Fix command-line slicing when a filament leaves out a per-variant setting

src/OrcaSlicer.cpp

@@ -3476,6 +3476,14 @@ int CLI::run(int argc, char **argv)
         }
         new_variant_counts = old_variant_counts;
         //filament_variant_count = old_variant_counts;
+        //ORCA: lay the per-variant options out one value per variant of the current filaments before each
+        //      loaded filament replaces its own variants, including an option only a loaded filament
+        //      defines, which otherwise starts as a single default value and never reaches the others.
+        for (const DynamicPrintConfig &config : load_filaments_config)
+            for (const std::string &opt_key : filament_options_with_variant)
+                if (opt_key != "filament_extruder_variant" && config.has(opt_key))
+                    m_print_config.option(opt_key, true);
+        normalize_filament_values_to_variants(m_print_config);
         for (int index = 0; index < load_filaments_config.size(); index++) {
             DynamicPrintConfig&  config = load_filaments_config[index];
             int filament_index = load_filaments_index[index];
@@ -3647,6 +3655,25 @@ int CLI::run(int argc, char **argv)
                 }
             }
 
+            //ORCA: a per-variant option the loaded filament does not define keeps the values of the
+            //      variants the filament already had, and a variant new to it takes its first one's.
+            const int old_start = old_start_indice[filament_index - 1];
+            std::vector<int> kept_variant_indice = new_variant_indice;
+            for (int &i : kept_variant_indice)
+                if (i < 0)
+                    i = old_start;
+            for (const std::string &opt_key : filament_options_with_variant) {
+                if (config.has(opt_key))
+                    continue;
+                auto *opt_vec_dst = dynamic_cast<ConfigOptionVectorBase *>(m_print_config.option(opt_key));
+                if (opt_vec_dst == nullptr || opt_vec_dst->size() < size_t(old_start + old_variant_count))
+                    continue;
+                // set_with_restore_2() pads its source in place
+                std::unique_ptr<ConfigOption> old_values(opt_vec_dst->clone());
+                opt_vec_dst->set_with_restore_2(static_cast<ConfigOptionVectorBase *>(old_values.get()), kept_variant_indice, old_start,
+                                                old_variant_count, true);
+            }
+
             //update the old index
             if (old_variant_count != new_variant_count)
             {
@@ -4081,6 +4108,9 @@ int CLI::run(int argc, char **argv)
     if (printer_technology == ptFFF) {
         fff_print_config.apply(m_print_config, true);
         m_print_config.apply(fff_print_config, true);
+        //ORCA: an option no preset or project defines has just come in as its single default value, and a
+        //      command line override may hold one value per filament.
+        normalize_filament_values_to_variants(m_print_config);
     } else {
         boost::nowide::cerr << "invalid printer_technology " << std::endl;
         record_exit_reson(outfile_dir, CLI_INVALID_PRINTER_TECH, 0, cli_errors[CLI_INVALID_PRINTER_TECH], sliced_info);

src/libslic3r/PrintConfig.cpp

@@ -9405,20 +9405,8 @@ void PrintConfigDef::handle_legacy_composite(DynamicPrintConfig &config)
     }
 
     // Orca: a config saved before a key joined filament_options_with_variant stores it once per filament
-    // rather than once per filament variant. Give every variant of a filament that filament's value.
-    if (auto *self_index = config.option<ConfigOptionInts>("filament_self_index"); self_index && !self_index->empty()) {
-        const int filament_count = *std::max_element(self_index->values.begin(), self_index->values.end());
-        if (filament_count > 0 && size_t(filament_count) < self_index->size()) {
-            for (const std::string &key : filament_options_with_variant) {
-                auto *opt = dynamic_cast<ConfigOptionVectorBase *>(config.option(key));
-                if (!opt || opt->size() != size_t(filament_count))
-                    continue;
-                std::unique_ptr<ConfigOption> per_filament(opt->clone());
-                for (size_t variant = 0; variant < self_index->size(); ++variant)
-                    opt->set_at(per_filament.get(), variant, self_index->values[variant] - 1);
-            }
-        }
-    }
+    // rather than once per filament variant, and one exported by an older CLI may store a single value.
+    normalize_filament_values_to_variants(config);
 }
 
 const PrintConfigDef print_config_def;
@@ -10735,6 +10723,25 @@ void set_variant_override(ConfigOptionVectorBase &target, const ConfigOptionVect
     target.set_to_index(&source, indices, stride);
 }
 
+void normalize_filament_values_to_variants(DynamicPrintConfig &config)
+{
+    const auto *self_index = config.option<ConfigOptionInts>("filament_self_index");
+    if (self_index == nullptr || self_index->empty())
+        return;
+    const int filament_count = *std::max_element(self_index->values.begin(), self_index->values.end());
+    if (filament_count <= 0 || size_t(filament_count) >= self_index->size())
+        return;
+    for (const std::string &key : filament_options_with_variant) {
+        auto *opt = dynamic_cast<ConfigOptionVectorBase *>(config.option(key));
+        if (opt == nullptr || (opt->size() != size_t(filament_count) && opt->size() != 1))
+            continue;
+        std::unique_ptr<ConfigOption> per_filament(opt->clone());
+        // set_at() takes the first value for a filament past the end of a single-value vector
+        for (size_t variant = 0; variant < self_index->size(); ++variant)
+            opt->set_at(per_filament.get(), variant, self_index->values[variant] - 1);
+    }
+}
+
 
 //used for object/region config
 //use the smallest of multiple to single

src/libslic3r/PrintConfig.hpp

@@ -884,6 +884,11 @@ extern std::set<std::string> empty_options;
 void set_variant_override(ConfigOptionVectorBase &target, const ConfigOptionVectorBase &source,
                           const std::vector<int> &variant_index, int stride = 1);
 
+// Orca: lays every filament_options_with_variant option out one value per filament variant, as
+// filament_self_index maps the variants to filaments. An option holding one value per filament, or a
+// single value, gives every variant of a filament that filament's value; other lengths are left alone.
+void normalize_filament_values_to_variants(DynamicPrintConfig &config);
+
 extern std::set<std::string> filament_dev_options;
 
 extern void update_static_print_config_from_dynamic(ConfigBase& config, const DynamicPrintConfig& dest_config, std::vector<int> variant_index, std::set<std::string>& key_set1, int stride = 1);

tests/libslic3r/test_config_variant_expansion.cpp

@@ -717,3 +717,15 @@ TEST_CASE("get_index_for_extruder scales the variant column by the requested str
     REQUIRE(col0_stride2 == 0);
     REQUIRE(col1_stride2 == 2);
 }
+
+// A per-variant filament option read with a single value gives it to every filament variant. A project
+// exported by an older CLI holds a single value for an option no loaded preset defined, such as
+// filament_ironing_flow.
+TEST_CASE("A per-variant filament option read with a single value gives it to every filament variant", "[Config]")
+{
+    // filament 1 defines Standard and High Flow, filament 2 Standard
+    DynamicPrintConfig config;
+    config.option<ConfigOptionInts>("filament_self_index", true)->values = {1, 1, 2};
+    config.load_from_ini_string("pressure_advance = 0.021", ForwardCompatibilitySubstitutionRule::Disable);
+    REQUIRE(config.option<ConfigOptionFloats>("pressure_advance")->values == std::vector<double>({0.021, 0.021, 0.021}));
+}