Merge Main into Belt Printer

Merge origin/main (00429da739) into belt-printer.

Conflicts resolved:
- src/CMakeLists.txt: keep both wxInspector workarounds.
- GCodeProcessor.cpp: keep the belt compare_pos / z_for_height lines.
- PrintObjectSlice.cpp: the belt bbox-Z guard also covers main's
  printable_region_ids bookkeeping.
- TreeSupport.cpp: the belt-floor check runs before main's PendingNode
  queueing.
- Tab.hpp: keep the belt fields, drop the removed upload description
  fields.
- tests/libslic3r/CMakeLists.txt: keep both test files.

Also included:
- eSUN PLA belt presets declare their own filament_id (OFkrxQC4) and
  scripts/filament_id_snapshot.json is regenerated, as main's filament_id
  check requires.
- Custom.json version bumped to 02.04.00.05 so the belt entries reach
  existing installs.
- Fix the ambiguous WithinRel call in the belt apron width test, which
  otherwise breaks the fff_print build.

tests/libslic3r/CMakeLists.txt

@@ -9,6 +9,7 @@ add_executable(${_TEST_NAME}_tests
     test_arrange.cpp
     test_bambu_networking.cpp
     test_belt_brim.cpp
+    test_buildvolume.cpp
     test_calib.cpp
     test_clipper_offset.cpp
     test_clipper_utils.cpp
@@ -19,6 +20,7 @@ add_executable(${_TEST_NAME}_tests
     test_preset_setting_id.cpp
     test_preset_diff.cpp
     test_vendor_cache.cpp
+    test_preset_options.cpp
     test_elephant_foot_compensation.cpp
     test_fill_corner_smoothing.cpp
     test_filament_mixer.cpp
@@ -29,6 +31,7 @@ add_executable(${_TEST_NAME}_tests
     test_polygon.cpp
     test_mutable_polygon.cpp
     test_mutable_priority_queue.cpp
+    test_minimum_spanning_tree.cpp
     test_nozzle_volume_type.cpp
     test_step.cpp
     test_stl.cpp
@@ -39,6 +42,8 @@ add_executable(${_TEST_NAME}_tests
     test_utils.cpp
     test_timeutils.cpp
     test_voronoi.cpp
+    test_wipe_tower_estimate.cpp
+    test_wipe_tower.cpp
     test_optimizers.cpp
     test_ordering_strategies.cpp
     # test_png_io.cpp

tests/libslic3r/test_3mf.cpp

@@ -1,6 +1,5 @@
 
 #include "libslic3r/Model.hpp"
-#include "libslic3r/TriangleSelector.hpp"
 #include "libslic3r/Format/3mf.hpp"
 #include "libslic3r/Format/bbs_3mf.hpp"
 #include "libslic3r/Format/STL.hpp"
@@ -9,9 +8,12 @@
 #include "libslic3r/Preset.hpp"
 #include "libslic3r/MultiNozzleUtils.hpp"
 #include "libslic3r/ProjectTask.hpp"
+#include "libslic3r/PublishSettings.hpp"
 
 #include "test_utils.hpp"
 
+#include <nlohmann/json.hpp>
+
 #include <boost/filesystem/operations.hpp>
 
 #include <catch2/catch_tostring.hpp>
@@ -499,7 +501,6 @@ SCENARIO("Nozzle-group metadata .3mf round-trip", "[3mf][MultiNozzle]") {
     }
 }
 
-
 // A mixed-color filament occupies an ordinary filament slot, and painting with it stores an
 // ordinary extruder state: a project saved by BambuStudio encodes filament 5 of a 5-slot setup
 // as paint state 5, with the mix described by the parallel filament_mixed_* project arrays.
@@ -590,3 +591,639 @@ SCENARIO("Mixed-color filament setup and painting round-trip through a .3mf", "[
         }
     }
 }
+// Locks the serialization contract of the "Publish" metadata: the orca_published flag and the
+// orca_published_keys JSON array in model.model_info->metadata_items must survive a store_bbs_3mf ->
+// load_bbs_3mf round-trip unchanged. (The full preset-preservation behavior is exercised
+// headlessly in test_preset_bundle_loading.cpp.)
+SCENARIO("Published 3MF round-trips the published flag and published_keys metadata", "[3mf]") {
+    GIVEN("a model carrying published metadata") {
+        Model model;
+        std::string src_file = std::string(TEST_DATA_DIR) + "/test_3mf/Prusa.stl";
+        REQUIRE(load_stl(src_file.c_str(), &model));
+        model.add_default_instances();
+
+        model.model_info = std::make_shared<ModelInfo>();
+        model.model_info->metadata_items[ORCA_PUBLISHED_TAG]      = "1";
+        model.model_info->metadata_items[ORCA_PUBLISHED_KEYS_TAG] = R"(["layer_height","wall_thickness"])";
+
+        // store_bbs_3mf stages project_settings.config through the model's backup path; point
+        // it at a writable temp dir (the default lives under a read-only root in CI).
+        ScopedTemporaryDir backup_dir("orca_pub");
+        model.set_backup_path(backup_dir.string());
+
+        WHEN("stored to and reloaded from a .3mf") {
+            ScopedTemporaryFile temp(".3mf");
+            const std::string test_file = temp.string();
+
+            DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+            StoreParams store_params;
+            store_params.path    = test_file.c_str();
+            store_params.model   = &model;
+            store_params.config  = &config;
+            store_params.strategy = SaveStrategy::Zip64 | SaveStrategy::Silence;
+            REQUIRE(store_bbs_3mf(store_params));
+
+            Model dst_model;
+            DynamicPrintConfig dst_config;
+            ConfigSubstitutionContext ctxt{ ForwardCompatibilitySubstitutionRule::Enable };
+            PlateDataPtrs        dst_plates;
+            std::vector<Preset*> project_presets;
+            bool   is_bbl_3mf = false, is_orca_3mf = false;
+            Semver file_version;
+            bool loaded = load_bbs_3mf(test_file.c_str(), &dst_config, &ctxt, &dst_model, &dst_plates,
+                                       &project_presets, &is_bbl_3mf, &is_orca_3mf, &file_version, nullptr,
+                                       LoadStrategy::LoadModel | LoadStrategy::LoadConfig);
+            THEN("the published metadata round-trips unchanged") {
+                REQUIRE(loaded);
+                REQUIRE(dst_model.model_info != nullptr);
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_TAG] == "1");
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_KEYS_TAG] == R"(["layer_height","wall_thickness"])");
+
+                // The orca_published_keys value is a JSON array of setting keys; it must parse back to
+                // the same keys that were selected.
+                nlohmann::json keys = nlohmann::json::parse(dst_model.model_info->metadata_items[ORCA_PUBLISHED_KEYS_TAG]);
+                REQUIRE(keys.is_array());
+                REQUIRE(keys.size() == 2);
+                REQUIRE(keys[0] == "layer_height");
+                REQUIRE(keys[1] == "wall_thickness");
+            }
+            release_PlateData_list(dst_plates);
+        }
+    }
+}
+
+// A normal 3MF (no Publish metadata) must load identically: the loader must not fabricate a
+// "orca_published" flag or orca_published_keys for files that never carried them.
+SCENARIO("Legacy 3MF without published metadata loads unchanged", "[3mf]") {
+    GIVEN("a model without any published metadata") {
+        Model model;
+        std::string src_file = std::string(TEST_DATA_DIR) + "/test_3mf/Prusa.stl";
+        REQUIRE(load_stl(src_file.c_str(), &model));
+        model.add_default_instances();
+
+        ScopedTemporaryDir backup_dir("orca_legacy");
+        model.set_backup_path(backup_dir.string());
+
+        WHEN("stored to and reloaded from a .3mf") {
+            ScopedTemporaryFile temp(".3mf");
+            const std::string test_file = temp.string();
+
+            DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+            StoreParams store_params;
+            store_params.path    = test_file.c_str();
+            store_params.model   = &model;
+            store_params.config  = &config;
+            store_params.strategy = SaveStrategy::Zip64 | SaveStrategy::Silence;
+            REQUIRE(store_bbs_3mf(store_params));
+
+            Model dst_model;
+            DynamicPrintConfig dst_config;
+            ConfigSubstitutionContext ctxt{ ForwardCompatibilitySubstitutionRule::Enable };
+            PlateDataPtrs        dst_plates;
+            std::vector<Preset*> project_presets;
+            bool   is_bbl_3mf = false, is_orca_3mf = false;
+            Semver file_version;
+            bool loaded = load_bbs_3mf(test_file.c_str(), &dst_config, &ctxt, &dst_model, &dst_plates,
+                                       &project_presets, &is_bbl_3mf, &is_orca_3mf, &file_version, nullptr,
+                                       LoadStrategy::LoadModel | LoadStrategy::LoadConfig);
+            THEN("no published key is fabricated") {
+                REQUIRE(loaded);
+                REQUIRE(dst_model.model_info != nullptr);
+                REQUIRE(dst_model.model_info->metadata_items.count(ORCA_PUBLISHED_TAG) == 0);
+                REQUIRE(dst_model.model_info->metadata_items.count(ORCA_PUBLISHED_KEYS_TAG) == 0);
+            }
+            release_PlateData_list(dst_plates);
+        }
+    }
+}
+
+// Locks the serialization contract of the orca_published_material_keys metadata: the per-entry JSON
+// must survive a store_bbs_3mf -> load_bbs_3mf round-trip verbatim, exactly like orca_published_keys.
+SCENARIO("Published 3MF round-trips the published_material_keys metadata", "[3mf]") {
+    GIVEN("a model carrying published material keys metadata") {
+        Model model;
+        std::string src_file = std::string(TEST_DATA_DIR) + "/test_3mf/Prusa.stl";
+        REQUIRE(load_stl(src_file.c_str(), &model));
+        model.add_default_instances();
+
+        const std::string material_keys_json =
+            R"([{"material":{"filament_type":"PLA","filament_vendor":"Generic","filament_id":"GFL99"},"slot":0,"keys":["filament_retraction_length","filament_z_hop"]}])";
+
+        model.model_info = std::make_shared<ModelInfo>();
+        model.model_info->metadata_items[ORCA_PUBLISHED_MATERIAL_TAG] = material_keys_json;
+
+        ScopedTemporaryDir backup_dir("orca_pub_mat");
+        model.set_backup_path(backup_dir.string());
+
+        WHEN("stored to and reloaded from a .3mf") {
+            ScopedTemporaryFile temp(".3mf");
+            const std::string test_file = temp.string();
+
+            DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+            StoreParams store_params;
+            store_params.path    = test_file.c_str();
+            store_params.model   = &model;
+            store_params.config  = &config;
+            store_params.strategy = SaveStrategy::Zip64 | SaveStrategy::Silence;
+            REQUIRE(store_bbs_3mf(store_params));
+
+            Model dst_model;
+            DynamicPrintConfig dst_config;
+            ConfigSubstitutionContext ctxt{ ForwardCompatibilitySubstitutionRule::Enable };
+            PlateDataPtrs        dst_plates;
+            std::vector<Preset*> project_presets;
+            bool   is_bbl_3mf = false, is_orca_3mf = false;
+            Semver file_version;
+            bool loaded = load_bbs_3mf(test_file.c_str(), &dst_config, &ctxt, &dst_model, &dst_plates,
+                                       &project_presets, &is_bbl_3mf, &is_orca_3mf, &file_version, nullptr,
+                                       LoadStrategy::LoadModel | LoadStrategy::LoadConfig);
+            THEN("the published material keys metadata round-trips unchanged") {
+                REQUIRE(loaded);
+                REQUIRE(dst_model.model_info != nullptr);
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_MATERIAL_TAG] == material_keys_json);
+
+                // The value must parse back to one material entry carrying the nested identity
+                // object, the author slot ordinal and the key list.
+                nlohmann::json entries = nlohmann::json::parse(material_keys_json);
+                REQUIRE(entries.is_array());
+                REQUIRE(entries.size() == 1);
+                REQUIRE(entries[0]["material"]["filament_type"] == "PLA");
+                REQUIRE(entries[0]["material"]["filament_vendor"] == "Generic");
+                REQUIRE(entries[0]["material"]["filament_id"] == "GFL99");
+                REQUIRE(entries[0]["slot"] == 0);
+                REQUIRE(entries[0]["keys"].is_array());
+                REQUIRE(entries[0]["keys"].size() == 2);
+                REQUIRE(entries[0]["keys"][0] == "filament_retraction_length");
+            }
+            release_PlateData_list(dst_plates);
+        }
+    }
+}
+
+SCENARIO("Minimal published 3MF omits project config, preset dumps and slicer tags", "[3mf]") {
+    GIVEN("a multi-instance model carrying published metadata and a published_config payload") {
+        Model model;
+        std::string src_file = std::string(TEST_DATA_DIR) + "/test_3mf/Prusa.stl";
+        REQUIRE(load_stl(src_file.c_str(), &model));
+        model.add_default_instances();
+        // A second instance: tag-less third-party files get their multi-instance objects split,
+        // published files must not (the loader recognizes them by their metadata).
+        model.objects.front()->add_instance();
+
+        DynamicPrintConfig full_cfg = DynamicPrintConfig::full_print_config();
+        full_cfg.set_key_value("layer_height", new ConfigOptionFloat(0.24));
+        full_cfg.set_key_value("retraction_length", new ConfigOptionFloats({ 1.2 }));
+
+        const std::vector<std::string> published_keys = { "layer_height", "retraction_length" };
+        const std::vector<PublishedMaterialEntry> material_keys = {
+            { "PLA", "Generic", "GFL99", "", "Generic PLA", 0, { "filament_retraction_length" } }
+        };
+
+        // The payload builder keeps the published and identity keys and drops everything else.
+        DynamicPrintConfig filtered_cfg = filter_published_config(full_cfg, published_keys, material_keys);
+        REQUIRE(filtered_cfg.option("layer_height") != nullptr);
+        REQUIRE(filtered_cfg.option("retraction_length") != nullptr);
+        REQUIRE(filtered_cfg.option("filament_colour") != nullptr);
+        REQUIRE(filtered_cfg.option("filament_type") != nullptr);
+        REQUIRE(filtered_cfg.option("wipe_tower_x") != nullptr);
+        REQUIRE(filtered_cfg.option("sparse_infill_density") == nullptr);
+        REQUIRE(filtered_cfg.option("machine_start_gcode") == nullptr);
+
+        // Serialize the payload exactly like export_published_3mf does.
+        std::string payload;
+        for (const std::string &key : filtered_cfg.keys())
+            payload += key + " = " + filtered_cfg.opt_serialize(key) + "\n";
+
+        model.model_info = std::make_shared<ModelInfo>();
+        model.model_info->metadata_items[ORCA_PUBLISHED_TAG]      = "1";
+        model.model_info->metadata_items[ORCA_PUBLISHED_KEYS_TAG] = R"(["layer_height","retraction_length"])";
+        model.model_info->metadata_items[ORCA_PUBLISHED_CONFIG_TAG] = payload;
+
+        ScopedTemporaryDir backup_dir("orca_min_pub");
+        model.set_backup_path(backup_dir.string());
+
+        WHEN("stored using SaveStrategy::MinimalPublished and reloaded") {
+            ScopedTemporaryFile temp(".3mf");
+            const std::string test_file = temp.string();
+
+            // Create a fake project preset to verify MinimalPublished omits it.
+            Preset preset(Preset::TYPE_PRINT, "TestPrintPreset");
+            preset.config = full_cfg;
+            std::vector<Preset*> project_presets = { &preset };
+
+            StoreParams store_params;
+            store_params.path    = test_file.c_str();
+            store_params.model   = &model;
+            store_params.config  = &filtered_cfg;
+            store_params.project_presets = project_presets;
+            store_params.strategy = SaveStrategy::Zip64 | SaveStrategy::Silence | SaveStrategy::MinimalPublished;
+            REQUIRE(store_bbs_3mf(store_params));
+
+            Model dst_model;
+            ScopedTemporaryDir loaded_backup_dir("orca_min_pub_loaded");
+            dst_model.set_backup_path(loaded_backup_dir.string());
+            DynamicPrintConfig dst_config;
+            ConfigSubstitutionContext ctxt{ ForwardCompatibilitySubstitutionRule::Enable };
+            PlateDataPtrs        dst_plates;
+            std::vector<Preset*> loaded_presets;
+            bool   is_bbl_3mf = false, is_orca_3mf = false;
+            Semver file_version;
+            bool loaded = load_bbs_3mf(test_file.c_str(), &dst_config, &ctxt, &dst_model, &dst_plates,
+                                       &loaded_presets, &is_bbl_3mf, &is_orca_3mf, &file_version, nullptr,
+                                       LoadStrategy::LoadModel | LoadStrategy::LoadConfig);
+            THEN("the 3MF loads without project config or embedded presets") {
+                REQUIRE(loaded);
+                REQUIRE(dst_config.empty());
+                REQUIRE(loaded_presets.empty());
+            }
+            THEN("the file carries no slicer tags and classifies as a generic 3MF") {
+                REQUIRE_FALSE(is_bbl_3mf);
+                REQUIRE_FALSE(is_orca_3mf);
+                // No Application / OrcaSlicer tag: old receivers import the geometry silently
+                // instead of showing a baked-in, wrong "old version" popup.
+                REQUIRE_FALSE(file_version.valid());
+            }
+            THEN("the geometry keeps BBS-grade handling: instances are not split") {
+                REQUIRE(dst_model.objects.size() == 1);
+                REQUIRE(dst_model.objects.front()->instances.size() == 2);
+            }
+            THEN("the published metadata and payload round-trip unchanged") {
+                REQUIRE(dst_model.model_info != nullptr);
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_TAG] == "1");
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_KEYS_TAG] == R"(["layer_height","retraction_length"])");
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_CONFIG_TAG] == payload);
+            }
+            THEN("the payload parses back to the published values") {
+                DynamicPrintConfig parsed_payload;
+                parsed_payload.load_from_ini_string(dst_model.model_info->metadata_items[ORCA_PUBLISHED_CONFIG_TAG], ForwardCompatibilitySubstitutionRule::Enable);
+                REQUIRE(parsed_payload.option("layer_height") != nullptr);
+                REQUIRE_THAT(parsed_payload.opt_float("layer_height"), Catch::Matchers::WithinAbs(0.24, 1e-6));
+                REQUIRE(parsed_payload.option("retraction_length") != nullptr);
+                REQUIRE_THAT(parsed_payload.opt<ConfigOptionFloats>("retraction_length")->get_at(0), Catch::Matchers::WithinAbs(1.2, 1e-6));
+            }
+            release_PlateData_list(dst_plates);
+        }
+    }
+}
+
+// A minimal published 3MF must not leak the slicer tags of the source project. The exporter seeds
+// metadata_item_map from the input file's metadata_items, so re-publishing a project opened from a
+// regular Orca/BBS 3MF (the typical remix flow) must strip the Application / OrcaSlicer tags it
+// came with, otherwise old receivers route onto the baked-in "old version" popup.
+SCENARIO("MinimalPublished strips slicer tags carried by the source project", "[3mf]") {
+    GIVEN("a model loaded from a regular Orca/BBS 3MF whose metadata carries the slicer tags") {
+        Model model;
+        std::string src_file = std::string(TEST_DATA_DIR) + "/test_3mf/Prusa.stl";
+        REQUIRE(load_stl(src_file.c_str(), &model));
+        model.add_default_instances();
+
+        model.model_info = std::make_shared<ModelInfo>();
+        model.model_info->metadata_items[ORCA_PUBLISHED_TAG] = "1";
+        model.model_info->metadata_items["Application"]     = "BambuStudio-2.0.0";
+        model.model_info->metadata_items["OrcaSlicer"]      = "2.1.0";
+
+        ScopedTemporaryDir backup_dir("orca_strip_tags");
+        model.set_backup_path(backup_dir.string());
+
+        WHEN("stored using SaveStrategy::MinimalPublished and reloaded") {
+            ScopedTemporaryFile temp(".3mf");
+            const std::string test_file = temp.string();
+
+            DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+            StoreParams store_params;
+            store_params.path    = test_file.c_str();
+            store_params.model   = &model;
+            store_params.config  = &config;
+            store_params.strategy = SaveStrategy::Zip64 | SaveStrategy::Silence | SaveStrategy::MinimalPublished;
+            REQUIRE(store_bbs_3mf(store_params));
+
+            Model dst_model;
+            DynamicPrintConfig dst_config;
+            ConfigSubstitutionContext ctxt{ ForwardCompatibilitySubstitutionRule::Enable };
+            PlateDataPtrs        dst_plates;
+            std::vector<Preset*> loaded_presets;
+            bool   is_bbl_3mf = false, is_orca_3mf = false;
+            Semver file_version;
+            bool loaded = load_bbs_3mf(test_file.c_str(), &dst_config, &ctxt, &dst_model, &dst_plates,
+                                       &loaded_presets, &is_bbl_3mf, &is_orca_3mf, &file_version, nullptr,
+                                       LoadStrategy::LoadModel | LoadStrategy::LoadConfig);
+            THEN("the source slicer tags are stripped, not carried through") {
+                REQUIRE(loaded);
+                REQUIRE(dst_model.model_info != nullptr);
+                REQUIRE(dst_model.model_info->metadata_items.count("Application") == 0);
+                REQUIRE(dst_model.model_info->metadata_items.count("OrcaSlicer") == 0);
+                // The published marker itself must survive.
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_TAG] == "1");
+            }
+            THEN("the file classifies as a generic 3MF without a version popup") {
+                REQUIRE_FALSE(is_bbl_3mf);
+                REQUIRE_FALSE(is_orca_3mf);
+                REQUIRE_FALSE(file_version.valid());
+            }
+            release_PlateData_list(dst_plates);
+        }
+    }
+}
+
+// An entry masks the non-published slots to their defaults so publishing slot 1 never leaks slot
+// 0's value into the file. Both a full entry (the whole-slot key list) and a partial entry (a
+// per-slot key) go through the same masking path in filter_published_config (keys and full_keys
+// are filtered identically), so the two forms are exercised together.
+SCENARIO("Published entries mask the other slots to their defaults", "[3mf]") {
+    const bool full = GENERATE(true, false);
+    GIVEN("a full print configuration with two filament slots") {
+        DynamicPrintConfig full_cfg = DynamicPrintConfig::full_print_config();
+        full_cfg.opt<ConfigOptionFloats>("filament_diameter")->values = { 1.75, 1.75 };
+        full_cfg.opt<ConfigOptionStrings>("filament_colour")->values = { "#111111", "#222222" };
+        // filament_flow_ratio carries a non-empty option default (1.0) of the same type, so the
+        // mask can restore it on the non-published slot.
+        full_cfg.opt<ConfigOptionFloatsNullable>("filament_flow_ratio", true)->values = { 1.02, 0.98 };
+
+        WHEN("filtering with a published entry for slot 1") {
+            PublishedMaterialEntry entry;
+            entry.slot = 1;
+            if (full) {
+                entry.full      = true;
+                entry.full_keys = { "filament_flow_ratio" };
+            } else {
+                entry.keys = { "filament_flow_ratio" };
+            }
+            DynamicPrintConfig filtered_cfg = filter_published_config(full_cfg, {}, { entry });
+
+            THEN("the selected key is present with the author's slot value") {
+                REQUIRE(filtered_cfg.option("filament_flow_ratio") != nullptr);
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloatsNullable>("filament_flow_ratio")->values[1], Catch::Matchers::WithinAbs(0.98, 1e-6));
+            }
+            THEN("the non-published slot is masked to its default") {
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloatsNullable>("filament_flow_ratio")->values[0], Catch::Matchers::WithinAbs(1.0, 1e-6));
+            }
+            THEN("the identity keys stay present") {
+                REQUIRE(filtered_cfg.option("filament_colour") != nullptr);
+            }
+        }
+    }
+}
+
+// A key needing slot masking that cannot be masked (no registered option default of the same
+// type) is dropped from the payload entirely instead of shipping the author's whole vector.
+SCENARIO("Unmaskable keys are dropped from the published payload instead of leaking", "[3mf]") {
+    GIVEN("a config carrying a synthetic def-less vector key and a maskable one") {
+        DynamicPrintConfig full_cfg = DynamicPrintConfig::full_print_config();
+        full_cfg.opt<ConfigOptionFloats>("filament_diameter")->values = { 1.75, 1.75 };
+        full_cfg.opt<ConfigOptionStrings>("filament_colour")->values  = { "#111111", "#222222" };
+        // Not a PrintConfig key: print_config_def has no default to mask with.
+        full_cfg.set_key_value("orca_synthetic_setting", new ConfigOptionFloats({ 9.9, 8.8 }));
+        full_cfg.opt<ConfigOptionFloatsNullable>("filament_flow_ratio", true)->values = { 1.02, 0.98 };
+
+        PublishedMaterialEntry partial_entry;
+        partial_entry.slot = 1;
+        partial_entry.keys = { "orca_synthetic_setting", "filament_flow_ratio" };
+
+        WHEN("filtering with a partial entry for slot 1") {
+            DynamicPrintConfig filtered_cfg = filter_published_config(full_cfg, {}, { partial_entry });
+
+            THEN("the unmaskable synthetic key is not published") {
+                REQUIRE(filtered_cfg.option("orca_synthetic_setting") == nullptr);
+            }
+            THEN("the maskable key is present, author slot kept, other slot masked") {
+                REQUIRE(filtered_cfg.opt<ConfigOptionFloatsNullable>("filament_flow_ratio") != nullptr);
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloatsNullable>("filament_flow_ratio")->values[1], Catch::Matchers::WithinAbs(0.98, 1e-6));
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloatsNullable>("filament_flow_ratio")->values[0], Catch::Matchers::WithinAbs(1.0, 1e-6));
+            }
+            THEN("the identity keys stay present") {
+                REQUIRE(filtered_cfg.option("filament_colour") != nullptr);
+            }
+        }
+    }
+}
+
+// A per-extruder printer key carrying a "#N" variant (e.g. retraction_length#1) must not serialize
+// every extruder's value: the base is masked to the author's extruder and the other slots are
+// restored to their option default, matching the material-side slot-masking invariant. A bare
+// printer base key (no variant) keeps whole-vector serialization.
+SCENARIO("Published per-extruder printer keys mask the other extruders to their defaults", "[3mf]") {
+    GIVEN("a full print configuration with three extruders carrying per-extruder retraction values") {
+        DynamicPrintConfig full_cfg = DynamicPrintConfig::full_print_config();
+        // Non-default values on the un-selected slots, so a leak is distinguishable from the mask
+        // restoring the option default (retraction_length defaults to {0.8}).
+        full_cfg.opt<ConfigOptionFloats>("retraction_length")->values = { 3.0, 1.2, 4.0 };
+
+        WHEN("filtering with only extruder 1's retraction_length checked") {
+            DynamicPrintConfig filtered_cfg = filter_published_config(full_cfg, { "retraction_length#1" }, {});
+
+            THEN("the author's extruder value survives") {
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloats>("retraction_length")->values[1], Catch::Matchers::WithinAbs(1.2, 1e-6));
+            }
+            THEN("the other extruders are masked to their default") {
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloats>("retraction_length")->values[0], Catch::Matchers::WithinAbs(0.8, 1e-6));
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloats>("retraction_length")->values[2], Catch::Matchers::WithinAbs(0.8, 1e-6));
+            }
+        }
+        WHEN("filtering the bare base key without a '#N' variant") {
+            DynamicPrintConfig filtered_cfg = filter_published_config(full_cfg, { "retraction_length" }, {});
+
+            THEN("the whole vector is serialized unmasked") {
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloats>("retraction_length")->values[0], Catch::Matchers::WithinAbs(3.0, 1e-6));
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloats>("retraction_length")->values[1], Catch::Matchers::WithinAbs(1.2, 1e-6));
+                REQUIRE_THAT(filtered_cfg.opt<ConfigOptionFloats>("retraction_length")->values[2], Catch::Matchers::WithinAbs(4.0, 1e-6));
+            }
+        }
+    }
+}
+
+// The extended per-entry fields (full dump list, published type and colour) travel inside the
+// published_material_keys metadata and round-trip unchanged.
+SCENARIO("Published 3MF round-trips the extended material metadata", "[3mf]") {
+    GIVEN("a model carrying extended published material keys metadata") {
+        Model model;
+        std::string src_file = std::string(TEST_DATA_DIR) + "/test_3mf/Prusa.stl";
+        REQUIRE(load_stl(src_file.c_str(), &model));
+        model.add_default_instances();
+
+        const std::string material_keys_json =
+            R"([{"material":{"filament_type":"PLA","filament_vendor":"Generic","filament_id":"GFL99","setting_id":"RFs9eCKYOMUSmvZf","name":"Generic PLA Matte @System"},"slot":1,"keys":[],"full":true,"full_keys":["filament_retraction_length","filament_colour"],"publish_type":true,"type":"PLA","publish_color":false,"color":""}])";
+
+        model.model_info = std::make_shared<ModelInfo>();
+        model.model_info->metadata_items[ORCA_PUBLISHED_MATERIAL_TAG] = material_keys_json;
+
+        ScopedTemporaryDir backup_dir("orca_pub_mat2");
+        model.set_backup_path(backup_dir.string());
+
+        WHEN("stored to and reloaded from a .3mf") {
+            ScopedTemporaryFile temp(".3mf");
+            const std::string test_file = temp.string();
+
+            DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+            StoreParams store_params;
+            store_params.path     = test_file.c_str();
+            store_params.model    = &model;
+            store_params.config   = &config;
+            store_params.strategy = SaveStrategy::Zip64 | SaveStrategy::Silence;
+            REQUIRE(store_bbs_3mf(store_params));
+
+            Model dst_model;
+            DynamicPrintConfig dst_config;
+            ConfigSubstitutionContext ctxt{ ForwardCompatibilitySubstitutionRule::Enable };
+            PlateDataPtrs        dst_plates;
+            std::vector<Preset*> project_presets;
+            bool   is_bbl_3mf = false, is_orca_3mf = false;
+            Semver file_version;
+            bool loaded = load_bbs_3mf(test_file.c_str(), &dst_config, &ctxt, &dst_model, &dst_plates,
+                                       &project_presets, &is_bbl_3mf, &is_orca_3mf, &file_version, nullptr,
+                                       LoadStrategy::LoadModel | LoadStrategy::LoadConfig);
+            THEN("the extended material metadata round-trips unchanged") {
+                REQUIRE(loaded);
+                REQUIRE(dst_model.model_info != nullptr);
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_MATERIAL_TAG] == material_keys_json);
+
+                // The value must parse back with every extended field intact.
+                nlohmann::json entries = nlohmann::json::parse(material_keys_json);
+                REQUIRE(entries.is_array());
+                REQUIRE(entries.size() == 1);
+                REQUIRE(entries[0]["full"].get<bool>() == true);
+                REQUIRE(entries[0]["full_keys"].is_array());
+                REQUIRE(entries[0]["full_keys"].size() == 2);
+                REQUIRE(entries[0]["publish_type"].get<bool>() == true);
+                REQUIRE(entries[0]["type"] == "PLA");
+                REQUIRE(entries[0]["publish_color"].get<bool>() == false);
+            }
+            release_PlateData_list(dst_plates);
+        }
+    }
+}
+
+// A published mixed filament serializes its whole definition (components, ratios, gradient)
+// masked to the author's slot: the mix slot's values survive, the non-published slots reset to
+// their defaults, so a partial publish never leaks another slot's mix data.
+SCENARIO("Published mixed-filament keys are masked to the author's slot", "[3mf]") {
+    GIVEN("a full print configuration with three slots, one of them mixed") {
+        DynamicPrintConfig full_cfg = DynamicPrintConfig::full_print_config();
+        full_cfg.opt<ConfigOptionFloats>("filament_diameter")->values = { 1.75, 1.75, 1.75 };
+        full_cfg.opt<ConfigOptionStrings>("filament_colour")->values  = { "#111111", "#222222", "#333333" };
+        full_cfg.opt<ConfigOptionBools>("filament_is_mixed")->values  = { 0, 0, 1 };
+        full_cfg.opt<ConfigOptionStrings>("filament_mixed_components")->values       = { "", "", "1,2" };
+        full_cfg.opt<ConfigOptionStrings>("filament_mixed_sublayer_ratios")->values   = { "", "", "0.6,0.4" };
+        full_cfg.opt<ConfigOptionBools>("filament_mixed_gradient")->values            = { 0, 0, 1 };
+        full_cfg.opt<ConfigOptionStrings>("filament_mixed_gradient_range")->values    = { "", "", "0.9,0.1" };
+        full_cfg.opt<ConfigOptionStrings>("filament_mixed_gradient_curve")->values    = { "", "", "0,0.1|1,0.9" };
+        full_cfg.opt<ConfigOptionBools>("filament_mixed_gradient_per_part")->values   = { 0, 0, 1 };
+
+        PublishedMaterialEntry mix_entry;
+        mix_entry.slot = 2;
+        mix_entry.keys = {
+            "filament_is_mixed",          "filament_mixed_components",       "filament_mixed_sublayer_ratios",
+            "filament_mixed_gradient",    "filament_mixed_gradient_range",   "filament_mixed_gradient_curve",
+            "filament_mixed_gradient_per_part"
+        };
+
+        WHEN("filtering with a mixed entry for slot 2") {
+            DynamicPrintConfig filtered_cfg = filter_published_config(full_cfg, {}, { mix_entry });
+
+            THEN("the author's mixed slot keeps its definition") {
+                REQUIRE(filtered_cfg.option("filament_is_mixed") != nullptr);
+                REQUIRE(filtered_cfg.opt<ConfigOptionBools>("filament_is_mixed")->values == std::vector<unsigned char>{ 0, 0, 1 });
+                const auto& components = filtered_cfg.opt<ConfigOptionStrings>("filament_mixed_components")->values;
+                REQUIRE(components.size() == 3);
+                CHECK(components[2] == "1,2");
+                CHECK(filtered_cfg.opt<ConfigOptionStrings>("filament_mixed_sublayer_ratios")->values[2] == "0.6,0.4");
+                CHECK(filtered_cfg.opt<ConfigOptionStrings>("filament_mixed_gradient_curve")->values[2] == "0,0.1|1,0.9");
+                CHECK(filtered_cfg.opt<ConfigOptionBools>("filament_mixed_gradient")->values[2]);
+                CHECK(filtered_cfg.opt<ConfigOptionBools>("filament_mixed_gradient_per_part")->values[2]);
+            }
+            THEN("the non-published slots are masked to their defaults") {
+                CHECK(filtered_cfg.opt<ConfigOptionStrings>("filament_mixed_components")->values[0] == "");
+                CHECK(filtered_cfg.opt<ConfigOptionStrings>("filament_mixed_components")->values[1] == "");
+                CHECK(filtered_cfg.opt<ConfigOptionBools>("filament_is_mixed")->values[0] == 0);
+                CHECK(filtered_cfg.opt<ConfigOptionBools>("filament_is_mixed")->values[1] == 0);
+            }
+            THEN("the identity keys stay present") {
+                REQUIRE(filtered_cfg.option("filament_colour") != nullptr);
+            }
+        }
+    }
+}
+
+// The published flag is gated on the exact string "1": any other serialized value means "not
+// published", so a receiver never treats a file as published on a loose truthiness check.
+TEST_CASE("is_published_3mf_flag accepts only the literal \"1\"", "[3mf]") {
+    CHECK(is_published_3mf_flag("1"));
+    CHECK_FALSE(is_published_3mf_flag("0"));
+    CHECK_FALSE(is_published_3mf_flag("false"));
+    CHECK_FALSE(is_published_3mf_flag("true"));
+    CHECK_FALSE(is_published_3mf_flag(""));
+    CHECK_FALSE(is_published_3mf_flag("YES"));
+}
+
+// bbs_3mf_is_published is the lightweight metadata probe used to decide whether a file was
+// produced by the publish feature (GUI "recently published" tracking). It must return true only
+// for a file whose metadata carries the flag set to "1", and false for legacy files and for a
+// file whose flag is present but not "1" (which loads as a normal, non-published 3MF).
+SCENARIO("bbs_3mf_is_published detects only genuinely published 3MFs", "[3mf]") {
+    auto store_model = [](const std::string &path, const std::string &flag_value, const std::string &keys_value) {
+        Model model;
+        std::string src_file = std::string(TEST_DATA_DIR) + "/test_3mf/Prusa.stl";
+        REQUIRE(load_stl(src_file.c_str(), &model));
+        model.add_default_instances();
+        model.model_info = std::make_shared<ModelInfo>();
+        // An empty flag_value means "don't write the flag at all" (a legacy file).
+        if (!flag_value.empty())
+            model.model_info->metadata_items[ORCA_PUBLISHED_TAG] = flag_value;
+        model.model_info->metadata_items[ORCA_PUBLISHED_KEYS_TAG] = keys_value;
+        ScopedTemporaryDir backup_dir("orca_is_pub");
+        model.set_backup_path(backup_dir.string());
+        DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+        StoreParams store_params;
+        store_params.path     = path.c_str();
+        store_params.model    = &model;
+        store_params.config   = &config;
+        store_params.strategy = SaveStrategy::Zip64 | SaveStrategy::Silence;
+        REQUIRE(store_bbs_3mf(store_params));
+    };
+
+    GIVEN("a minimal published 3MF whose flag is \"1\"") {
+        ScopedTemporaryFile temp(".3mf");
+        store_model(temp.string(), "1", R"(["layer_height"])");
+        WHEN("probed by bbs_3mf_is_published") {
+            THEN("it is recognized as published") {
+                CHECK(bbs_3mf_is_published(temp.string()));
+            }
+        }
+    }
+    GIVEN("a legacy 3MF without any published flag") {
+        ScopedTemporaryFile temp(".3mf");
+        store_model(temp.string(), "", R"(["layer_height"])");
+        WHEN("probed by bbs_3mf_is_published") {
+            THEN("it is not recognized as published") {
+                CHECK_FALSE(bbs_3mf_is_published(temp.string()));
+            }
+        }
+    }
+    GIVEN("a 3MF carrying the flag set to \"0\"") {
+        ScopedTemporaryFile temp(".3mf");
+        store_model(temp.string(), "0", R"(["layer_height"])");
+        WHEN("probed and loaded") {
+            THEN("it is not recognized as published") {
+                CHECK_FALSE(bbs_3mf_is_published(temp.string()));
+            }
+            THEN("it loads as a normal, non-published 3MF") {
+                Model dst_model;
+                DynamicPrintConfig dst_config;
+                ConfigSubstitutionContext ctxt{ ForwardCompatibilitySubstitutionRule::Enable };
+                PlateDataPtrs        dst_plates;
+                std::vector<Preset*> project_presets;
+                bool   is_bbl_3mf = false, is_orca_3mf = false;
+                Semver file_version;
+                REQUIRE(load_bbs_3mf(temp.string().c_str(), &dst_config, &ctxt, &dst_model, &dst_plates,
+                                     &project_presets, &is_bbl_3mf, &is_orca_3mf, &file_version, nullptr,
+                                     LoadStrategy::LoadModel | LoadStrategy::LoadConfig));
+                REQUIRE(dst_model.model_info != nullptr);
+                // The key is present but not "1", so nothing treats the file as published; the
+                // stored keys still round-trip verbatim.
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_TAG] == "0");
+                REQUIRE(dst_model.model_info->metadata_items[ORCA_PUBLISHED_KEYS_TAG] == R"(["layer_height"])");
+                release_PlateData_list(dst_plates);
+            }
+        }
+    }
+}
+

tests/libslic3r/test_arachne_walls.cpp

@@ -22,6 +22,8 @@
 #include "libslic3r/Arachne/utils/ExtrusionLine.hpp"
 #include "libslic3r/Arachne/BeadingStrategy/BeadingStrategyFactory.hpp"
 #include "libslic3r/Arachne/BeadingStrategy/BeadingStrategy.hpp"
+#include "libslic3r/Feature/FuzzySkin/FuzzySkin.hpp"
+#include "libslic3r/Flow.hpp"
 #include "libslic3r/Polygon.hpp"
 #include "libslic3r/ExPolygon.hpp"
 #include "libslic3r/ClipperUtils.hpp"
@@ -309,3 +311,71 @@ TEST_CASE("Beading interpolation tolerates a thicker side with fewer insets", "[
         CHECK(result.bead_widths[i] == expected.bead_widths[i]);
     }
 }
+
+namespace {
+
+// Closed 20 mm square loop at a uniform width.
+Arachne::ExtrusionJunctions square_loop(coord_t width)
+{
+    const coord_t s = scaled<coord_t>(20.);
+    return {{Point(0, 0), width, 0}, {Point(s, 0), width, 0}, {Point(s, s), width, 0}, {Point(0, s), width, 0}, {Point(0, 0), width, 0}};
+}
+
+FuzzySkinConfig thick_fuzzy_config(FuzzySkinMode mode, NoiseType noise_type, double thickness_mm)
+{
+    FuzzySkinConfig cfg{};
+    cfg.type              = FuzzySkinType::All;
+    cfg.thickness         = scaled<coord_t>(thickness_mm);
+    cfg.point_distance    = scaled<coord_t>(0.3);
+    cfg.fuzzy_first_layer = true;
+    cfg.noise_type        = noise_type;
+    cfg.noise_scale       = 1.0;
+    cfg.noise_octaves     = 4;
+    cfg.noise_persistence = 0.5;
+    cfg.mode              = mode;
+    cfg.layer_id          = 5;
+    return cfg;
+}
+
+} // namespace
+
+// Extrusion and Combined mode add noise to each junction's width. A junction narrower than
+// height * (1 - PI/4) makes Flow::rounded_rectangle_extrusion_spacing() throw and fails the slice.
+// The fuzz thickness is 3x the line width so the clamp is hit on every run regardless of RNG seed.
+// Ridged multifractal is covered because its output is not bounded to [-1, 1], so it scales past
+// the configured thickness; the floor has to hold for any noise value, not just an in-range one.
+TEST_CASE("Fuzzy skin extrusion width is floored at the minimum the flow accepts", "[Arachne][FuzzySkin]") {
+    using namespace Slic3r::Feature::FuzzySkin;
+
+    const double layer_height = GENERATE(0.08, 0.2, 0.28);
+    const auto   mode         = GENERATE(FuzzySkinMode::Extrusion, FuzzySkinMode::Combined);
+    const auto   noise_type   = GENERATE(NoiseType::Classic, NoiseType::Perlin, NoiseType::Billow, NoiseType::RidgedMulti, NoiseType::Voronoi);
+    CAPTURE(layer_height, int(mode), int(noise_type));
+
+    const double line_width_mm = 0.42;
+    auto         loop          = square_loop(scaled<coord_t>(line_width_mm));
+    fuzzy_extrusion_line(loop, /*slice_z*/ 1.0, layer_height, thick_fuzzy_config(mode, noise_type, 3 * line_width_mm));
+
+    REQUIRE(loop.size() > 100);
+
+    const auto   narrowest    = std::min_element(loop.begin(), loop.end(), [](const auto& a, const auto& b) { return a.w < b.w; });
+    const double narrowest_mm = unscaled<double>(narrowest->w);
+    const double floor_mm     = layer_height * (1. - 0.25 * PI);
+    CAPTURE(narrowest_mm, floor_mm);
+
+    CHECK(narrowest_mm < line_width_mm); // the clamp was exercised
+    CHECK(narrowest_mm > floor_mm);
+    CHECK_NOTHROW(Flow::rounded_rectangle_extrusion_spacing(float(narrowest_mm), float(layer_height)));
+}
+
+// Displacement mode only moves points; widths must pass through unchanged.
+TEST_CASE("Fuzzy skin displacement mode leaves widths untouched", "[Arachne][FuzzySkin]") {
+    using namespace Slic3r::Feature::FuzzySkin;
+
+    const coord_t width = scaled<coord_t>(0.42);
+    auto          loop  = square_loop(width);
+    fuzzy_extrusion_line(loop, /*slice_z*/ 1.0, /*layer_height*/ 0.2, thick_fuzzy_config(FuzzySkinMode::Displacement, NoiseType::Classic, 1.26));
+
+    REQUIRE(loop.size() > 100);
+    CHECK(std::all_of(loop.begin(), loop.end(), [width](const auto& j) { return j.w == width; }));
+}

tests/libslic3r/test_arrange.cpp

@@ -4,6 +4,8 @@
 #include "libslic3r/BoundingBox.hpp"
 #include "libslic3r/ClipperUtils.hpp"
 #include "libslic3r/ExPolygon.hpp"
+#include "libslic3r/Print.hpp"
+#include "libslic3r/PrintConfig.hpp"
 
 using namespace Slic3r;
 using namespace Slic3r::arrangement;
@@ -24,11 +26,13 @@ ArrangePolygon make_square(coord_t side)
     return ap;
 }
 
-ArrangePolygons squares(int n, double side_mm)
+ArrangePolygons squares(int n, double side_mm, double height_mm = 0.)
 {
     ArrangePolygons items;
-    for (int i = 0; i < n; ++i)
+    for (int i = 0; i < n; ++i) {
         items.emplace_back(make_square(scaled(side_mm)));
+        items.back().height = height_mm;
+    }
     return items;
 }
 
@@ -82,6 +86,38 @@ void require_no_overlap(const ArrangePolygons &items)
     REQUIRE(disjoint(placed_shapes(items)));
 }
 
+// The sequential-print floor is chosen by comparing object height against the nozzle,
+// so the two are defined together and every expectation is derived from them.
+constexpr double NOZZLE_HEIGHT_MM = 2.5;
+constexpr double CLEARANCE_MM     = 30.;
+constexpr double NOZZLE_FLOOR_MM  = MAX_OUTER_NOZZLE_DIAMETER / 2.;
+
+ArrangeParams seq_print_params(coord_t min_dist)
+{
+    ArrangeParams p       = quiet_params(min_dist);
+    p.is_seq_print        = true;
+    p.clearance_radius    = float(CLEARANCE_MM);
+    p.nozzle_height       = float(NOZZLE_HEIGHT_MM);
+    p.object_skirt_offset = 0.f;
+    return p;
+}
+
+// update_selected_items_inflation reads the bed out of the config to cap inflation.
+DynamicPrintConfig bed_config()
+{
+    DynamicPrintConfig c;
+    c.set_key_value("printable_area", new ConfigOptionPoints{{0, 0}, {200, 0}, {200, 200}, {0, 200}});
+    return c;
+}
+
+ArrangePolygons squares_of_heights(const std::vector<double> &heights_mm)
+{
+    ArrangePolygons items;
+    for (double height_mm : heights_mm)
+        items.push_back(squares(1, 20., height_mm).front());
+    return items;
+}
+
 } // namespace
 
 // Prove the overlap check the other tests rely on actually detects overlap.
@@ -222,3 +258,61 @@ TEST_CASE("Arrange aligns the pile to a custom center", "[Arrange]")
         REQUIRE(ap.bed_idx == 0);
     require_no_overlap(items);
 }
+
+TEST_CASE("Sequential print floors the object distance by object height", "[Arrange]")
+{
+    // The only place sequential-print clearance is enforced. The arrange menu offers
+    // no floor of its own, so a stored 0 has to be raised here or not at all.
+    struct Case
+    {
+        std::string         description;
+        std::vector<double> heights;
+        double              skirt_offset_mm;
+        double              expected_floor_mm;
+    };
+
+    auto c = GENERATE(values<Case>({
+        {"objects taller than the nozzle need the full clearance",     {NOZZLE_HEIGHT_MM * 2, NOZZLE_HEIGHT_MM * 2}, 0., CLEARANCE_MM},
+        {"an object exactly at the nozzle height counts as tall",      {NOZZLE_HEIGHT_MM,     NOZZLE_HEIGHT_MM},     0., CLEARANCE_MM},
+        {"one tall object among short ones is enough",                 {NOZZLE_HEIGHT_MM / 2, NOZZLE_HEIGHT_MM * 2}, 0., CLEARANCE_MM},
+        {"objects the nozzle clears keep only the nozzle-width floor", {NOZZLE_HEIGHT_MM / 2, NOZZLE_HEIGHT_MM / 2}, 0., NOZZLE_FLOOR_MM},
+        {"a wide skirt raises the floor for short objects",            {NOZZLE_HEIGHT_MM / 2, NOZZLE_HEIGHT_MM / 2}, 3., 6.},
+    }));
+
+    DYNAMIC_SECTION(c.description)
+    {
+        ArrangePolygons    items = squares_of_heights(c.heights);
+        DynamicPrintConfig cfg   = bed_config();
+        ArrangeParams      p     = seq_print_params(0);
+        p.object_skirt_offset    = float(c.skirt_offset_mm);
+
+        update_selected_items_inflation(items, &cfg, p);
+
+        CHECK(p.min_obj_distance >= scaled(c.expected_floor_mm));
+        CHECK(p.min_obj_distance <= scaled(c.expected_floor_mm + 0.01));
+        // Half each, so a pair ends up a full min_obj_distance apart.
+        CHECK(items.front().inflation == p.min_obj_distance / 2);
+    }
+}
+
+TEST_CASE("Sequential print keeps an object distance already above the floor", "[Arrange]")
+{
+    const coord_t      stored = scaled(CLEARANCE_MM * 2);
+    ArrangePolygons    items  = squares_of_heights({NOZZLE_HEIGHT_MM * 2, NOZZLE_HEIGHT_MM * 2});
+    DynamicPrintConfig cfg    = bed_config();
+    ArrangeParams      p      = seq_print_params(stored);
+
+    update_selected_items_inflation(items, &cfg, p);
+    CHECK(p.min_obj_distance == stored);
+}
+
+TEST_CASE("Layered printing does not floor the object distance", "[Arrange]")
+{
+    ArrangePolygons    items = squares_of_heights({NOZZLE_HEIGHT_MM * 2, NOZZLE_HEIGHT_MM * 2});
+    DynamicPrintConfig cfg   = bed_config();
+    ArrangeParams      p     = seq_print_params(0);
+    p.is_seq_print           = false;
+
+    update_selected_items_inflation(items, &cfg, p);
+    CHECK(p.min_obj_distance == 0);
+}

tests/libslic3r/test_buildvolume.cpp

@@ -0,0 +1,40 @@
+#include <catch2/catch_all.hpp>
+
+#include "libslic3r/BuildVolume.hpp"
+
+using namespace Slic3r;
+
+static std::vector<Vec2d> rect_area(double w, double d)
+{
+    return { { 0., 0. }, { w, 0. }, { w, d }, { 0., d } };
+}
+
+// extruder_printable_height and extruder_printable_area are independent config options, so a
+// profile can leave the heights short. BuildVolume must not index past the end of the heights.
+TEST_CASE("BuildVolume falls back to the bed height when extruder_printable_height is short", "[BuildVolume]")
+{
+    const std::vector<Vec2d>              bed     = rect_area(200., 200.);
+    const std::vector<std::vector<Vec2d>> areas   = { rect_area(200., 200.), rect_area(100., 200.) };
+    const std::vector<double>             heights = { 180. };
+
+    const BuildVolume build_volume(bed, 250., areas, heights);
+
+    REQUIRE(build_volume.get_extruder_area_count() == 2);
+    // The extruder with a height of its own keeps it, and differs from the bed, so it gets its own volume.
+    CHECK_THAT(build_volume.get_extruder_area_volume(0).bboxf.max.z(), Catch::Matchers::WithinAbs(180., 1e-6));
+    // The extruder without one falls back to the bed's printable_height instead of reading out of range.
+    CHECK_THAT(build_volume.get_extruder_area_volume(1).bboxf.max.z(), Catch::Matchers::WithinAbs(250., 1e-6));
+}
+
+TEST_CASE("BuildVolume keeps per-extruder heights when both vectors match", "[BuildVolume]")
+{
+    const std::vector<Vec2d>              bed     = rect_area(200., 200.);
+    const std::vector<std::vector<Vec2d>> areas   = { rect_area(120., 200.), rect_area(100., 200.) };
+    const std::vector<double>             heights = { 180., 200.5 };
+
+    const BuildVolume build_volume(bed, 250., areas, heights);
+
+    REQUIRE(build_volume.get_extruder_area_count() == 2);
+    CHECK_THAT(build_volume.get_extruder_area_volume(0).bboxf.max.z(), Catch::Matchers::WithinAbs(180., 1e-6));
+    CHECK_THAT(build_volume.get_extruder_area_volume(1).bboxf.max.z(), Catch::Matchers::WithinAbs(200.5, 1e-6));
+}

tests/libslic3r/test_config.cpp

@@ -828,3 +828,391 @@ SCENARIO("ConfigOptionVector::set_to_index throws on incompatible type", "[Confi
         }
     }
 }
+
+TEST_CASE("read_cli applies valid values and collects non-option arguments", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--nozzle-temperature", "210,190", "--reduce-crossing-wall=1", "model.3mf"};
+    REQUIRE(config.read_cli(5, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionInts>("nozzle_temperature")->values == std::vector<int>{210, 190});
+    REQUIRE(config.opt<ConfigOptionBool>("reduce_crossing_wall")->value);
+    REQUIRE(extra == t_config_option_keys{"model.3mf"});
+    REQUIRE(keys == t_config_option_keys{"nozzle_temperature", "reduce_crossing_wall"});
+}
+
+TEST_CASE("read_cli rejects nil for a non-nullable vector option", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--nozzle-temperature", "nil"};
+    REQUIRE_FALSE(config.read_cli(3, argv, &extra, &keys));
+}
+
+TEST_CASE("read_cli rejects an invalid boolean value", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--reduce-crossing-wall=maybe"};
+    REQUIRE_FALSE(config.read_cli(2, argv, &extra, &keys));
+}
+
+TEST_CASE("read_cli accepts the common spellings of a boolean value", "[Config]") {
+    const auto [text, expected] = GENERATE(table<const char*, bool>({
+        {"--reduce-crossing-wall=1", true},
+        {"--reduce-crossing-wall=true", true},
+        {"--reduce-crossing-wall=Yes", true},
+        {"--reduce-crossing-wall=on", true},
+        {"--reduce-crossing-wall=enabled", true},
+        {"--reduce-crossing-wall=TRUE", true},
+        {"--reduce-crossing-wall=oN", true},
+        {"--reduce-crossing-wall=0", false},
+        {"--reduce-crossing-wall=false", false},
+        {"--reduce-crossing-wall=No", false},
+        {"--reduce-crossing-wall=off", false},
+        {"--reduce-crossing-wall=disabled", false},
+        {"--reduce-crossing-wall=FALSE", false},
+        {"--reduce-crossing-wall=DiSaBlEd", false},
+    }));
+
+    DYNAMIC_SECTION(text) {
+        Slic3r::DynamicPrintConfig config;
+        t_config_option_keys extra, keys;
+        const char* argv[] = {"orca-slicer", text};
+        REQUIRE(config.read_cli(2, argv, &extra, &keys));
+        REQUIRE(config.opt<ConfigOptionBool>("reduce_crossing_wall")->value == expected);
+    }
+}
+
+TEST_CASE("read_cli accepts the common boolean spellings inside a bools vector", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-soluble=true,no,1"};
+    REQUIRE(config.read_cli(2, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionBools>("filament_soluble")->values == std::vector<unsigned char>{1, 0, 1});
+}
+
+TEST_CASE("read_cli trims whitespace around boolean spellings", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--reduce-crossing-wall= true ", "--filament-soluble= true , no ,1"};
+    REQUIRE(config.read_cli(3, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionBool>("reduce_crossing_wall")->value);
+    REQUIRE(config.opt<ConfigOptionBools>("filament_soluble")->values == std::vector<unsigned char>{1, 0, 1});
+}
+
+TEST_CASE("read_cli normalizes boolean spellings when a bools vector is repeated", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-soluble=true", "--filament-soluble=off"};
+    REQUIRE(config.read_cli(3, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionBools>("filament_soluble")->values == std::vector<unsigned char>{1, 0});
+}
+
+TEST_CASE("read_cli keeps nil alongside boolean spellings in a nullable bools vector", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--enable-overhang-speed=nil,yes,off"};
+    REQUIRE(config.read_cli(2, argv, &extra, &keys));
+    auto* opt = config.opt<ConfigOptionBoolsNullable>("enable_overhang_speed");
+    REQUIRE(opt != nullptr);
+    REQUIRE(opt->values.size() == 3);
+    REQUIRE(opt->is_nil(0));
+    REQUIRE(opt->values[1] == 1);
+    REQUIRE(opt->values[2] == 0);
+}
+
+TEST_CASE("read_cli rejects an empty item inside a bools vector", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-soluble=true,,1"};
+    REQUIRE_FALSE(config.read_cli(2, argv, &extra, &keys));
+}
+
+TEST_CASE("read_cli rejects an unknown spelling next to a valid one in a bools vector", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-soluble=true,affirmative"};
+    REQUIRE_FALSE(config.read_cli(2, argv, &extra, &keys));
+}
+
+// The normalization lives in read_cli's boolean branches, so options of other types keep the
+// value verbatim - a path named "on" or a colour named "true" must not turn into "1".
+TEST_CASE("read_cli leaves boolean spellings alone for non-boolean options", "[Config]") {
+    SECTION("string option") {
+        Slic3r::DynamicPrintAndCLIConfig config;
+        t_config_option_keys extra, keys;
+        const char* argv[] = {"orca-slicer", "--logfile=true"};
+        REQUIRE(config.read_cli(2, argv, &extra, &keys));
+        REQUIRE(config.opt<ConfigOptionString>("logfile")->value == "true");
+    }
+    SECTION("strings vector option") {
+        Slic3r::DynamicPrintConfig config;
+        t_config_option_keys extra, keys;
+        const char* argv[] = {"orca-slicer", "--filament-colour=on;off"};
+        REQUIRE(config.read_cli(2, argv, &extra, &keys));
+        REQUIRE(config.opt<ConfigOptionStrings>("filament_colour")->values == std::vector<std::string>{"on", "off"});
+    }
+}
+
+TEST_CASE("read_cli treats a bare boolean flag as true without consuming the next argument", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--reduce-crossing-wall", "model.3mf"};
+    REQUIRE(config.read_cli(3, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionBool>("reduce_crossing_wall")->value);
+    REQUIRE(extra == t_config_option_keys{"model.3mf"});
+}
+
+TEST_CASE("read_cli rejects an invalid scalar numeric value", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--top-shell-layers", "several"};
+    REQUIRE_FALSE(config.read_cli(3, argv, &extra, &keys));
+}
+
+TEST_CASE("read_cli appends values when a vector option is repeated", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--nozzle-temperature", "210", "--nozzle-temperature", "190,200"};
+    REQUIRE(config.read_cli(5, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionInts>("nozzle_temperature")->values == std::vector<int>{210, 190, 200});
+    // the key is recorded once, on first use
+    REQUIRE(keys == t_config_option_keys{"nozzle_temperature"});
+}
+
+TEST_CASE("read_cli parses a bools vector given in the --flag=values form", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-soluble=1,0,1"};
+    REQUIRE(config.read_cli(2, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionBools>("filament_soluble")->values == std::vector<unsigned char>{1, 0, 1});
+}
+
+TEST_CASE("read_cli rejects an invalid value inside a bools vector", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-soluble=1,maybe"};
+    REQUIRE_FALSE(config.read_cli(2, argv, &extra, &keys));
+}
+
+TEST_CASE("read_cli appends true for a bare bools vector flag", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-soluble"};
+    REQUIRE(config.read_cli(2, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionBools>("filament_soluble")->values == std::vector<unsigned char>{1});
+}
+
+TEST_CASE("read_cli splits a strings vector on semicolons and unescapes quoted items", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-colour", "#FF0000;\"a\\nb\";#00FF00"};
+    REQUIRE(config.read_cli(3, argv, &extra, &keys));
+    auto& values = config.opt<ConfigOptionStrings>("filament_colour")->values;
+    REQUIRE(values == std::vector<std::string>{"#FF0000", "a\nb", "#00FF00"});
+}
+
+TEST_CASE("read_cli rejects a strings vector with an unterminated quote", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-colour", "\"oops"};
+    REQUIRE_FALSE(config.read_cli(3, argv, &extra, &keys));
+}
+
+TEST_CASE("read_cli parses a points vector in the NxM coordinate form", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--printable-area", "0x0,200x0,200x200,0x200"};
+    REQUIRE(config.read_cli(3, argv, &extra, &keys));
+    auto& points = config.opt<ConfigOptionPoints>("printable_area")->values;
+    REQUIRE(points.size() == 4);
+    REQUIRE_THAT(points[1].x(), Catch::Matchers::WithinAbs(200.0, 1e-9));
+    REQUIRE_THAT(points[1].y(), Catch::Matchers::WithinAbs(0.0, 1e-9));
+    REQUIRE_THAT(points[3].x(), Catch::Matchers::WithinAbs(0.0, 1e-9));
+    REQUIRE_THAT(points[3].y(), Catch::Matchers::WithinAbs(200.0, 1e-9));
+}
+
+// logfile is a CLI-only option, so it needs the config type whose def pulls in cli_misc_config_def.
+TEST_CASE("read_cli stores the log file path as a string", "[Config]") {
+    Slic3r::DynamicPrintAndCLIConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--logfile", "orca.log"};
+    REQUIRE(config.read_cli(3, argv, &extra, &keys));
+    REQUIRE(config.opt<ConfigOptionString>("logfile")->value == "orca.log");
+}
+
+TEST_CASE("read_cli accepts nil entries for a nullable vector option", "[Config]") {
+    Slic3r::DynamicPrintConfig config;
+    t_config_option_keys extra, keys;
+    const char* argv[] = {"orca-slicer", "--filament-retraction-length", "nil,2.5"};
+    REQUIRE(config.read_cli(3, argv, &extra, &keys));
+    auto* opt = config.opt<ConfigOptionFloatsNullable>("filament_retraction_length");
+    REQUIRE(opt != nullptr);
+    REQUIRE(opt->values.size() == 2);
+    REQUIRE(opt->is_nil(0));
+    REQUIRE_FALSE(opt->is_nil(1));
+    REQUIRE_THAT(opt->values[1], Catch::Matchers::WithinAbs(2.5, 1e-9));
+}
+
+// get_at() returns values.front() for an out-of-range index, so calling it on an empty vector
+// option is UB. filament_id and filament_is_support are unpopulated on a CLI from-scratch slice.
+TEST_CASE("get_filament_type treats empty vector options as absent", "[Config][Filament]")
+{
+    DynamicPrintConfig config;
+    std::string displayed;
+
+    SECTION("an empty filament_type yields no type at all")
+    {
+        config.set_key_value("filament_type", new ConfigOptionStrings());
+        REQUIRE(config.get_filament_type(displayed, 0) == "");
+    }
+
+    SECTION("an empty filament_is_support falls back to the plain filament type")
+    {
+        config.set_key_value("filament_type", new ConfigOptionStrings({"PETG"}));
+        config.set_key_value("filament_is_support", new ConfigOptionBools());
+        REQUIRE(config.get_filament_type(displayed, 0) == "PETG");
+        REQUIRE(displayed == "PETG");
+    }
+
+    SECTION("a support filament with an empty filament_id resolves from the type alone")
+    {
+        config.set_key_value("filament_type", new ConfigOptionStrings({"PLA"}));
+        config.set_key_value("filament_is_support", new ConfigOptionBools({true}));
+        config.set_key_value("filament_id", new ConfigOptionStrings());
+        REQUIRE(config.get_filament_type(displayed, 0) == "PLA-S");
+        REQUIRE(displayed == "Sup.PLA");
+    }
+
+    SECTION("a populated filament_id still selects the support type by id")
+    {
+        config.set_key_value("filament_type", new ConfigOptionStrings({"PETG"}));
+        config.set_key_value("filament_is_support", new ConfigOptionBools({true}));
+        config.set_key_value("filament_id", new ConfigOptionStrings({"GFS00"}));
+        REQUIRE(config.get_filament_type(displayed, 0) == "PLA-S");
+        REQUIRE(displayed == "Sup.PLA");
+    }
+}
+
+namespace {
+
+// min_object_distance reads exactly these three options.
+DynamicPrintConfig spacing_config(PrinterTechnology tech, PrintSequence seq, double clearance_radius)
+{
+    DynamicPrintConfig c;
+    c.set_key_value("printer_technology", new ConfigOptionEnum<PrinterTechnology>(tech));
+    c.set_key_value("print_sequence", new ConfigOptionEnum<PrintSequence>(seq));
+    c.set_key_value("extruder_clearance_radius", new ConfigOptionFloat(clearance_radius));
+    return c;
+}
+
+} // namespace
+
+TEST_CASE("min_object_distance floors object spacing per print sequence", "[Config]")
+{
+    struct Case
+    {
+        std::string       description;
+        PrinterTechnology tech;
+        PrintSequence     sequence;
+        double            clearance_radius;
+        double            expected;
+    };
+
+    auto c = GENERATE(values<Case>({
+        {"sequential FFF takes a clearance radius above the floor", ptFFF, PrintSequence::ByObject, 12., 12.},
+        {"sequential FFF holds the floor at the radius",            ptFFF, PrintSequence::ByObject,  6.,  6.},
+        {"sequential FFF holds the floor below the radius",         ptFFF, PrintSequence::ByObject,  4.,  6.},
+        {"layered FFF ignores the clearance radius",                ptFFF, PrintSequence::ByLayer,  12.,  6.},
+        {"SLA is a flat 6mm",                                       ptSLA, PrintSequence::ByObject, 12.,  6.},
+        {"SLA ignores the print sequence too",                      ptSLA, PrintSequence::ByLayer,  12.,  6.},
+    }));
+
+    DYNAMIC_SECTION(c.description)
+    {
+        CHECK_THAT(min_object_distance(spacing_config(c.tech, c.sequence, c.clearance_radius)),
+                   Catch::Matchers::WithinAbs(c.expected, 1e-9));
+    }
+}
+
+TEST_CASE("min_object_distance yields no floor when an FFF config lacks the options", "[Config]")
+{
+    // Missing options yield 0 rather than an error, so a caller gets no floor at all.
+    SECTION("no clearance radius") {
+        DynamicPrintConfig c;
+        c.set_key_value("printer_technology", new ConfigOptionEnum<PrinterTechnology>(ptFFF));
+        c.set_key_value("print_sequence", new ConfigOptionEnum<PrintSequence>(PrintSequence::ByObject));
+        CHECK_THAT(min_object_distance(c), Catch::Matchers::WithinAbs(0., 1e-9));
+    }
+
+    SECTION("no print sequence") {
+        DynamicPrintConfig c;
+        c.set_key_value("printer_technology", new ConfigOptionEnum<PrinterTechnology>(ptFFF));
+        c.set_key_value("extruder_clearance_radius", new ConfigOptionFloat(12.));
+        CHECK_THAT(min_object_distance(c), Catch::Matchers::WithinAbs(0., 1e-9));
+    }
+
+    SECTION("nothing at all") {
+        CHECK_THAT(min_object_distance(DynamicPrintConfig{}), Catch::Matchers::WithinAbs(0., 1e-9));
+    }
+
+    SECTION("an unset printer technology is treated as FFF") {
+        DynamicPrintConfig c;
+        c.set_key_value("print_sequence", new ConfigOptionEnum<PrintSequence>(PrintSequence::ByObject));
+        c.set_key_value("extruder_clearance_radius", new ConfigOptionFloat(12.));
+        CHECK_THAT(min_object_distance(c), Catch::Matchers::WithinAbs(12., 1e-9));
+    }
+}
+
+TEST_CASE("Static print configs compare, order and hash by their option values", "[Config]")
+{
+    // PrintObjectConfig comes from PRINT_CONFIG_CLASS_DEFINE; PrintConfig combines MachineEnvelopeConfig
+    // and GCodeConfig through PRINT_CONFIG_CLASS_DERIVED_DEFINE. Both generate hash(), operator==,
+    // operator< and the option registration from the same option list. The hash inequalities use fixed
+    // inputs, so they are deterministic; they check that hash() covers the changed option.
+    SECTION("default-constructed configs are equal and find their options by key")
+    {
+        PrintObjectConfig a, b;
+        REQUIRE(a == b);
+        REQUIRE(a.hash() == b.hash());
+        REQUIRE_FALSE(a < b);
+        REQUIRE_FALSE(b < a);
+        REQUIRE(a.optptr("layer_height") == &a.layer_height);
+        REQUIRE(a.optptr("brim_object_gap") == &a.brim_object_gap);
+    }
+
+    SECTION("one differing option makes the configs unequal and orders them")
+    {
+        PrintObjectConfig a, b;
+        b.layer_height.value = a.layer_height.value + 0.05;
+        REQUIRE(a != b);
+        REQUIRE(a.hash() != b.hash());
+        REQUIRE(a < b);
+        REQUIRE_FALSE(b < a);
+    }
+
+    SECTION("ordering is decided by the first option in declaration order that differs")
+    {
+        PrintObjectConfig a, b;
+        a.brim_object_gap.value = b.brim_object_gap.value + 1.0;  // declared first
+        a.layer_height.value    = b.layer_height.value - 0.05;    // declared later, points the other way
+        REQUIRE(b < a);
+        REQUIRE_FALSE(a < b);
+    }
+
+    SECTION("a derived config sees differences in its parents and in its own options")
+    {
+        PrintConfig a, b;
+        REQUIRE(a == b);
+        REQUIRE(a.hash() == b.hash());
+
+        b.gcode_flavor.value = b.gcode_flavor.value == gcfMarlinLegacy ? gcfKlipper : gcfMarlinLegacy;  // GCodeConfig parent
+        REQUIRE(a != b);
+        REQUIRE(a.hash() != b.hash());
+
+        PrintConfig c, d;
+        d.skirt_distance.value = c.skirt_distance.value + 1.0;  // PrintConfig's own list
+        REQUIRE(c != d);
+        REQUIRE(c.hash() != d.hash());
+        REQUIRE(c.optptr("skirt_distance") == &c.skirt_distance);
+        REQUIRE(c.optptr("gcode_flavor") == &c.gcode_flavor);
+    }
+}

tests/libslic3r/test_config_variant_expansion.cpp

@@ -130,6 +130,12 @@ TEST_CASE("get_config_index_base resolves (volume type, extruder type, id) to a
     }
 }
 
+TEST_CASE("support interface pattern registry includes spiral inset", "[Config]")
+{
+    const auto &values = ConfigOptionEnum<SupportMaterialInterfacePattern>::get_enum_values();
+    REQUIRE(values.at("spiralinset") == SupportMaterialInterfacePattern::smipSpiralInset);
+}
+
 TEST_CASE("get_extruder_nozzle_volume_count reads the per-extruder volume-type layout", "[Config]")
 {
     std::vector<std::vector<NozzleVolumeType>> nozzle_volume_types;
@@ -478,4 +484,113 @@ TEST_CASE("update_values_to_printer_extruders_for_multiple_filaments resolves pe
         REQUIRE(config.option<ConfigOptionFloats>("filament_max_volumetric_speed")->values == std::vector<double>({12., 21.}));
         REQUIRE(config.option<ConfigOptionInts>("filament_self_index")->values == std::vector<int>({1, 2}));
     }
+
+    SECTION("a variant option shorter than the filament slots keeps its first value instead of zero") {
+        DynamicPrintConfig config;
+        config.option<ConfigOptionEnumsGeneric>("extruder_type", true)->values = {etDirectDrive, etDirectDrive};
+        config.option<ConfigOptionEnumsGeneric>("nozzle_volume_type", true)->values = {nvtStandard, nvtHighFlow};
+        config.option<ConfigOptionStrings>("extruder_variant_list", true)->values = {"Direct Drive Standard,Direct Drive High Flow",
+                                                                                     "Direct Drive Standard,Direct Drive High Flow"};
+        make_filament_arrays(config);
+        config.option<ConfigOptionInts>("filament_map", true)->values = {1, 2};
+        // no loaded preset carries the key, so only its single registered default is present
+        config.option<ConfigOptionFloatsNullable>("filament_cooling_before_tower", true)->values = {10.};
+        // only the first filament's two variant columns were loaded
+        config.option<ConfigOptionFloatsNullable>("filament_ramming_volumetric_speed", true)->values = {-1., -2.};
+
+        std::vector<std::vector<NozzleVolumeType>> nozzle_volume_types;
+        int extruder_count = 2;
+        int count = config.get_extruder_nozzle_volume_count(extruder_count, nozzle_volume_types);
+
+        config.update_values_to_printer_extruders_for_multiple_filaments(config, extruder_count, count, filament_keys,
+            "filament_self_index", "filament_extruder_variant");
+
+        // filament 2 resolves to column 3 (its extruder's High Flow column), past the end of both vectors
+        REQUIRE_THAT(config.option<ConfigOptionFloatsNullable>("filament_cooling_before_tower")->values,
+                     Catch::Matchers::Approx(std::vector<double>({10., 10.})));
+        REQUIRE_THAT(config.option<ConfigOptionFloatsNullable>("filament_ramming_volumetric_speed")->values,
+                     Catch::Matchers::Approx(std::vector<double>({-1., -1.})));
+        REQUIRE(config.option<ConfigOptionFloats>("filament_max_volumetric_speed")->values == std::vector<double>({12., 21.}));
+    }
+}
+
+// update_values_from_multi_to_multi_2 walks the DESTINATION PRINTER's variant list while writing
+// into a row taken from the destination PRINT preset, whose arrays are sized to its own
+// print_extruder_variant. Those two widths disagree until the print preset is re-selected for the
+// new printer -- Tab::load_current_preset() runs this migration first -- so a project authored on
+// a single-variant printer, opened and switched to a wider one, wrote past the end of the row.
+TEST_CASE("update_values_from_multi_to_multi_2 sizes the destination row to the variant count",
+          "[Config][VariantExpansion]")
+{
+    const std::vector<std::string> src_variants{"Direct Drive Standard"};
+    const std::vector<std::string> dst_variants{"Direct Drive Standard", "Direct Drive High Flow",
+                                                "Direct Drive Standard", "Direct Drive High Flow"};
+    const std::set<std::string>    keys{"outer_wall_speed"};
+
+    // The per-object override as authored on the single-variant printer.
+    const auto object_override = [] {
+        DynamicPrintConfig c;
+        c.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {42.};
+        return c;
+    };
+
+    SECTION("a row narrower than the variant list is grown, not overrun") {
+        DynamicPrintConfig object_config = object_override();
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200.};
+
+        REQUIRE(object_config.update_values_from_multi_to_multi_2(src_variants, dst_variants, dst, keys) == 0);
+
+        const auto& out = object_config.option<ConfigOptionFloatsNullable>("outer_wall_speed")->values;
+        REQUIRE(out.size() == dst_variants.size());
+        // Both "Direct Drive Standard" columns match the source variant, so they take the override.
+        CHECK(out[0] == Catch::Approx(42.));
+        CHECK(out[2] == Catch::Approx(42.));
+        // The High Flow columns have no matching source variant: nil, so the destination keeps
+        // tracking the print preset rather than being pinned to another variant's value.
+        CHECK(std::isnan(out[1]));
+        CHECK(std::isnan(out[3]));
+    }
+
+    // The regression guard: where the row already matches the variant list -- every case that was
+    // not corrupting the heap -- the resize is a no-op and the output is unchanged.
+    SECTION("a correctly sized row is untouched") {
+        DynamicPrintConfig object_config = object_override();
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200., 500., 210., 510.};
+
+        REQUIRE(object_config.update_values_from_multi_to_multi_2(src_variants, dst_variants, dst, keys) == 0);
+
+        const auto& out = object_config.option<ConfigOptionFloatsNullable>("outer_wall_speed")->values;
+        REQUIRE(out.size() == 4);
+        CHECK(out[0] == Catch::Approx(42.));    // matched -> override
+        CHECK(out[1] == Catch::Approx(500.));   // unmatched -> preset value preserved
+        CHECK(out[2] == Catch::Approx(42.));
+        CHECK(out[3] == Catch::Approx(510.));
+    }
+
+    // is_nil(idx) indexes values[idx] with no bounds check, so a source shorter than its own
+    // variant list read out of range before the guard was added.
+    SECTION("a source shorter than its variant list is read in range") {
+        DynamicPrintConfig object_config = object_override();   // one value...
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200., 500.};
+
+        REQUIRE(object_config.update_values_from_multi_to_multi_2(
+            {"Direct Drive Standard", "Direct Drive Standard"},   // ...but two source variants
+            {"Direct Drive Standard", "Direct Drive High Flow"}, dst, keys) == 0);
+
+        const auto& out = object_config.option<ConfigOptionFloatsNullable>("outer_wall_speed")->values;
+        REQUIRE(out.size() == 2);
+        CHECK(out[0] == Catch::Approx(42.));
+        CHECK(out[1] == Catch::Approx(500.));
+    }
+
+    SECTION("an empty destination variant list is refused") {
+        DynamicPrintConfig object_config = object_override();
+        DynamicPrintConfig dst;
+        dst.option<ConfigOptionFloatsNullable>("outer_wall_speed", true)->values = {200.};
+
+        CHECK(object_config.update_values_from_multi_to_multi_2(src_variants, {}, dst, keys) == -1);
+    }
 }

tests/libslic3r/test_marchingsquares.cpp

@@ -1,4 +1,6 @@
+#ifndef NOMINMAX
 #define NOMINMAX
+#endif
 
 #include <catch2/catch_all.hpp>
 #include "test_utils.hpp"

tests/libslic3r/test_minimum_spanning_tree.cpp

@@ -0,0 +1,66 @@
+#include <catch2/catch_all.hpp>
+
+#include <algorithm>
+
+#include "libslic3r/MinimumSpanningTree.hpp"
+#include "libslic3r/Point.hpp"
+
+using namespace Slic3r;
+
+// A 5x5 lattice: at every step of Prim's algorithm several candidates sit at the same
+// distance from the tree, so the tie-break decides the tree's shape.
+static std::vector<Point> lattice()
+{
+    std::vector<Point> vertices;
+    for (int y = 0; y < 5; ++y)
+        for (int x = 0; x < 5; ++x)
+            vertices.emplace_back(Point::new_scale(x, y));
+    return vertices;
+}
+
+static std::vector<Point> sorted_neighbours(const MinimumSpanningTree &mst, const Point &vertex)
+{
+    std::vector<Point> neighbours = mst.adjacent_nodes(vertex);
+    std::sort(neighbours.begin(), neighbours.end());
+    return neighbours;
+}
+
+TEST_CASE("Minimum spanning tree connects every vertex", "[MinimumSpanningTree]")
+{
+    const std::vector<Point> vertices = lattice();
+    const MinimumSpanningTree mst(vertices);
+
+    REQUIRE(mst.vertices().size() == vertices.size());
+    size_t adjacency_entries = 0;
+    for (const Point &vertex : vertices) {
+        const std::vector<Point> neighbours = mst.adjacent_nodes(vertex);
+        REQUIRE(! neighbours.empty());
+        adjacency_entries += neighbours.size();
+    }
+    // A tree on n vertices has n - 1 edges, each listed from both ends.
+    REQUIRE(adjacency_entries == 2 * (vertices.size() - 1));
+}
+
+TEST_CASE("Minimum spanning tree does not depend on the order of the non-root vertices", "[MinimumSpanningTree][Regression]")
+{
+    const std::vector<Point> vertices = lattice();
+    const MinimumSpanningTree reference(vertices);
+
+    // The root stays first: Prim's tree legitimately depends on where it starts.
+    // Every other order of the remaining vertices must give the same tree.
+    std::vector<std::vector<Point>> orders;
+    orders.emplace_back(vertices);
+    std::reverse(orders.back().begin() + 1, orders.back().end());
+    for (size_t shift = 1; shift + 1 < vertices.size(); ++shift) {
+        orders.emplace_back(vertices);
+        std::rotate(orders.back().begin() + 1, orders.back().begin() + 1 + shift, orders.back().end());
+    }
+
+    for (const std::vector<Point> &order : orders) {
+        const MinimumSpanningTree mst(order);
+        for (const Point &vertex : vertices) {
+            INFO("vertex " << vertex.x() << "," << vertex.y());
+            REQUIRE(sorted_neighbours(mst, vertex) == sorted_neighbours(reference, vertex));
+        }
+    }
+}

tests/libslic3r/test_preset_options.cpp

@@ -0,0 +1,70 @@
+// Regression test for the "option in def + UI but missing from preset key list"
+// crash class.
+//
+// The print preset's DynamicPrintConfig is seeded with only the keys returned by
+// Preset::print_options() (PresetBundle.cpp). A field added to PrintRegionConfig
+// or PrintObjectConfig and registered via print_config_def plus a TabPrint
+// optgroup, but left out of print_options(), still gets its control built; on tab
+// activation reload_config -> get_config_value dispatches to opt_bool/opt_int on a
+// DynamicPrintConfig with no entry for the key, and the accessor null-derefs the
+// result of option<T>(key).
+//
+// The invariant asserted here is the inverse: every key declared on
+// PrintRegionConfig and PrintObjectConfig appears in Preset::print_options() or
+// Preset::filament_options(), the two preset key lists that seed a print preset's
+// DynamicConfig.
+
+#include <catch2/catch_all.hpp>
+
+#include "libslic3r/Preset.hpp"
+#include "libslic3r/PrintConfig.hpp"
+
+#include <set>
+
+using namespace Slic3r;
+
+namespace {
+
+// Deprecated keys renamed in handle_legacy() (ironing_direction ->
+// ironing_angle, wall_infill_order -> wall_sequence); neither is in a
+// preset list. Register new options in a preset list, not here.
+const std::set<std::string> kDeprecatedRegionFields = {
+    "ironing_direction",
+    "wall_infill_order",
+};
+
+void check_keys_are_in_a_preset(const t_config_option_keys& keys, const std::string& class_name)
+{
+    REQUIRE_FALSE(keys.empty());
+    const auto& print_options    = Preset::print_options();
+    const auto& filament_options = Preset::filament_options();
+    const std::set<std::string> in_print(print_options.begin(), print_options.end());
+    const std::set<std::string> in_filament(filament_options.begin(), filament_options.end());
+    for (const std::string& key : keys) {
+        DYNAMIC_SECTION(class_name << "::" << key)
+        {
+            INFO("'" << key << "' on " << class_name
+                     << " is missing from "
+                        "Preset::print_options()/filament_options(); add it to "
+                        "s_Preset_print_options (or s_Preset_filament_options) in Preset.cpp.");
+            const bool registered = in_print.count(key) || in_filament.count(key) || kDeprecatedRegionFields.count(key);
+            REQUIRE(registered);
+        }
+    }
+}
+
+} // namespace
+
+// Bodies are laid out like the rest of the test suite rather than collapsed
+// onto the brace line.
+// clang-format off
+TEST_CASE("Every PrintRegionConfig field is registered in a preset key list", "[Preset][Config]")
+{
+    check_keys_are_in_a_preset(PrintRegionConfig::defaults().keys(), "PrintRegionConfig");
+}
+
+TEST_CASE("Every PrintObjectConfig field is registered in a preset key list", "[Preset][Config]")
+{
+    check_keys_are_in_a_preset(PrintObjectConfig::defaults().keys(), "PrintObjectConfig");
+}
+// clang-format on

tests/libslic3r/test_preset_setting_id.cpp

@@ -5,10 +5,10 @@
 using namespace Slic3r;
 
 // Golden vectors from the Python reference generate_preset_setting_id (defined in
-// scripts/assign_vendor_setting_ids.py). The C++ generate_preset_setting_id() MUST stay
-// byte-identical to it, otherwise app-side on-the-fly ids would diverge from the
+// scripts/orca_id_tool.py). The C++ generate_preset_setting_id() MUST stay byte-identical
+// to it, otherwise app-side on-the-fly ids would diverge from the
 // script-assigned ones in the profiles. Regenerate a vector with:
-//   python3 -c "from assign_vendor_setting_ids import generate_preset_setting_id as g; print(g('Afinia','filament','Afinia ABS @Afinia H400'))"
+//   python3 -c "import sys; sys.path.insert(0, 'scripts'); from orca_id_tool import generate_preset_setting_id as g; print(g('Afinia','filament','Afinia ABS @Afinia H400'))"
 TEST_CASE("preset setting_id matches the Python reference", "[Preset][setting_id]") {
     struct Vec { const char* vendor; const char* type; const char* name; const char* expected; };
     const Vec vectors[] = {

tests/libslic3r/test_utils.cpp

@@ -2,6 +2,13 @@
 
 #include "libslic3r/Utils.hpp"
 
+#include "test_utils.hpp"
+
+#include <algorithm>
+#include <cctype>
+#include <fstream>
+#include <string>
+
 #ifndef _WIN32
 #include <unistd.h>     // getuid
 #endif
@@ -52,3 +59,32 @@ TEST_CASE("per-user temp root is unchanged on Windows, isolated elsewhere", "[ut
     REQUIRE_THAT(root, Catch::Matchers::StartsWith(base + "/orcaslicer_"));
 #endif
 }
+
+TEST_CASE("copy_file reports the OS error when the destination cannot be written", "[utils]") {
+    ScopedTemporaryFile source(".txt");
+    {
+        std::ofstream ofs(source.string(), std::ios::binary);
+        ofs << "orca";
+    }
+    REQUIRE(boost::filesystem::exists(source.path()));
+
+    // A directory that was never created, so the copy fails on every platform.
+    const boost::filesystem::path destination = source.path().parent_path() / "orca-missing-dir" / "copy.txt";
+    REQUIRE_FALSE(boost::filesystem::exists(destination.parent_path()));
+
+    std::string error_message;
+    REQUIRE(copy_file(source.string(), destination.string(), error_message) == FAIL_COPY_FILE);
+    REQUIRE_FALSE(error_message.empty());
+
+#ifdef _WIN32
+    // The Windows branch formats GetLastError() itself. Writing that as
+    // "Error: " + errCode adds an integer to a string literal, which indexes into the
+    // literal instead of appending and runs off its end for any code above 7.
+    const std::string prefix = "Error: ";
+    REQUIRE(error_message.rfind(prefix, 0) == 0);
+
+    const std::string code = error_message.substr(prefix.size());
+    REQUIRE_FALSE(code.empty());
+    REQUIRE(std::all_of(code.begin(), code.end(), [](unsigned char c) { return std::isdigit(c) != 0; }));
+#endif // _WIN32
+}

tests/libslic3r/test_wipe_tower.cpp

@@ -0,0 +1,93 @@
+#include <catch2/catch_all.hpp>
+
+#include <cmath>
+
+#include "libslic3r/BoundingBox.hpp"
+#include "libslic3r/ClipperUtils.hpp"
+#include "libslic3r/GCode/WipeTower.hpp"
+#include "libslic3r/GCode/WipeTower2.hpp"
+
+using namespace Slic3r;
+using Catch::Matchers::WithinAbs;
+
+// A Bambu P1S project that reproduced the off-plate brim: two PLAs priming 30 and 45 mm3 in
+// separate adhesiveness categories on a 35 mm tower, 0.21 mm layers, 0.4 nozzle (0.5 mm lines),
+// 150 % infill gap (0.75 mm line pitch), rib width 8, 16 mm tall.
+static std::vector<WipeTower::PurgeEstimate> cube_purges(int first_category = 100)
+{
+    return {{30.f, first_category}, {45.f, 0}};
+}
+
+TEST_CASE("Cone base polygon bulges past the body box", "[WipeTower]") {
+    // Zero angle: plain body box.
+    const Polygon box = WipeTower2::cone_base_polygon(35., 20., 100., 0.);
+    CHECK(box.points.size() == 4);
+    CHECK(get_extents(box).size() == Point::new_scale(Vec2d(35., 20.)));
+    // A 25-degree cone on a 100 mm tower: base radius R = tan(12.5deg)*100 = 22.2 mm,
+    // which exceeds the body half-depth, so the footprint bulges to center +- R in y
+    // (support_scale keeps the x extent compressed near the body).
+    const Polygon     base = WipeTower2::cone_base_polygon(35., 20., 100., 25.);
+    const BoundingBox bb   = get_extents(base);
+    const double      R    = std::tan(25. / 2. * M_PI / 180.) * 100.;
+    CHECK_THAT(unscaled(bb.min.y()), WithinAbs(10. - R, 0.1));
+    CHECK_THAT(unscaled(bb.max.y()), WithinAbs(10. + R, 0.1));
+    // The footprint always contains the body box.
+    CHECK(diff(Polygons{box}, Polygons{base}).empty());
+}
+
+TEST_CASE("Type1 block-stack depth quantizes each purge to whole lines", "[WipeTower]") {
+    // A 0.5 mm line at 0.21 mm carries 0.0955 mm3 per mm, so across the 34 mm between the
+    // perimeters 30 mm3 is 10 lines and 45 mm3 is 14: 7.5 + 10.5 at the 0.75 mm pitch behind
+    // one perimeter width. The generated mesh of the project measured exactly this.
+    CHECK_THAT(WipeTower::estimate_tower_blocks_depth(cube_purges(), 35.f, 0.21f, 0.4f, 1.5f), WithinAbs(18.5f, 0.01f));
+    // Sharing one category, a layer can never purge into every filament (one of them starts
+    // the layer), so the block is sized by its worst layer and the 10-line purge drops out.
+    CHECK_THAT(WipeTower::estimate_tower_blocks_depth(cube_purges(0), 35.f, 0.21f, 0.4f, 1.5f), WithinAbs(11.0f, 0.01f));
+    CHECK_THAT(WipeTower::estimate_tower_blocks_depth({}, 35.f, 0.2f, 0.4f, 1.f), WithinAbs(0.f, 1e-6f));
+    // A width narrower than two perimeter widths cannot hold purge lines.
+    CHECK_THAT(WipeTower::estimate_tower_blocks_depth({{45.f, 0}}, 0.9f, 0.2f, 0.4f, 1.f), WithinAbs(0.f, 1e-6f));
+}
+
+TEST_CASE("A nozzle change adds its ramming lines to the block", "[WipeTower]") {
+    // 10 mm of 1.75 mm filament (24.05 mm3) laid as 1.0 mm nozzle-change lines at 0.2 mm
+    // (0.1914 mm2 each) is 125.7 mm; across the 48.5 mm available that is 3 lines of 1.0 mm.
+    std::vector<WipeTower::PurgeEstimate> purges{{100.f, 0}, {100.f, 0}};
+    const float without_change = WipeTower::estimate_tower_blocks_depth(purges, 50.f, 0.2f, 0.4f, 1.f);
+    purges.front().filament_change_length = 10.f;
+    CHECK_THAT(WipeTower::estimate_tower_blocks_depth(purges, 50.f, 0.2f, 0.4f, 1.f) - without_change, WithinAbs(3.f, 1e-4f));
+}
+
+TEST_CASE("Rib tower footprint estimate covers the generated footprint", "[WipeTower]") {
+    // The generated first-layer wall bbox of the project measured 29.56 mm from the sliced
+    // G-code; the volume-only estimate said 23.585 mm.
+    const float side = WipeTower::estimate_rib_tower_bbox_side(cube_purges(), 35.f, 0.21f, 0.4f, 1.5f, 8.f, 0.f, 16.f);
+    CHECK(side >= 29.56f);
+    CHECK(side <= 29.56f + 4.f); // without grossly over-reserving plate space
+    // Separate categories stack their blocks, so the footprint must not shrink when they differ.
+    CHECK(side >= WipeTower::estimate_rib_tower_bbox_side(cube_purges(0), 35.f, 0.21f, 0.4f, 1.5f, 8.f, 0.f, 16.f));
+    CHECK_THAT(WipeTower::estimate_rib_tower_bbox_side({}, 35.f, 0.2f, 0.4f, 1.f, 8.f, 0.f, 16.f), WithinAbs(0.f, 1e-6f));
+}
+
+TEST_CASE("Rib footprint extends the ribs, not the body, below the stability minimum", "[WipeTower]") {
+    // A 10 mm body under a 90 mm print: the ribs stretch to the minimum depth's diagonal, and
+    // the rib width is capped at half the body, so the square grows to minimum + 5 / sqrt(2).
+    const float min_depth = WipeTower::get_limit_depth_by_height(90.f);
+    REQUIRE(min_depth > 10.f);
+    CHECK_THAT(WipeTower::rib_footprint_side(10.f, 10.f, 8.f, 0.f, 90.f), WithinAbs(min_depth + 5.f / std::sqrt(2.f), 1e-4f));
+    // The extra rib length runs along the diagonal, so it shows as its projection on each axis.
+    const float plain = WipeTower::rib_footprint_side(30.f, 30.f, 8.f, 0.f, 5.f);
+    CHECK_THAT(plain, WithinAbs(30.f + 8.f / std::sqrt(2.f), 1e-4f));
+    CHECK_THAT(WipeTower::rib_footprint_side(30.f, 30.f, 8.f, 4.f, 5.f) - plain, WithinAbs(4.f / std::sqrt(2.f), 1e-4f));
+    // A negative extra length cannot pull the ribs inside the diagonal.
+    CHECK_THAT(WipeTower::rib_footprint_side(30.f, 30.f, 8.f, -4.f, 5.f), WithinAbs(plain, 1e-4f));
+    CHECK_THAT(WipeTower::rib_footprint_side(0.f, 30.f, 8.f, 0.f, 5.f), WithinAbs(0.f, 1e-6f));
+}
+
+TEST_CASE("Brim width estimate matches each generator's loop quantization", "[WipeTower]") {
+    // 3 mm configured, 0.4 nozzle, 0.2 first layer: 0.4571 mm spacing, 7 loops. WipeTower2
+    // prints and reports the 7 loops; WipeTower reports half a spacing of line width on top.
+    const float spacing = 0.5f - 0.2f * float(1. - M_PI_4);
+    CHECK_THAT(WipeTower::estimate_brim_real_width(3.f, 0.4f, 0.2f, true), WithinAbs(7.f * spacing, 1e-4f));
+    CHECK_THAT(WipeTower::estimate_brim_real_width(3.f, 0.4f, 0.2f, false), WithinAbs(7.5f * spacing, 1e-4f));
+    CHECK_THAT(WipeTower::estimate_brim_real_width(0.f, 0.4f, 0.2f, true), WithinAbs(0.f, 1e-6f));
+}

tests/libslic3r/test_wipe_tower_estimate.cpp

@@ -0,0 +1,351 @@
+#include <catch2/catch_all.hpp>
+
+#include "libslic3r/BoundingBox.hpp"
+#include "libslic3r/ClipperUtils.hpp"
+#include "libslic3r/GCode/WipeTower.hpp"
+#include "libslic3r/GCode/WipeTower2.hpp"
+#include "libslic3r/GCode/WipeTowerEstimate.hpp"
+#include "libslic3r/PrintConfig.hpp"
+
+#include <cmath>
+#include <numeric>
+#include <string>
+
+using namespace Slic3r;
+using Catch::Matchers::WithinAbs;
+
+// Rectangle wall, one nozzle, 100 mm3 prime volume on a 50 mm wide tower at 0.2 mm layers: one
+// purge is 10 mm of depth. The flush matrix is off here; the shipped-default case covers it.
+// Built as PresetBundle::full_config builds the GUI's: apply() creates each enum as a
+// ConfigOptionEnumGeneric, where full_print_config() would clone the static defaults'
+// ConfigOptionEnum<T>. The estimate has to read either.
+static DynamicPrintConfig preset_shaped_defaults()
+{
+    DynamicPrintConfig config;
+    config.apply(FullPrintConfig::defaults());
+    return config;
+}
+
+static DynamicPrintConfig make_config(const char *wall_type = "rectangle")
+{
+    DynamicPrintConfig config = preset_shaped_defaults();
+    config.set_key_value("prime_tower_width", new ConfigOptionFloat(50.));
+    config.set_key_value("prime_volume", new ConfigOptionFloat(100.));
+    config.set_key_value("filament_prime_volume", new ConfigOptionFloats({100.}));
+    config.set_key_value("filament_adhesiveness_category", new ConfigOptionInts({0}));
+    config.set_key_value("prime_tower_infill_gap", new ConfigOptionPercent(100.));
+    config.set_key_value("wipe_tower_extra_spacing", new ConfigOptionPercent(100.));
+    config.set_key_value("prime_tower_brim_width", new ConfigOptionFloat(3.));
+    config.set_deserialize_strict("wipe_tower_wall_type", wall_type);
+    config.set_key_value("wipe_tower_rib_width", new ConfigOptionFloat(8.));
+    config.set_key_value("wipe_tower_extra_rib_length", new ConfigOptionFloat(0.));
+    config.set_key_value("nozzle_diameter", new ConfigOptionFloats({0.4}));
+    config.set_key_value("initial_layer_print_height", new ConfigOptionFloat(0.2));
+    config.set_deserialize_strict("timelapse_type", "0");
+    config.set_key_value("enable_wrapping_detection", new ConfigOptionBool(false));
+    config.set_key_value("raft_layers", new ConfigOptionInt(0));
+    config.set_key_value("purge_in_prime_tower", new ConfigOptionBool(false));
+    config.set_key_value("single_extruder_multi_material", new ConfigOptionBool(false));
+    return config;
+}
+
+static std::vector<unsigned int> filaments(size_t count)
+{
+    std::vector<unsigned int> ids(count);
+    std::iota(ids.begin(), ids.end(), 0u);
+    return ids;
+}
+
+// The first `count` filaments on the given planner; Type2 unless a case says otherwise.
+static WipeTowerFootprint estimate(const ConfigBase &config, size_t count, double layer_height, double height, WipeTowerType type = WipeTowerType::Type2)
+{
+    return estimate_wipe_tower_footprint(config, type, filaments(count), layer_height, height);
+}
+
+// What both planners print for a 3 mm brim at 0.4 nozzle and 0.2 first layer (0.4571 mm loops).
+static double printed_brim(double configured, WipeTowerType type)
+{
+    return WipeTower::estimate_brim_real_width(float(configured), 0.4f, 0.2f, type == WipeTowerType::Type2);
+}
+
+TEST_CASE("A rectangle wall tower is sized by the purge volume", "[WipeTowerEstimate]") {
+    const DynamicPrintConfig config = make_config();
+    // Three filaments purge twice per layer; a 5 mm object keeps the stability floor at 5 mm.
+    const WipeTowerFootprint fp = estimate(config, 3, 0.2, 5.);
+    CHECK_THAT(fp.width, WithinAbs(50., 1e-9));
+    CHECK_THAT(fp.depth, WithinAbs(20., 1e-9));
+    CHECK_THAT(fp.height, WithinAbs(5., 1e-9));
+    CHECK_THAT(fp.brim_width, WithinAbs(printed_brim(3., WipeTowerType::Type2), 1e-6));
+    // Thinner layers need more depth for the same volume.
+    CHECK_THAT(estimate(config, 3, 0.1, 5.).depth, WithinAbs(40., 1e-9));
+}
+
+TEST_CASE("Each planner spaces its purge lines by its own option", "[WipeTowerEstimate]") {
+    // Type2 reads wipe_tower_extra_spacing and Type1 prime_tower_infill_gap; neither sees the
+    // other's key. Type2's extra flow cancels out of its depth.
+    DynamicPrintConfig config = make_config();
+    config.set_key_value("wipe_tower_extra_flow", new ConfigOptionPercent(250.));
+    CHECK_THAT(estimate(config, 3, 0.2, 5.).depth, WithinAbs(20., 1e-9));
+    config.set_key_value("wipe_tower_extra_spacing", new ConfigOptionPercent(150.));
+    CHECK_THAT(estimate(config, 3, 0.2, 5.).depth, WithinAbs(30., 1e-9));
+    const double type1_spaced = estimate(config, 3, 0.2, 5., WipeTowerType::Type1).depth;
+    config.set_key_value("prime_tower_infill_gap", new ConfigOptionPercent(150.));
+    CHECK_THAT(estimate(config, 3, 0.2, 5.).depth, WithinAbs(30., 1e-9));
+    // Type1 stacks whole lines behind one 0.5 mm perimeter width, so only the stack scales.
+    CHECK_THAT(estimate(config, 3, 0.2, 5., WipeTowerType::Type1).depth - 0.5, WithinAbs(1.5 * (type1_spaced - 0.5), 1e-6));
+}
+
+TEST_CASE("Type1 sizes the tower from each filament's own prime volume", "[WipeTowerEstimate]") {
+    // The Bambu P1S project of the WipeTower cases: 30 and 45 mm3 in two categories on a 35 mm
+    // tower at 0.21 mm, 150 % gap, is 18.5 mm of stacked blocks (11 mm sharing one category).
+    DynamicPrintConfig config = make_config();
+    config.set_key_value("prime_tower_width", new ConfigOptionFloat(35.));
+    config.set_key_value("prime_tower_infill_gap", new ConfigOptionPercent(150.));
+    config.set_key_value("initial_layer_print_height", new ConfigOptionFloat(0.21));
+    config.set_key_value("filament_prime_volume", new ConfigOptionFloats({30., 45.}));
+    config.set_key_value("filament_adhesiveness_category", new ConfigOptionInts({100, 0}));
+    const std::vector<WipeTower::PurgeEstimate> purges{{30.f, 100}, {45.f, 0}};
+    const double blocks = WipeTower::estimate_tower_blocks_depth(purges, 35.f, 0.21f, 0.4f, 1.5f);
+    REQUIRE_THAT(blocks, WithinAbs(18.5, 0.01));
+    CHECK_THAT(estimate(config, 2, 0.21, 5., WipeTowerType::Type1).depth, WithinAbs(blocks, 1e-4));
+    // The ids pick the volumes, so their order does not matter and a lone filament has no purge.
+    CHECK_THAT(estimate_wipe_tower_footprint(config, WipeTowerType::Type1, {1, 0}, 0.21, 5.).depth, WithinAbs(blocks, 1e-4));
+    CHECK_THAT(estimate(config, 1, 0.21, 5., WipeTowerType::Type1).depth, WithinAbs(0., 1e-9));
+    config.set_key_value("filament_adhesiveness_category", new ConfigOptionInts({0, 0}));
+    CHECK_THAT(estimate(config, 2, 0.21, 5., WipeTowerType::Type1).depth, WithinAbs(11., 0.01));
+    // A rib wall squares the same stack.
+    config.set_deserialize_strict("wipe_tower_wall_type", "rib");
+    const WipeTowerFootprint rib = estimate(config, 2, 0.21, 5., WipeTowerType::Type1);
+    CHECK_THAT(rib.width, WithinAbs(rib.depth, 1e-9));
+    CHECK_THAT(rib.depth, WithinAbs(WipeTower::estimate_rib_tower_bbox_side({{30.f, 0}, {45.f, 0}}, 35.f, 0.21f, 0.4f, 1.5f, 8.f, 0.f, 5.f), 1e-4));
+}
+
+TEST_CASE("A second nozzle adds the ramming of one nozzle change per layer", "[WipeTowerEstimate]") {
+    // Two filaments on two nozzles: the tool order crosses once per layer, and Type1 rams 10 mm
+    // of filament as three 1.0 mm nozzle-change lines (see the WipeTower case).
+    DynamicPrintConfig config = make_config();
+    config.set_key_value("nozzle_diameter", new ConfigOptionFloats({0.4, 0.4}));
+    config.set_key_value("filament_change_length", new ConfigOptionFloats({10., 10.}));
+    config.set_key_value("filament_diameter", new ConfigOptionFloats({1.75, 1.75}));
+    config.set_key_value("filament_map", new ConfigOptionInts({1, 1}));
+    const double same_nozzle = estimate(config, 2, 0.2, 5., WipeTowerType::Type1).depth;
+    config.set_key_value("filament_map", new ConfigOptionInts({1, 2}));
+    CHECK_THAT(estimate(config, 2, 0.2, 5., WipeTowerType::Type1).depth - same_nozzle, WithinAbs(3., 1e-4));
+}
+
+TEST_CASE("The tower is sized for the first layer when it is the thinnest", "[WipeTowerEstimate]") {
+    // Both planners reserve the worst layer: a 0.28 mm print with a 0.2 mm first layer needs
+    // the 0.2 mm depth, while a thicker first layer changes nothing.
+    DynamicPrintConfig config = make_config();
+    const double at_thinnest = estimate(config, 3, 0.2, 5.).depth;
+    CHECK_THAT(estimate(config, 3, 0.28, 5.).depth, WithinAbs(at_thinnest, 1e-9));
+    config.set_key_value("initial_layer_print_height", new ConfigOptionFloat(0.3));
+    CHECK(estimate(config, 3, 0.28, 5.).depth < at_thinnest);
+}
+
+TEST_CASE("Object height sets the stability floor and the auto brim", "[WipeTowerEstimate]") {
+    DynamicPrintConfig config = make_config();
+    // Two filaments purge once: 10 mm, lifted to the 20 mm floor of a 100 mm tower.
+    CHECK_THAT(estimate(config, 2, 0.2, 100.).depth, WithinAbs(20., 1e-9));
+    config.set_key_value("prime_tower_brim_width", new ConfigOptionFloat(-1.));
+    const double auto_brim = WipeTower::get_auto_brim_by_height(50.f);
+    CHECK_THAT(estimate(config, 2, 0.2, 50.).brim_width, WithinAbs(printed_brim(auto_brim, WipeTowerType::Type2), 1e-6));
+    CHECK_THAT(estimate(config, 2, 0.2, 50., WipeTowerType::Type1).brim_width, WithinAbs(printed_brim(auto_brim, WipeTowerType::Type1), 1e-6));
+}
+
+TEST_CASE("A single filament only gets a tower when one is printed anyway", "[WipeTowerEstimate]") {
+    DynamicPrintConfig config = make_config();
+    CHECK_THAT(estimate(config, 1, 0.2, 100.).depth, WithinAbs(0., 1e-9));
+    CHECK_THAT(estimate(config, 0, 0.2, 100.).width, WithinAbs(0., 1e-9));
+
+    // Wrapping detection prints a tower on the first layers whatever the filament count: the
+    // Type1 planner's fixed 10 mm, the stability floor otherwise.
+    config.set_key_value("enable_wrapping_detection", new ConfigOptionBool(true));
+    CHECK_THAT(estimate(config, 1, 0.2, 100.).depth, WithinAbs(20., 1e-9));
+    CHECK_THAT(estimate(config, 1, 0.2, 100., WipeTowerType::Type1).depth, WithinAbs(WipeTower::get_wrapping_detection_depth(), 1e-9));
+    config.set_key_value("enable_wrapping_detection", new ConfigOptionBool(false));
+
+    // A raft is not one of them: normalize_fdm_2 clears enable_prime_tower for a plate that
+    // purges one filament unless smooth timelapse or wrapping detection is on, so a raft
+    // alone leaves no tower to reserve for.
+    config.set_key_value("raft_layers", new ConfigOptionInt(3));
+    CHECK_THAT(estimate(config, 1, 0.2, 100.).depth, WithinAbs(0., 1e-9));
+    config.set_key_value("raft_layers", new ConfigOptionInt(0));
+
+    config.set_deserialize_strict("timelapse_type", "1");
+    // A tower printed with no tool change is exactly the planner's idle depth: there is
+    // nothing to purge, and WipeTower2 sizes it at the stability floor.
+    CHECK_THAT(estimate(config, 1, 0.2, 100.).depth, WithinAbs(20., 1e-9));
+    CHECK_THAT(estimate(config, 1, 0.2, 5.).depth, WithinAbs(WipeTower::get_limit_depth_by_height(5.f), 1e-9));
+}
+
+TEST_CASE("A tool change reserves a tower even with nothing to purge", "[WipeTowerEstimate]") {
+    // The purge volumes are configurable down to zero, but the tool changes are still printed
+    // on the tower and both planners still floor it - so the estimate has to floor it too.
+    // Type1 plans per filament and already reserves one; Type2 has only the volume to go on.
+    const double     height = GENERATE(5., 100.);
+    const float      floor  = WipeTower::get_limit_depth_by_height(float(height));
+    const char      *wall   = GENERATE("rectangle", "rib");
+    DynamicPrintConfig config = make_config(wall);
+    config.set_key_value("prime_volume", new ConfigOptionFloat(0.));
+    config.set_key_value("filament_prime_volume", new ConfigOptionFloats({0.}));
+
+    CHECK(estimate(config, 3, 0.2, height, WipeTowerType::Type2).depth >= floor);
+    CHECK(estimate(config, 3, 0.2, height, WipeTowerType::Type1).depth >= floor);
+    // Still nothing for a lone filament with no other reason.
+    CHECK_THAT(estimate(config, 1, 0.2, height, WipeTowerType::Type2).depth, WithinAbs(0., 1e-9));
+    CHECK_THAT(estimate(config, 1, 0.2, height, WipeTowerType::Type1).depth, WithinAbs(0., 1e-9));
+}
+
+TEST_CASE("Both wall types agree on whether there is a tower at all", "[WipeTowerEstimate]") {
+    // A wall type may only change the shape of the tower, never whether one is reserved:
+    // reporting no tower for one that is built collapses the validation hull to a point.
+    const double height = GENERATE(5., 100.);
+    DynamicPrintConfig rect = make_config();
+    DynamicPrintConfig rib  = make_config("rib");
+
+    // No tool change and nothing else that prints a tower - neither wall type reserves one.
+    CHECK_THAT(estimate(rect, 1, 0.2, height).depth, WithinAbs(0., 1e-9));
+    CHECK_THAT(estimate(rib, 1, 0.2, height).depth, WithinAbs(0., 1e-9));
+
+    // Not even on a dual-nozzle printer, where a lone filament still needs no purge.
+    rect.set_key_value("nozzle_diameter", new ConfigOptionFloats({0.4, 0.4}));
+    rib.set_key_value("nozzle_diameter", new ConfigOptionFloats({0.4, 0.4}));
+    CHECK_THAT(estimate(rect, 1, 0.2, height).depth, WithinAbs(0., 1e-9));
+    CHECK_THAT(estimate(rib, 1, 0.2, height).depth, WithinAbs(0., 1e-9));
+
+    // With a tool change both reserve one, and both respect the stability floor.
+    CHECK(estimate(rect, 2, 0.2, height).depth >= WipeTower::get_limit_depth_by_height(float(height)));
+    CHECK(estimate(rib, 2, 0.2, height).depth >= WipeTower::get_limit_depth_by_height(float(height)));
+}
+
+TEST_CASE("A rib wall squares the tower and caps the rib width", "[WipeTowerEstimate]") {
+    DynamicPrintConfig config = make_config("rib");
+    // sqrt(200 / 0.2) = 31.62 mm square, plus the 8 mm rib bulge along the diagonal.
+    const double body = std::sqrt(1000.);
+    WipeTowerFootprint fp = estimate(config, 3, 0.2, 5.);
+    CHECK_THAT(fp.depth, WithinAbs(8. / std::sqrt(2.) + body, 1e-5));
+    CHECK_THAT(fp.width, WithinAbs(fp.depth, 1e-9));
+    // The extra rib length runs along the diagonal and grows the footprint by its projection.
+    config.set_key_value("wipe_tower_extra_rib_length", new ConfigOptionFloat(4.));
+    CHECK_THAT(estimate(config, 3, 0.2, 5.).depth, WithinAbs((8. + 4.) / std::sqrt(2.) + body, 1e-5));
+    // A tiny tower caps the rib width at half its depth: 5 mm body, 2.5 mm rib.
+    config.set_key_value("wipe_tower_extra_rib_length", new ConfigOptionFloat(0.));
+    config.set_key_value("prime_volume", new ConfigOptionFloat(5.));
+    CHECK_THAT(estimate(config, 2, 0.2, 5.).depth, WithinAbs(2.5 / std::sqrt(2.) + 5., 1e-5));
+}
+
+TEST_CASE("Every wall and tower type is read the same from a preset and a static config", "[WipeTowerEstimate]") {
+    // The GUI, arrange and the CLI pass a DynamicPrintConfig whose enums are
+    // ConfigOptionEnumGeneric; Print passes a static config whose enums are ConfigOptionEnum<T>.
+    // Both the wall type and the planner selection are read by value, so both give the same shape.
+    const char *wall_type  = GENERATE("rectangle", "cone", "rib");
+    const char *tower_type = GENERATE("type1", "type2");
+    DynamicPrintConfig preset = make_config(wall_type);
+    preset.set_deserialize_strict("wipe_tower_type", tower_type);
+    REQUIRE(dynamic_cast<const ConfigOptionEnumGeneric *>(preset.option("wipe_tower_wall_type")) != nullptr);
+
+    FullPrintConfig static_config;
+    static_config.apply(preset, true);
+    REQUIRE(static_config.wipe_tower_wall_type.serialize() == wall_type);
+    REQUIRE(static_config.wipe_tower_type.serialize() == tower_type);
+
+    const WipeTowerType type = resolve_wipe_tower_type(preset);
+    CHECK(type == (std::string(tower_type) == "type1" ? WipeTowerType::Type1 : WipeTowerType::Type2));
+    CHECK(resolve_wipe_tower_type(static_config) == type);
+
+    // Three filaments purge twice per layer on a 5 mm object.
+    const WipeTowerFootprint fp          = estimate(preset, 3, 0.2, 5., type);
+    const WipeTowerFootprint from_static = estimate(static_config, 3, 0.2, 5., type);
+    CHECK(fp.depth > 0.);
+    if (std::string(wall_type) == "rib")
+        CHECK_THAT(fp.width, WithinAbs(fp.depth, 1e-9));
+    else
+        CHECK_THAT(fp.width, WithinAbs(50., 1e-9));
+    CHECK_THAT(from_static.width, WithinAbs(fp.width, 1e-9));
+    CHECK_THAT(from_static.depth, WithinAbs(fp.depth, 1e-9));
+    CHECK_THAT(from_static.brim_width, WithinAbs(fp.brim_width, 1e-9));
+
+    // Smooth timelapse is the other enum the estimate reads: a lone filament gets a tower
+    // through both storages too.
+    preset.set_deserialize_strict("timelapse_type", "1");
+    static_config.apply(preset, true);
+    CHECK(estimate(preset, 1, 0.2, 5., type).depth > 0.);
+    CHECK(estimate(static_config, 1, 0.2, 5., type).depth > 0.);
+}
+
+TEST_CASE("The first-layer outline bulges only for a Type2 cone wall", "[WipeTowerEstimate]") {
+    // Read off a preset-shaped config, whose enums are ConfigOptionEnumGeneric: a cast to
+    // ConfigOptionEnum<T> sees no wall type there and would never find the cone.
+    DynamicPrintConfig config = make_config("cone");
+    config.set_key_value("wipe_tower_cone_angle", new ConfigOptionFloat(25.));
+    REQUIRE(dynamic_cast<const ConfigOptionEnumGeneric *>(config.option("wipe_tower_wall_type")) != nullptr);
+    const Polygon box = Polygon::new_scale({{0., 0.}, {35., 0.}, {35., 20.}, {0., 20.}});
+    auto is_box = [&box](const Polygon &outline) { return diff(Polygons{outline}, Polygons{box}).empty(); };
+
+    // A 25-degree cone on a 100 mm tower has a 22 mm base radius, past the 10 mm half-depth.
+    const Polygon cone = estimate_wipe_tower_first_layer_outline(config, WipeTowerType::Type2, 35., 20., 100.);
+    CHECK(unscaled(get_extents(cone).max.y()) > 20. + 1.);
+    CHECK(diff(Polygons{box}, Polygons{cone}).empty());
+    // Type1 ignores the cone option, and the other wall types have no cone.
+    CHECK(is_box(estimate_wipe_tower_first_layer_outline(config, WipeTowerType::Type1, 35., 20., 100.)));
+    for (const char *wall_type : {"rectangle", "rib"}) {
+        config.set_deserialize_strict("wipe_tower_wall_type", wall_type);
+        CHECK(is_box(estimate_wipe_tower_first_layer_outline(config, WipeTowerType::Type2, 35., 20., 100.)));
+    }
+    // The static config Print holds gives the same outline.
+    config.set_deserialize_strict("wipe_tower_wall_type", "cone");
+    FullPrintConfig static_config;
+    static_config.apply(config, true);
+    const Polygon from_static = estimate_wipe_tower_first_layer_outline(static_config, WipeTowerType::Type2, 35., 20., 100.);
+    CHECK(from_static.points == cone.points);
+}
+
+TEST_CASE("A Bambu Lab printer always gets the Type1 planner", "[WipeTowerEstimate]") {
+    DynamicPrintConfig config = make_config();
+    config.set_deserialize_strict("wipe_tower_type", "type2");
+    config.set_key_value("printer_model", new ConfigOptionString("Bambu Lab X1 Carbon"));
+    CHECK(resolve_wipe_tower_type(config) == WipeTowerType::Type1);
+    config.set_key_value("printer_model", new ConfigOptionString("Voron 2.4"));
+    CHECK(resolve_wipe_tower_type(config) == WipeTowerType::Type2);
+    config.erase("wipe_tower_type");
+    CHECK(resolve_wipe_tower_type(config) == WipeTowerType::Type2);
+}
+
+TEST_CASE("A dual nozzle purges every filament plus the filament change", "[WipeTowerEstimate]") {
+    DynamicPrintConfig config = make_config();
+    config.set_key_value("nozzle_diameter", new ConfigOptionFloats({0.4, 0.4}));
+    config.set_key_value("filament_change_length", new ConfigOptionFloats({10., 10.}));
+    config.set_key_value("filament_diameter", new ConfigOptionFloats({1.75, 1.75}));
+    // Two purges of 100 mm3 plus one 10 mm filament change: (200 + 10 * pi * 1.75^2 / 4) / (0.2 * 50).
+    const double change_volume = 10. * PI * 1.75 * 1.75 / 4.;
+    CHECK_THAT(estimate(config, 2, 0.2, 5.).depth, WithinAbs((200. + change_volume) / 10., 1e-9));
+}
+
+TEST_CASE("The shipped defaults size the tower from the flush matrix", "[WipeTowerEstimate]") {
+    // Both keys default to true, so the shipped configuration purges the flush volumes rather
+    // than the prime volume, with no infill gap on top - the flush volumes already hold it.
+    DynamicPrintConfig config = preset_shaped_defaults();
+    REQUIRE(config.opt_bool("purge_in_prime_tower"));
+    REQUIRE(config.opt_bool("single_extruder_multi_material"));
+    config.set_key_value("prime_tower_width", new ConfigOptionFloat(50.));
+    config.set_deserialize_strict("wipe_tower_wall_type", "rectangle");
+    config.set_key_value("nozzle_diameter", new ConfigOptionFloats({0.4}));
+
+    const double flush_volume = WipeTower2::estimate_semm_flush_volume(config, 2);
+    const double expected     = std::max(double(WipeTower::get_limit_depth_by_height(5.f)), flush_volume / (0.2 * 50.));
+    CHECK_THAT(estimate(config, 2, 0.2, 5.).depth, WithinAbs(expected, 1e-6));
+}
+
+TEST_CASE("A config missing a tower key falls back to that key's default", "[WipeTowerEstimate]") {
+    // The signature takes any ConfigBase: an absent key must read as its declared default.
+    const DynamicPrintConfig full = make_config();
+    DynamicPrintConfig       partial = full;
+    partial.erase("wipe_tower_extra_spacing");
+    REQUIRE(partial.option("wipe_tower_extra_spacing") == nullptr);
+
+    DynamicPrintConfig defaulted = full;
+    defaulted.set_key_value("wipe_tower_extra_spacing",
+                            print_config_def.get("wipe_tower_extra_spacing")->default_value->clone());
+    CHECK_THAT(estimate(partial, 3, 0.2, 5.).depth, WithinAbs(estimate(defaulted, 3, 0.2, 5.).depth, 1e-9));
+}