Add CI\CD step to prepare cache file in ahead of time so user does not need to wait

.github/workflows/build_orca.yml

@@ -117,6 +117,15 @@ jobs:
         run: |
           ./build_release_macos.sh -s -n -x ${{ !vars.SELF_HOSTED && '-1' || '' }} -a ${{ inputs.arch }} -t 10.15
 
+      - name: Generate system presets cache (macOS)
+        if: runner.os == 'macOS' && !inputs.macos-combine-only
+        working-directory: ${{ github.workspace }}
+        shell: bash
+        run: |
+          tool=$(find build/${{ inputs.arch }} -name generate_system_cache -type f | head -1)
+          profiles=$(find build/${{ inputs.arch }} -path "*/Resources/profiles" -type d | head -1)
+          "$tool" --path "$profiles" --log_level 2
+
       - name: Pack macOS app bundle ${{ inputs.arch }}
         if: runner.os == 'macOS' && !inputs.macos-combine-only
         working-directory: ${{ github.workspace }}
@@ -292,6 +301,14 @@ jobs:
         #   WindowsSDKVersion: '10.0.26100.0\'
         run: .\build_release_vs.bat slicer
 
+      - name: Generate system presets cache (Windows)
+        if: runner.os == 'Windows'
+        shell: pwsh
+        run: |
+          $profiles = Get-ChildItem -Recurse -Path build -Directory -Filter profiles |
+            Where-Object { $_.FullName -match 'resources' } | Select-Object -First 1
+          .\build\src\Release\generate_system_cache.exe --path $profiles.FullName --log_level 2
+
       - name: Create installer Win
         if: runner.os == 'Windows' && !vars.SELF_HOSTED
         working-directory: ${{ github.workspace }}/build
@@ -400,6 +417,20 @@ jobs:
           retention-days: 5
           if-no-files-found: error
 
+      - name: Generate system presets cache (Linux)
+        if: runner.os == 'Linux'
+        shell: bash
+        run: |
+          ./build/src/Release/generate_system_cache --path build/package/resources/profiles --log_level 2
+          # Re-pack the AppImage so the cache is included
+          appimage=$(find build -maxdepth 1 -name "OrcaSlicer_Linux_AppImage*.AppImage" | head -1)
+          chmod +x "$appimage"
+          "$appimage" --appimage-extract
+          cp build/package/resources/profiles/system_presets_cache.cache squashfs-root/resources/profiles/
+          appimagetool=$(find build -name "appimagetool.AppImage" | head -1)
+          ARCH=$(uname -m) "$appimagetool" --appimage-extract-and-run squashfs-root "$appimage"
+          rm -rf squashfs-root
+
       - name: Run external slicer regression tests
         if: runner.os == 'Linux'
         timeout-minutes: 20

src/CMakeLists.txt

@@ -111,6 +111,11 @@ if(ORCA_TOOLS)
     endif()
     target_link_libraries(OrcaSlicer_profile_validator libslic3r boost_headeronly libcurl OpenSSL::SSL OpenSSL::Crypto)
     target_compile_definitions(OrcaSlicer_profile_validator PRIVATE -DBOOST_ALL_NO_LIB -DBOOST_USE_WINAPI_VERSION=0x602 -DBOOST_SYSTEM_USE_UTF8)
+
+    # generate_system_cache: pre-generates resources/profiles/system_presets_cache.cache for CI bundling.
+    add_executable(generate_system_cache dev-utils/generate_system_cache.cpp)
+    target_link_libraries(generate_system_cache libslic3r boost_headeronly)
+    target_compile_definitions(generate_system_cache PRIVATE -DBOOST_ALL_NO_LIB -DBOOST_USE_WINAPI_VERSION=0x602 -DBOOST_SYSTEM_USE_UTF8)
 endif()
 
 # Create a slic3r executable

src/dev-utils/generate_system_cache.cpp

@@ -0,0 +1,86 @@
+#include "libslic3r/PresetBundle.hpp"
+#include "libslic3r/PresetBundleCache.hpp"
+#include "libslic3r/Utils.hpp"
+
+#include <boost/filesystem.hpp>
+#include <boost/log/trivial.hpp>
+#include <boost/program_options.hpp>
+#include <iostream>
+
+using namespace Slic3r;
+namespace fs = boost::filesystem;
+namespace po = boost::program_options;
+
+int main(int argc, char* argv[])
+{
+    po::options_description desc("OrcaSlicer System Cache Generator\nUsage");
+    // clang-format off
+    desc.add_options()
+        ("help,h", "Show help")
+#ifdef __APPLE__
+        ("path,p", po::value<std::string>()->default_value("../../../../../../../resources/profiles"), "Path to profiles directory")
+#else
+        ("path,p", po::value<std::string>()->default_value("../../../resources/profiles"), "Path to profiles directory")
+#endif
+        ("log_level,l", po::value<int>()->default_value(2), "Log level (0=trace, 2=info, 4=error)");
+    // clang-format on
+
+    po::variables_map vm;
+    try {
+        po::store(po::parse_command_line(argc, argv, desc), vm);
+        if (vm.count("help")) { std::cout << desc << "\n"; return 0; }
+        po::notify(vm);
+    } catch (const po::error& e) {
+        std::cerr << "Error: " << e.what() << "\n" << desc << "\n";
+        return 1;
+    }
+
+    const std::string profiles_path = vm["path"].as<std::string>();
+    const int         log_level     = vm["log_level"].as<int>();
+
+    if (!fs::exists(profiles_path) || !fs::is_directory(profiles_path)) {
+        std::cerr << "Error: '" << profiles_path << "' is not a valid directory\n";
+        return 1;
+    }
+
+    set_logging_level(log_level);
+    // In validation_mode, load_system_presets_from_json uses data_dir() directly
+    // (no /system/ suffix), so point data_dir at the profiles directory.
+    set_data_dir(profiles_path);
+    set_resources_dir(fs::path(profiles_path).parent_path().make_preferred().string());
+
+    // load_presets creates user preset dirs under data_dir().
+    const fs::path user_dir = fs::path(data_dir()) / PRESET_USER_DIR;
+    if (!fs::exists(user_dir))
+        fs::create_directories(user_dir);
+
+    AppConfig app_config;
+    app_config.set("preset_folder", "default");
+
+    auto preset_bundle = std::make_unique<PresetBundle>();
+    preset_bundle->set_is_validation_mode(true);
+    preset_bundle->set_default_suppressed(true);
+
+    std::cout << "Loading system presets from: " << profiles_path << "\n";
+
+    try {
+        preset_bundle->load_presets(app_config, ForwardCompatibilitySubstitutionRule::EnableSilent);
+    } catch (const std::exception& ex) {
+        std::cerr << "Failed to load presets: " << ex.what() << "\n";
+        return 1;
+    }
+
+    const std::string cache_path =
+        (fs::path(profiles_path) / "system_presets_cache.cache").make_preferred().string();
+
+    PresetBundleCache::SystemPresetsCache cache;
+    cache.capture(*preset_bundle, profiles_path);
+    cache.save(cache_path);
+
+    std::cout << "Cache written: " << cache_path << "\n"
+              << "  Vendor profiles:  " << cache.vendor_profiles.size()   << "\n"
+              << "  Print presets:    " << cache.print_presets.size()     << "\n"
+              << "  Filament presets: " << cache.filament_presets.size()  << "\n"
+              << "  Printer presets:  " << cache.printer_presets.size()   << "\n";
+    return 0;
+}

src/libslic3r/PresetBundle.cpp

@@ -2208,6 +2208,26 @@ std::pair<PresetsConfigSubstitutions, std::string> PresetBundle::load_system_pre
             BOOST_LOG_TRIVIAL(info) << "PresetBundle: system presets loaded from cache in " << ms << " ms";
             return {PresetsConfigSubstitutions{}, ""};
         }
+
+        // Try bundled cache shipped with the installer (first launch, before user cache exists).
+        // Validates against resources/profiles/ — the same directory it was generated from in CI.
+        {
+            const std::string bundled_dir =
+                (boost::filesystem::path(resources_dir()) / "profiles").make_preferred().string();
+            PresetBundleCache::SystemPresetsCache bundled;
+            if (bundled.load(PresetBundleCache::SystemPresetsCache::bundled_cache_path()) &&
+                bundled.is_valid(bundled_dir)) {
+                bundled.apply(*this);
+                update_system_maps();
+                // Promote to user cache so subsequent launches skip this check.
+                bundled.save(cache_file);
+                const auto ms = std::chrono::duration_cast<std::chrono::milliseconds>(
+                    std::chrono::steady_clock::now() - t0).count();
+                BOOST_LOG_TRIVIAL(info) << "PresetBundle: system presets loaded from bundled cache in " << ms << " ms";
+                return {PresetsConfigSubstitutions{}, ""};
+            }
+        }
+
         BOOST_LOG_TRIVIAL(info) << __FUNCTION__ << " cache miss, falling back to JSON load";
     }
 

src/libslic3r/PresetBundleCache.cpp

@@ -116,6 +116,12 @@ std::string SystemPresetsCache::cache_path()
                .make_preferred().string();
 }
 
+std::string SystemPresetsCache::bundled_cache_path()
+{
+    return (boost::filesystem::path(resources_dir()) / "profiles" / "system_presets_cache.cache")
+               .make_preferred().string();
+}
+
 bool SystemPresetsCache::is_valid(const std::string& system_dir) const
 {
     if (format_version != FORMAT_VERSION)

src/libslic3r/PresetBundleCache.hpp

@@ -119,6 +119,7 @@ struct SystemPresetsCache {
     }
 
     static std::string cache_path();
+    static std::string bundled_cache_path();
     bool is_valid(const std::string& system_dir) const;
     void capture(const PresetBundle& bundle, const std::string& system_dir);
     void apply(PresetBundle& bundle) const;