Build only the OCCT and solver pieces the Design tab needs

SLIC3R_CAD=OFF now builds without SolveSpace or OCCT's ModelingAlgorithms
module, leaving the dependency set identical to upstream's, and the Design
tab's mate connector preference no longer appears in builds without the tab.
When the deps prefix and the project disagree about the option, the configure
fails naming the cause, rather than failing at link time or at first launch
on Windows. The Windows packaging step stages exactly the toolkits libslic3r
links.

CMakeLists.txt

@@ -1043,34 +1043,28 @@ function(orcaslicer_copy_dlls target config postfix output_dlls)
             ${TOP_LEVEL_PROJECT_DIR}/deps/WebView2/lib/win-${_arch}/WebView2Loader.dll
         DESTINATION ${_out_dir})
 
-    # Copy EVERY OCCT DLL the deps build produced. Do NOT hand-maintain an explicit
+    # Stage the OCCT toolkits libslic3r links (published as OCCT_LIBS), not whatever the
-    # list here: it silently drifts from what libslic3r links (src/libslic3r OCCT_LIBS)
+    # deps prefix happens to hold, and fail the configure if one of them is missing.
-    # and their transitive OCCT deps, yielding a portable/installer that fails at launch
-    # with "OrcaSlicer.dll error 126 (dependency not found)" — e.g. missing TKFillet/
-    # TKOffset/TKBool/TKFeat. Glob everything instead; the built occt/ dir is the one
-    # source of truth. (OCCT is Shared only on Windows — deps/OCCT/OCCT.cmake.)
-    file(GLOB _occt_dlls "${CMAKE_PREFIX_PATH}/bin/occt/*.dll")
-    # The glob degrades silently: it ships whatever the deps prefix holds. That is not the
-    # same as shipping what we link. A deps tree built with BUILD_MODULE_ModelingAlgorithms=OFF
-    # (upstream OrcaSlicer's setting) simply has no TKFillet.dll / TKOffset.dll, so the glob
-    # copies 40 of 42 DLLs, the build succeeds, and the slicer dies at launch with
-    # "error 126 (dependency not found)". The explicit per-file list this replaced failed
-    # the configure instead. Assert the real invariant: every linked toolkit has a DLL.
     if (NOT OCCT_LIBS)
         message(FATAL_ERROR "OCCT_LIBS is not set; libslic3r must be configured first.")
     endif ()
+    set(_occt_bin "${CMAKE_PREFIX_PATH}/bin/occt")
+    set(_occt_dlls "")
+    set(_occt_staged "")
     set(_missing_occt "")
     foreach (_tk IN LISTS OCCT_LIBS)
-        if (NOT EXISTS "${CMAKE_PREFIX_PATH}/bin/occt/${_tk}.dll")
+        if (EXISTS "${_occt_bin}/${_tk}.dll")
+            list(APPEND _occt_dlls "${_occt_bin}/${_tk}.dll")
+            list(APPEND _occt_staged "${_out_dir}/${_tk}.dll")
+        else ()
             list(APPEND _missing_occt "${_tk}.dll")
         endif ()
     endforeach ()
     if (_missing_occt)
         message(FATAL_ERROR
-            "OCCT DLLs missing from ${CMAKE_PREFIX_PATH}/bin/occt/: ${_missing_occt}\n"
+            "OCCT DLLs missing from ${_occt_bin}/: ${_missing_occt}\n"
-            "Rebuild the dependencies (build_release_vs2022.bat deps). This fork sets "
+            "Rebuild the dependencies (build_release_vs2022.bat deps) with the same "
-            "BUILD_MODULE_ModelingAlgorithms=ON, so a deps tree built from upstream "
+            "SLIC3R_CAD setting as this project.")
-            "OrcaSlicer lacks TKFillet/TKOffset and the slicer would fail at startup.")
     endif ()
     file(COPY ${_occt_dlls}
             ${CMAKE_PREFIX_PATH}/bin/freetype.dll
@@ -1083,9 +1077,6 @@ function(orcaslicer_copy_dlls target config postfix output_dlls)
 
         ${_out_dir}/freetype.dll
     )
-    # Mirror every OCCT DLL staged above (all OpenCASCADE toolkits are named TK*) into
-    # the install/portable manifest, so this list can never drift from what was copied.
-    file(GLOB _occt_staged "${_out_dir}/TK*.dll")
     list(APPEND _dll_list ${_occt_staged})
     set(${output_dlls} ${_dll_list} PARENT_SCOPE)
 

deps/CMakeLists.txt

@@ -55,6 +55,7 @@ endif ()
 
 set(DEP_DOWNLOAD_DIR ${CMAKE_CURRENT_SOURCE_DIR}/DL_CACHE CACHE PATH "Path for downloaded source packages.")
 set(FLATPAK FALSE CACHE BOOL "Toggles various build settings for flatpak, like /usr/local in DESTDIR or not building wxwidgets")
+option(SLIC3R_CAD "Build the SolveSpace solver and OCCT ModelingAlgorithms module the parametric Design/CAD tab needs. Must match the main project's SLIC3R_CAD." ON)
 
 if ("${DESTDIR}" STREQUAL "" OR "${DESTDIR}" STREQUAL "${AUTOGENERATED_DESTDIR}")
     if (LINUX AND (NOT DEFINED USE_OLD_DESTDIR_PREV OR USE_OLD_DESTDIR_PREV) AND EXISTS "${CMAKE_BINARY_DIR}/destdir/usr/local" AND NOT EXISTS "${CMAKE_BINARY_DIR}/OrcaSlicer_dep/usr/local")
@@ -350,7 +351,11 @@ include(GLEW/GLEW.cmake)
 
 include(GLFW/GLFW.cmake)
 include(OpenCSG/OpenCSG.cmake)
-include(SLVS/SLVS.cmake)
+set(SLVS_PKG "")
+if (SLIC3R_CAD)
+    include(SLVS/SLVS.cmake)
+    set(SLVS_PKG dep_SLVS)
+endif ()
 
 include(TBB/TBB.cmake)
 
@@ -440,7 +445,7 @@ set(_dep_list
     dep_NLopt
     dep_OpenVDB
     dep_OpenCSG
-    dep_SLVS
+    ${SLVS_PKG}
     dep_OpenCV
     dep_Eigen
     dep_CGAL

deps/OCCT/OCCT.cmake

@@ -4,8 +4,9 @@ else()
     set(library_build_type "Static")
 endif()
 
-# The parametric Design/CAD tab is the only consumer of OCCT's ModelingAlgorithms
+# SLIC3R_CAD (declared in deps/CMakeLists.txt) builds OCCT's ModelingAlgorithms module
-# module (fillet/offset/loft). With it OFF the deps prefix matches upstream exactly.
+# (fillet/offset/loft), whose only consumer is the parametric Design/CAD tab. With it OFF
+# the deps prefix matches upstream exactly.
 #
 # With it ON the delta is THREE toolkits, not two: TKFillet (7.40 MiB archive, used via
 # BRepFilletAPI), TKOffset (5.38 MiB, used via BRepOffsetAPI) and TKFeat (4.42 MiB), which
@@ -17,9 +18,6 @@ endif()
 # shipped bytes. The Windows figure is a real DLL cost and has NOT been measured -- an
 # earlier "3.77 MiB, Windows only" note here covered only two of the three toolkits and is
 # not a number to quote. See docs/cad_dependency_weight.md.
-#
-# Must match the SLIC3R_CAD passed to the main project.
-option(SLIC3R_CAD "Build OCCT's ModelingAlgorithms module (required by the Design/CAD tab)" ON)
 
 if (IN_GIT_REPO)
     set(OCCT_DIRECTORY_FLAG --directory ${BINARY_DIR_REL}/dep_OCCT-prefix/src/dep_OCCT)

src/libslic3r/AppConfig.cpp

@@ -310,12 +310,14 @@ void AppConfig::set_defaults()
     if (get("zoom_to_mouse").empty())
         set_bool("zoom_to_mouse", false);
 
+#ifdef SLIC3R_CAD
     // Design tab: draw a mate connector as a face rather than as the abstract disc + roll
     // quadrant. Defaults ON — face orientation is hardwired perception, so the roll and the
     // verse read without being learned, which no abstract glyph achieves. Turning it off
     // restores the conventional CAD representation for users who expect it (snaporca-x0kd).
     if (get("design_connector_face_glyph").empty())
         set_bool("design_connector_face_glyph", true);
+#endif
 
 //#ifdef SUPPORT_SHOW_HINTS
     if (get("show_hints").empty())

src/libslic3r/CMakeLists.txt

@@ -604,7 +604,6 @@ find_package(JPEG REQUIRED)
 find_package(Draco REQUIRED)
 
 set(OCCT_LIBS
-    TKBool
     TKXDESTEP
     TKSTEP
     TKSTEP209
@@ -632,23 +631,29 @@ set(OCCT_LIBS
     TKMath
     TKernel
 )
-# The CAD kernel is the only consumer of OCCT's ModelingAlgorithms module. Upstream's
+# The CAD kernel is the only consumer of OCCT's ModelingAlgorithms module: TKFillet
-# DataExchange already pulls TKBool in transitively, so the true delta is these two.
+# (BRepFilletAPI), TKOffset (BRepOffsetAPI) and TKBool, which the other two need.
 #
 # PREPEND, never append: this list is single-pass static link order, dependents before
 # dependencies — note TKernel, which everything needs, is deliberately last. TKOffset
 # references BRepAlgo_Loop, which TKBool defines, so TKOffset must come BEFORE TKBool.
-# Appending put it after, and the Snapmaker fork's Flatpak build — the one configuration
+# Appending put it after, and a strictly single-pass linker (the Flatpak build) failed with
-# whose linker is strictly single-pass — failed with
 #     libTKOffset.a(BRepOffset_MakeLoops.cxx.o): undefined reference to
 #     `BRepAlgo_Loop::BRepAlgo_Loop()'
 # while the ordinary Linux, macOS and Windows links resolved it anyway. Use set() rather
 # than list(PREPEND), which needs CMake 3.15 and this project supports 3.13.
 if (SLIC3R_CAD)
-    set(OCCT_LIBS TKFillet TKOffset ${OCCT_LIBS})
+    set(OCCT_LIBS TKFillet TKOffset TKBool ${OCCT_LIBS})
+    # deps is configured separately, so its SLIC3R_CAD can differ from ours. The module is
+    # all-or-nothing, so one absent toolkit proves it; fail here rather than at link time.
+    if (NOT TARGET TKFillet)
+        message(FATAL_ERROR
+            "SLIC3R_CAD is ON, but the OpenCASCADE in ${CMAKE_PREFIX_PATH} was built without "
+            "BUILD_MODULE_ModelingAlgorithms. Rebuild the dependencies with -DSLIC3R_CAD=ON, "
+            "or configure this project with -DSLIC3R_CAD=OFF.")
+    endif ()
 endif ()
-# Publish the link list so the Windows packaging step can assert it ships a DLL for
+# Published for the Windows packaging step in the top-level CMakeLists.txt.
-# every toolkit we link, instead of shipping whatever the deps prefix happens to hold.
 set(OCCT_LIBS "${OCCT_LIBS}" CACHE INTERNAL "OCCT toolkits linked by libslic3r")
 
 target_link_libraries(libslic3r

src/slic3r/GUI/Preferences.cpp

@@ -1817,11 +1817,13 @@ void PreferencesDialog::create_items()
     auto reverse_mouse_zoom    = create_item_checkbox(_L("Reverse mouse zoom"), _L("If enabled, reverses the direction of zoom with mouse wheel."), "reverse_mouse_wheel_zoom");
     g_sizer->Add(reverse_mouse_zoom);
 
+#ifdef SLIC3R_CAD
     auto item_connector_face_glyph = create_item_checkbox(_L("Draw mate connectors as a face"),
         _L("In the Design tab, draw a mate connector as a small face instead of the conventional "
            "disc with a roll quadrant. A face's orientation is read without being learned. "
            "Turn this off for the conventional CAD representation."), "design_connector_face_glyph");
     g_sizer->Add(item_connector_face_glyph);
+#endif
 
     std::vector<wxString> ButtonDragActions = {_L("None"), _L("Pan"), _L("Rotate")};
     auto item_left_mouse_drag  = create_item_combobox(_L("Left Mouse Drag"), _L("Set the action that dragging the left mouse button should perform."), "left_mouse_drag_action", ButtonDragActions);