Add real slice validation for all printers (#14771)

# Description

Adds a --slice (-s) mode to the profile validator that slices a
two-colour cube through every shipped printer, expanding all custom
g-code (change_filament_gcode, machine start/end, etc.). This catches
invalid-placeholder / bad-flow / slicing errors that the static JSON
checks and unit tests can't see.

Included:
- Validator: new -s sweep mode; per-profile error attribution in the
log; resolves the synthetic 2nd-filament nozzle-mapping so multi-nozzle
BBL printers (incl. the Direct-Drive+Bowden X2D) validate cleanly.
- CI, two complementary paths:
- check_profiles.yml — runs the sweep on profile-only PRs (nightly
binary).
- build_all.yml — new parallel slice_check_linux job runs it on
engine/src PRs with the PR-built binary (build_all doesn't trigger on
resources/**, so no overlap). Runs off the build's artifact, so it
doesn't lengthen the build leg.
- Profile fixes surfaced by the sweep: Creality, FLSun, Ginger, Qidi,
RatRig, iQ.
- Engine: whitelist BBL firmware T-opcodes (T1001/T65279/T65535) in the
time estimator (log-only, no g-code change); dedupe a
per-filament/per-layer log flood in get_config_index.

# Screenshots/Recordings/Graphs

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## Tests

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changes made in this PR.
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[How to Download Pull Requests Artifacts for
Testing](https://www.orcaslicer.com/wiki/how_to_download_pr_artifacts)

.github/workflows/build_all.yml

@@ -165,6 +165,30 @@ jobs:
       os: ${{ vars.SELF_HOSTED && 'orca-macos-arm64' || 'macos-14' }}
       artifact: ${{ github.sha }}-tests-macos-arm64
       test-dir: build/arm64/tests
+  # Slice a two-colour cube through every shipped printer with this PR's engine
+  # so all custom g-code (change_filament_gcode, machine start/end, etc.) is
+  # expanded - catches slicing regressions the static profile checks and unit
+  # tests can't see. Profile-only PRs are covered by check_profiles.yml (nightly
+  # binary); this covers src/engine PRs with the PR-built binary. Runs in
+  # parallel off build_linux's artifact so it doesn't lengthen the build leg.
+  slice_check_linux:
+    name: Slice check (Linux x86_64)
+    needs: build_linux
+    if: ${{ !cancelled() && success() }}
+    runs-on: ${{ vars.SELF_HOSTED && 'orca-lnx-server' || 'ubuntu-24.04' }}
+    steps:
+      - name: Checkout repository
+        uses: actions/checkout@v7
+      - name: Download profile validator
+        uses: actions/download-artifact@v8
+        with:
+          name: ${{ github.sha }}-profile-validator-linux-x86_64
+          path: validator-bin
+      - name: Validate slice (expand custom g-code)
+        timeout-minutes: 60
+        run: |
+          chmod +x validator-bin/OrcaSlicer_profile_validator
+          ./validator-bin/OrcaSlicer_profile_validator -p "${{ github.workspace }}/resources/profiles" -s -l 2
   publish_test_results:
     name: Publish Test Results
     needs: [unit_tests_linux_x86_64, unit_tests_linux_aarch64, unit_tests_windows_x64, unit_tests_windows_arm64, unit_tests_macos_arm64]

.github/workflows/build_orca.yml

@@ -508,6 +508,20 @@ jobs:
           retention-days: 5
           if-no-files-found: error
 
+        # Ship the freshly-built validator so the parallel slice_check_linux job
+        # (build_all.yml) can slice-sweep the shipped profiles with this PR's
+        # engine. Stable sha-based name mirrors the tests artifact above so the
+        # downstream job downloads it by exact name.
+      - name: Upload profile validator (for slice check)
+        if: runner.os == 'Linux' && inputs.arch != 'aarch64'
+        uses: actions/upload-artifact@v7
+        with:
+          name: ${{ github.sha }}-profile-validator-linux-x86_64
+          overwrite: true
+          path: ./build/src/Release/OrcaSlicer_profile_validator
+          retention-days: 5
+          if-no-files-found: error
+
       - name: Run external slicer regression tests
         if: runner.os == 'Linux' && inputs.arch != 'aarch64'
         timeout-minutes: 20

.github/workflows/check_profiles.yml

@@ -49,6 +49,15 @@ jobs:
           set +e
           ./OrcaSlicer_profile_validator -p ${{ github.workspace }}/resources/profiles -l 2 2>&1 | tee ${{ runner.temp }}/validate_system.log
           exit ${PIPESTATUS[0]}
+      # Slice a two-colour cube through every printer so all custom g-code (incl. change_filament_gcode)
+      # is expanded - catches undefined-placeholder / invalid-flow bugs the static checks above cannot see.
+      - name: validate slice (expand custom g-code)
+        id: validate_slice
+        continue-on-error: true
+        run: |
+          set +e
+          ./OrcaSlicer_profile_validator -p ${{ github.workspace }}/resources/profiles -s -l 2 2>&1 | tee ${{ runner.temp }}/validate_slice.log
+          exit ${PIPESTATUS[0]}
       # For now run filament subtype check only for BBL profiles until we fix other vendors' profiles.
       - name: validate filament subtype check for BBL profiles
         id: validate_filament_subtypes
@@ -166,7 +175,7 @@ jobs:
           echo "${{ github.event.pull_request.number }}" > ${{ runner.temp }}/profile-check-results/pr_number.txt
 
       - name: Prepare comment artifact
-        if: ${{ always() && github.event_name == 'pull_request' && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_filament_subtypes.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
+        if: ${{ always() && github.event_name == 'pull_request' && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_slice.outcome == 'failure' || steps.validate_filament_subtypes.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
         run: |
           {
             # Marker matched by check_profiles_comment.yml to delete prior comments.
@@ -192,6 +201,15 @@ jobs:
               echo ""
             fi
 
+            if [ "${{ steps.validate_slice.outcome }}" = "failure" ]; then
+              echo "### Slice Validation Failed (custom g-code expansion)"
+              echo ""
+              echo '```'
+              head -c 30000 ${{ runner.temp }}/validate_slice.log || echo "No output captured"
+              echo '```'
+              echo ""
+            fi
+
             if [ "${{ steps.validate_filament_subtypes.outcome }}" = "failure" ]; then
               echo "### BBL Filament Subtype Validation Failed"
               echo ""
@@ -223,7 +241,7 @@ jobs:
           retention-days: 1
 
       - name: Fail if any check failed
-        if: ${{ always() && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_filament_subtypes.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
+        if: ${{ always() && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_slice.outcome == 'failure' || steps.validate_filament_subtypes.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
         run: |
           echo "One or more profile checks failed. See above for details."
           exit 1

.github/workflows/unit_tests.yml

@@ -28,11 +28,15 @@ jobs:
       - name: Checkout
         uses: actions/checkout@v7
         with:
-          # tests/data is referenced by absolute path (TEST_DATA_DIR).
+          # Tests reach outside tests/ at runtime: tests/data (TEST_DATA_DIR) and
+          # resources/profiles (PROFILES_DIR) by baked-in absolute path, plus
+          # resources/info (nozzle data) via resources_dir() during a real slice.
+          # Check out all of resources/ so no test hits a missing-file path.
           sparse-checkout: |
             .github
             scripts
             tests
+            resources
       - name: Apt-Install Dependencies
         if: runner.os == 'Linux' && !vars.SELF_HOSTED
         uses: ./.github/actions/apt-install-deps