_volume_map_opt && filament_volume_map_opt->values.size() == num_filaments)
+        filament_volume_maps = filament_volume_map_opt->values;
     //in some middle state, they may be different
     if (filament_maps.size() != num_filaments) {
         filament_maps.resize(num_filaments, 1);
@@ -3967,6 +4025,9 @@ DynamicPrintConfig PresetBundle::full_fff_config(bool apply_extruder, std::optio
     else {
         assert(filament_maps.size() == num_filaments);
     }
+    if (filament_volume_maps.size() != num_filaments) {
+        filament_volume_maps.resize(num_filaments, nvtStandard);
+    }
 
     auto* extruder_diameter = dynamic_cast<const ConfigOptionFloats*>(out.option("nozzle_diameter"));
     // Collect the "compatible_printers_condition" and "inherits" values over all presets (print, filaments, printers) into a single vector.
@@ -4023,7 +4084,7 @@ DynamicPrintConfig PresetBundle::full_fff_config(bool apply_extruder, std::optio
         //BBS: update filament config related with variants
         DynamicPrintConfig filament_config = this->filaments.get_edited_preset().config;
         if (apply_extruder && ((extruder_count > 1) || different_extruder))
-            filament_config.update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[0]);
+            filament_config.update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[0], (NozzleVolumeType)filament_volume_maps[0]);
         out.apply(filament_config);
         compatible_printers_condition.emplace_back(this->filaments.get_edited_preset().compatible_printers_condition());
         compatible_prints_condition  .emplace_back(this->filaments.get_edited_preset().compatible_prints_condition());
@@ -4117,7 +4178,7 @@ DynamicPrintConfig PresetBundle::full_fff_config(bool apply_extruder, std::optio
         for (size_t i = 0; i < num_filaments; ++i) {
             filament_temp_configs[i] = *(filament_configs[i]);
             if (apply_extruder && ((extruder_count > 1) || different_extruder))
-                filament_temp_configs[i].update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[i]);
+                filament_temp_configs[i].update_values_to_printer_extruders(out, extruder_count, extruder_volume_type_count, nozzle_volume_types, filament_options_with_variant, "", "filament_extruder_variant", 1, filament_maps[i], (NozzleVolumeType)filament_volume_maps[i]);
         }
 
         // loop through options and apply them to the resulting config.

src/libslic3r/PresetBundle.hpp

@@ -175,7 +175,8 @@ public:
                                                     const DynamicPrintConfig       &project_config,
                                                     std::vector<Preset>            &in_filament_presets,
                                                     bool                            apply_extruder,
-                                                    std::optional<std::vector<int>> filament_maps_new);
+                                                    std::optional<std::vector<int>> filament_maps_new,
+                                                    std::optional<std::vector<int>> filament_volume_maps_new = std::nullopt);
 
     // ORCA: utility function to find the vendor for a given preset name
     static std::string find_preset_vendor(const std::string& preset_name, Preset::Type type);
@@ -383,10 +384,14 @@ public:
     bool                        has_defauls_only() const
         { return prints.has_defaults_only() && filaments.has_defaults_only() && printers.has_defaults_only(); }
 
-    DynamicPrintConfig          full_config(bool apply_extruder = true, std::optional<std::vector<int>>filament_maps = std::nullopt) const;
+    DynamicPrintConfig          full_config(bool apply_extruder = true, std::optional<std::vector<int>>filament_maps = std::nullopt, std::optional<std::vector<int>> filament_volume_maps = std::nullopt) const;
     // full_config() with the some "useless" config removed.
     DynamicPrintConfig          full_config_secure(std::optional<std::vector<int>>filament_maps = std::nullopt) const;
 
+    // Default per-filament nozzle-volume types: each filament inherits the volume type of the
+    // extruder it maps to (1-based f_maps), Standard when unknown.
+    std::vector<int> get_default_nozzle_volume_types_for_filaments(std::vector<int>& f_maps);
+
     // Per-extruder flush matrix [extruder_id][from_filament][to_filament] in mm^3, optionally scaled
     // by the per-extruder flush_multiplier (or flush_multiplier_fast when prime_volume_mode==Fast).
     // Used by the print-dispatch nozzle-mapping flush-weight estimate.
@@ -543,7 +548,7 @@ private:
     /*ConfigSubstitutions         load_config_file_config_bundle(
         const std::string &path, const boost::property_tree::ptree &tree, ForwardCompatibilitySubstitutionRule compatibility_rule);*/
 
-    DynamicPrintConfig          full_fff_config(bool apply_extruder, std::optional<std::vector<int>> filament_maps=std::nullopt) const;
+    DynamicPrintConfig          full_fff_config(bool apply_extruder, std::optional<std::vector<int>> filament_maps=std::nullopt, std::optional<std::vector<int>> filament_volume_maps=std::nullopt) const;
     DynamicPrintConfig          full_sla_config() const;
 
     // Orca: used for validation only

src/libslic3r/Print.cpp

@@ -334,8 +334,11 @@ bool Print::invalidate_state_by_config_options(const ConfigOptionResolver & /* n
             || opt_key == "other_layers_print_sequence_nums" 
             || opt_key == "toolchange_ordering"
             || opt_key == "extruder_ams_count"
+            || opt_key == "extruder_nozzle_stats"
             || opt_key == "filament_map_mode"
             || opt_key == "filament_map"
+            || opt_key == "filament_nozzle_map"
+            || opt_key == "filament_volume_map"
             || opt_key == "filament_adhesiveness_category"
             || opt_key == "filament_tower_interface_pre_extrusion_dist"
             || opt_key == "filament_tower_interface_pre_extrusion_length"
@@ -2509,6 +2512,10 @@ void Print::process(long long *time_cost_with_cache, bool use_cache)
             std::vector<int>filament_maps = this->get_filament_maps();
             auto map_mode = get_filament_map_mode();
             // get recommended filament map
+            // Orca: the sequential write-back stays gated to auto modes. In manual modes the
+            // config maps already carry the user's assignment (the per-object ToolOrdering below
+            // consumes them directly), so a write-back would only re-store the pre-slice values;
+            // keeping the gate avoids churning the config on every sequential manual slice.
             if (map_mode < FilamentMapMode::fmmManual) {
                 // Grouping returns a nozzle-aware result; the 1-based extruder map
                 // for the by-object path is derived from it.
@@ -2516,7 +2523,25 @@ void Print::process(long long *time_cost_with_cache, bool use_cache)
                 auto derived_maps = grouping_result.get_extruder_map(false);
                 if (!derived_maps.empty()) {
                     filament_maps = derived_maps;
-                    update_filament_maps_to_config(filament_maps);
+                    // Write the maps back: used filaments adopt the engine's extruder/nozzle
+                    // choice, unused ones keep their config assignment.
+                    // Orca: the config maps are the merge base; fall back to a synthesized base
+                    // when no producer sized them to the filament count (CLI runs until the
+                    // per-filament synthesis lands there), where indexing per filament would
+                    // run out of bounds.
+                    std::vector<int> base_filament_map = m_config.filament_map.values;
+                    if (base_filament_map.size() != derived_maps.size())
+                        base_filament_map.assign(derived_maps.size(), 1);
+                    std::vector<int> base_volume_map = m_config.filament_volume_map.values;
+                    if (base_volume_map.size() != derived_maps.size())
+                        base_volume_map.assign(derived_maps.size(), (int)nvtStandard);
+                    // Orca: as on the non-sequential path, the engine's concrete volume
+                    // assignment (get_volume_map()) is deliberately not merged in until the
+                    // layer-aware g-code resolvers consume it; the config keeps its own
+                    // (GUI-injected or project) volume map, size-corrected above.
+                    update_filament_maps_to_config(FilamentGroupUtils::update_used_filament_values(base_filament_map, derived_maps, used_filaments),
+                                                   base_volume_map,
+                                                   grouping_result.get_nozzle_map());
                 }
             }
             // check map valid both in auto and mannual mode
@@ -3198,14 +3223,30 @@ void Print::finalize_first_layer_convex_hull()
     m_first_layer_convex_hull = Geometry::convex_hull(m_first_layer_convex_hull.points);
 }
 
-void Print::update_filament_maps_to_config(std::vector<int> f_maps)
+void Print::update_filament_maps_to_config(std::vector<int> f_maps, std::vector<int> f_volume_maps, std::vector<int> f_nozzle_maps)
 {
-    if (m_config.filament_map.values != f_maps)
+    if ((m_config.filament_map.values != f_maps) || (m_config.filament_volume_map.values != f_volume_maps) || (m_config.filament_nozzle_map.values != f_nozzle_maps))
     {
         BOOST_LOG_TRIVIAL(info) << __FUNCTION__ << boost::format(": filament maps changed after pre-slicing.");
         m_ori_full_print_config.option<ConfigOptionInts>("filament_map", true)->values = f_maps;
         m_config.filament_map.values = f_maps;
 
+        if (!f_volume_maps.empty()) {
+            m_ori_full_print_config.option<ConfigOptionInts>("filament_volume_map", true)->values = f_volume_maps;
+            m_config.filament_volume_map.values = f_volume_maps;
+        }
+        else {
+            m_ori_full_print_config.option<ConfigOptionInts>("filament_volume_map", true)->values.resize(f_maps.size(), nvtStandard);
+            m_config.filament_volume_map.values.resize(f_maps.size(), nvtStandard);
+        }
+
+        if (!f_nozzle_maps.empty()) {
+            m_ori_full_print_config.option<ConfigOptionInts>("filament_nozzle_map", true)->values = f_nozzle_maps;
+            m_config.filament_nozzle_map.values = f_nozzle_maps;
+        }
+    }
+
+    {
         int extruder_count = 1, extruder_volume_type_count = 1;
         bool support_multi = m_ori_full_print_config.support_different_extruders(extruder_count);
         std::vector<std::vector<NozzleVolumeType>> nozzle_volume_types;
@@ -3221,15 +3262,22 @@ void Print::update_filament_maps_to_config(std::vector<int> f_maps)
         auto opt_extruder_type = dynamic_cast<const ConfigOptionEnumsGeneric*>(m_ori_full_print_config.option("extruder_type"));
         auto opt_nozzle_volume_type = dynamic_cast<const ConfigOptionEnumsGeneric*>(m_ori_full_print_config.option("nozzle_volume_type"));
         // Orca: the loop tolerates configs without the extruder options (unit tests, degenerate
-        // presets); the volume-map override keeps the sizing guard used everywhere else, and the
-        // grouping engine does not produce per-filament volume maps yet, so m_config only carries
-        // a map when the project supplied one.
+        // presets); the backfill and the override are bounds-checked because the change block above
+        // is skipped when the maps are unchanged, in which case the stored map may be shorter than
+        // the filament count.
+        auto* ori_volume_map = m_ori_full_print_config.option<ConfigOptionInts>("filament_volume_map", true);
         for (int index = 0; opt_extruder_type && opt_nozzle_volume_type && index < f_maps.size(); index++)
         {
             ExtruderType extruder_type = (ExtruderType)(opt_extruder_type->get_at(f_maps[index] - 1));
             NozzleVolumeType nozzle_volume_type = (NozzleVolumeType)(opt_nozzle_volume_type->get_at(f_maps[index] - 1));
-            if ((extruder_volume_type_count > extruder_count)
-                && f_maps.size() > 1 && m_config.filament_volume_map.values.size() == f_maps.size())
+            if (f_volume_maps.empty()) {
+                // No per-filament map supplied: backfill from the extruder's own volume type.
+                if (m_config.filament_volume_map.values.size() > index)
+                    m_config.filament_volume_map.values[index] = nozzle_volume_type;
+                if (ori_volume_map->values.size() > index)
+                    ori_volume_map->values[index] = nozzle_volume_type;
+            }
+            else if ((extruder_volume_type_count > extruder_count) && (m_config.filament_volume_map.values.size() > index))
                 nozzle_volume_type = (NozzleVolumeType)(m_config.filament_volume_map.values[index]);
             m_config.filament_map_2.values[index] = m_ori_full_print_config.get_index_for_extruder(f_maps[index], "print_extruder_id", extruder_type, nozzle_volume_type, "print_extruder_variant");
         }
@@ -3254,8 +3302,11 @@ void Print::update_filament_maps_to_config(std::vector<int> f_maps)
                 compute_filament_override_value(opt_key, opt_old_machine, opt_new_machine, opt_new_filament, m_full_print_config, print_diff, filament_overrides, m_config.filament_map_2.values);
         }
 
-        t_config_option_keys keys(filament_options_with_variant.begin(), filament_options_with_variant.end());
-        m_config.apply_only(m_full_print_config, keys, true);
+        if ((extruder_count > 1) || support_multi) {
+            t_config_option_keys keys(filament_options_with_variant.begin(), filament_options_with_variant.end());
+            keys.push_back("filament_self_index");
+            m_config.apply_only(m_full_print_config, keys, true);
+        }
         if (!print_diff.empty()) {
             m_placeholder_parser.apply_config(filament_overrides);
             m_config.apply(filament_overrides);

src/libslic3r/Print.hpp

@@ -1005,7 +1005,7 @@ public:
     const WipeTowerData&        wipe_tower_data(size_t filaments_cnt = 0) const;
     const ToolOrdering& 		tool_ordering() const { return m_tool_ordering; }
 
-    void update_filament_maps_to_config(std::vector<int> f_maps);
+    void update_filament_maps_to_config(std::vector<int> f_maps, std::vector<int> f_volume_maps = std::vector<int>{}, std::vector<int> f_nozzle_maps = std::vector<int>{});
     void apply_config_for_render(const DynamicConfig &config);
 
     // 1 based group ids

src/libslic3r/PrintApply.cpp

@@ -1212,7 +1212,7 @@ Print::ApplyStatus Print::apply(const Model &model, DynamicPrintConfig new_full_
 
     //BBS: process the filament_map related logic
     std::unordered_set<std::string> print_diff_set(print_diff.begin(), print_diff.end());
-    if (print_diff_set.find("filament_map_mode") == print_diff_set.end())
+    if (!print_diff_set.empty() && print_diff_set.find("filament_map_mode") == print_diff_set.end())
     {
         FilamentMapMode map_mode = new_full_config.option<ConfigOptionEnum<FilamentMapMode>>("filament_map_mode", true)->value;
         if (is_auto_filament_map_mode(map_mode)) {
@@ -1224,9 +1224,29 @@ Print::ApplyStatus Print::apply(const Model &model, DynamicPrintConfig new_full_
                 old_opt->set(new_opt);
                 m_config.filament_map = *new_opt;
             }
+            if (print_diff_set.find("filament_volume_map") != print_diff_set.end()) {
+                print_diff_set.erase("filament_volume_map");
+                //full_config_diff.erase("filament_volume_map");
+                ConfigOptionInts* old_opt = m_full_print_config.option<ConfigOptionInts>("filament_volume_map", true);
+                ConfigOptionInts* new_opt = new_full_config.option<ConfigOptionInts>("filament_volume_map", true);
+                old_opt->set(new_opt);
+                m_config.filament_volume_map = *new_opt;
+            }
+            if (print_diff_set.find("filament_nozzle_map") != print_diff_set.end()) {
+                print_diff_set.erase("filament_nozzle_map");
+                //full_config_diff.erase("filament_nozzle_map");
+                ConfigOptionInts* old_opt = m_full_print_config.option<ConfigOptionInts>("filament_nozzle_map", true);
+                ConfigOptionInts* new_opt = new_full_config.option<ConfigOptionInts>("filament_nozzle_map", true);
+                old_opt->set(new_opt);
+                m_config.filament_nozzle_map = *new_opt;
+            }
         }
         else {
             print_diff_set.erase("extruder_ams_count");
+            if (map_mode == fmmManual) {
+                // filament_nozzle_map is an engine output, not a GUI input, in manual mode
+                print_diff_set.erase("filament_nozzle_map");
+            }
             std::vector<int> old_filament_map = m_config.filament_map.values;
             std::vector<int> new_filament_map = new_full_config.option<ConfigOptionInts>("filament_map", true)->values;
 
@@ -1243,8 +1263,32 @@ Print::ApplyStatus Print::apply(const Model &model, DynamicPrintConfig new_full_
                         break;
                     }
                 }
-                if (same_map)
+                if (same_map) {
                     print_diff_set.erase("filament_map");
+
+                    // The extruder retract overrides are keyed by the (unchanged) filament map;
+                    // recompute them and drop diffs whose recomputed value matches the current
+                    // config, so a cosmetic reordering of unused filaments does not invalidate.
+                    const auto& retract_keys = print_config_def.extruder_retract_keys();
+                    const std::string filament_prefix = "filament_";
+                    std::vector<int> old_f_map_indices(old_filament_map.size(), 0);
+                    for (size_t i = 0; i < old_filament_map.size(); i++)
+                        old_f_map_indices[i] = old_filament_map[i] - 1;
+
+                    for (const auto& rk : retract_keys) {
+                        if (print_diff_set.find(rk) == print_diff_set.end())
+                            continue;
+                        const ConfigOption* opt_old   = m_config.option(rk);
+                        const ConfigOption* opt_new_m = new_full_config.option(rk);
+                        const ConfigOption* opt_new_f = new_full_config.option(filament_prefix + rk);
+                        if (opt_old && opt_new_m && opt_new_f) {
+                            std::unique_ptr<ConfigOption> opt_recomputed(opt_new_m->clone());
+                            opt_recomputed->apply_override(opt_new_f, old_f_map_indices);
+                            if (*opt_old == *opt_recomputed)
+                                print_diff_set.erase(rk);
+                        }
+                    }
+                }
             }
         }
         if (print_diff_set.size() != print_diff.size())
@@ -1265,11 +1309,12 @@ Print::ApplyStatus Print::apply(const Model &model, DynamicPrintConfig new_full_
     {
         ExtruderType extruder_type = (ExtruderType)(opt_extruder_type->get_at(filament_maps[index] - 1));
         NozzleVolumeType nozzle_volume_type = (NozzleVolumeType)(opt_nozzle_volume_type->get_at(filament_maps[index] - 1));
-        // Orca: the per-filament volume map is only trustworthy when a producer explicitly sized it
-        // to the filament count; the registered default is a 1-element vector (see
+        // Orca: honour the per-filament volume map only when a producer sized it to the filament
+        // count; mis-sized maps (stale project values, CLI runs until the per-filament synthesis
+        // lands there) must not be indexed per filament (see
         // update_values_to_printer_extruders_for_multiple_filaments for the same guard).
         if ((extruder_volume_type_count > extruder_count) && opt_filament_volume_maps
-            && filament_maps.size() > 1 && opt_filament_volume_maps->values.size() == filament_maps.size())
+            && opt_filament_volume_maps->values.size() == filament_maps.size())
             nozzle_volume_type = (NozzleVolumeType)(opt_filament_volume_maps->values[index]);
         m_config.filament_map_2.values[index] = new_full_config.get_index_for_extruder(filament_maps[index], "print_extruder_id", extruder_type, nozzle_volume_type, "print_extruder_variant");
     }
@@ -1694,6 +1739,12 @@ Print::ApplyStatus Print::apply(const Model &model, DynamicPrintConfig new_full_
         m_default_object_config.apply_only(new_full_config, new_changed_keys, true);
         // Handle changes to regions config defaults
         m_default_region_config.apply_only(new_full_config, new_changed_keys, true);
+        // Orca: keep the pre-expansion snapshot in sync with this late normalization pass.
+        // The engine map write-back rebuilds m_full_print_config from m_ori_full_print_config
+        // after slicing; a stale snapshot would resurrect the un-normalized values (e.g.
+        // enable_prime_tower on a single-filament print) in the dumped config and spuriously
+        // re-invalidate the g-code on the next apply.
+        m_ori_full_print_config.apply_only(new_full_config, new_changed_keys, true);
         m_full_print_config = std::move(new_full_config);
         update_filament_self_index_cache();
     }

src/libslic3r/PrintConfig.cpp

@@ -2743,8 +2743,10 @@ void PrintConfigDef::init_fff_params()
 
     // Per-filament nozzle-volume-type override (multi-volume/Hybrid). Round-trips through .3mf
     // plate metadata (filament_volume_maps) and steers per-filament slot resolution when an
-    // extruder exposes several volume types; inert for existing printers (no producer sizes it
-    // to the filament count until the write-back pipeline lands).
+    // extruder exposes several volume types. Producers: the GUI full-config composition injects
+    // a filament-count-sized map (plate map, else per-extruder defaults) and the project config
+    // keeps it sized; expansion trusts the map only when its size matches the filament count
+    // (CLI runs may still carry the 1-element default).
     def = this->add("filament_volume_map", coInts);
     def->mode = comDevelop;
     def->set_default_value(new ConfigOptionInts{(int)(NozzleVolumeType::nvtStandard)});
@@ -2774,8 +2776,10 @@ void PrintConfigDef::init_fff_params()
     def->mode = comAdvanced;
     def->set_default_value(new ConfigOptionEnum<FilamentMapMode>(fmmAutoForFlush));
 
-    // Fully-manual mode (fmmNozzleManual): per-filament -> physical-nozzle assignment.
-    // Inert until the nozzle-assignment engine consumes it. Internal use only, no translation.
+    // Per-filament -> physical-nozzle assignment. Written back by the grouping engine after
+    // slicing (all non-sequential modes) and read back to the plate config; a user input only
+    // in fully-manual mode (fmmNozzleManual). Dumped in the g-code header for diagnostics.
+    // Internal use only, no translation.
     def = this->add("filament_nozzle_map", coInts);
     def->mode = comDevelop;
     def->set_default_value(new ConfigOptionInts{1});
@@ -10533,12 +10537,12 @@ void DynamicPrintConfig::update_values_to_printer_extruders_for_multiple_filamen
 
         auto opt_filament_volume_maps = dynamic_cast<const ConfigOptionInts*>(printer_config.option("filament_volume_map"));
         std::vector<int> filament_volume_maps;
-        // Orca: the per-filament volume map is only trustworthy when a producer explicitly
-        // sized it to the filament count; the registered default is a 1-element vector and
-        // stale project values may be mis-sized. A single-filament config cannot be told
-        // apart from that default by size, so it is ignored too until the pipeline that
-        // seeds the map lands; anything untrusted must not distort slot resolution.
-        if (opt_filament_volume_maps && filament_count > 1 && opt_filament_volume_maps->values.size() == filament_count)
+        // Orca: honour the per-filament volume map only when a producer sized it to the
+        // filament count. The full-config producers (PresetBundle injection, engine
+        // write-back) always size it; mis-sized maps (stale project values, CLI runs until
+        // the per-filament synthesis lands there) must not distort slot resolution nor be
+        // indexed out of bounds.
+        if (opt_filament_volume_maps && opt_filament_volume_maps->values.size() == filament_count)
             filament_volume_maps = opt_filament_volume_maps->values;
         auto opt_ids = id_name.empty()? nullptr: dynamic_cast<const ConfigOptionInts*>(this->option(id_name));
         std::vector<int> variant_index;