From 9f1d72e5573fbd47108858ce568d9bd70b488767 Mon Sep 17 00:00:00 2001
From: Hanif Koh <hanifkoh@outlook.com>
Date: Wed, 26 Aug 2026 18:01:34 +0800
Subject: [PATCH] Create Directories Recursively, and early exit gracefully if
 failed to create

---
 src/OrcaSlicer.cpp      | 23 +++++++++++++++++++++--
 src/libslic3r/utils.cpp |  6 +++++-
 2 files changed, 26 insertions(+), 3 deletions(-)

diff --git a/src/OrcaSlicer.cpp b/src/OrcaSlicer.cpp
index 8176e9f444..2bd0b22ae4 100644
--- a/src/OrcaSlicer.cpp
+++ b/src/OrcaSlicer.cpp
@@ -7311,6 +7311,10 @@ bool CLI::setup(int argc, char **argv)
             m_config.option(optdef.first, true);
 
     set_data_dir(m_config.opt_string("datadir"));
+    if (!data_dir().empty() && !boost::filesystem::exists(data_dir())) {
+        boost::nowide::cerr << "Could not create data directory: " << data_dir() << std::endl;
+        return false;
+    }
 
     //FIXME Validating at this stage most likely does not make sense, as the config is not fully initialized yet.
     if (!validity.empty()) {
@@ -7423,6 +7427,10 @@ bool CLI::export_models(IO::ExportFormat format, std::string path_dir)
                 for (ModelObject* model_object : model.objects)
                 {
                     const std::string path = this->output_filepath(*model_object, index++, format, path_dir);
+                    if (path.empty()) {
+                        boost::nowide::cerr << "Could not create output directory for STL export" << std::endl;
+                        return false;
+                    }
                     success = Slic3r::store_stl(path.c_str(), model_object, true);
                     if (success)
                         BOOST_LOG_TRIVIAL(info) << "Model successfully exported to " << path << std::endl;
@@ -7548,8 +7556,19 @@ std::string CLI::output_filepath(const ModelObject &object, unsigned int index,
     output_path = subdir + "/"+file_name;
 
     boost::filesystem::path subdir_path(subdir);
-    if (!boost::filesystem::exists(subdir_path))
-        boost::filesystem::create_directory(subdir_path);
+    if (!boost::filesystem::exists(subdir_path)) {
+        try {
+            boost::filesystem::create_directories(subdir_path);
+        } catch (const boost::filesystem::filesystem_error &ex) {
+            BOOST_LOG_TRIVIAL(error) << __FUNCTION__ << ": failed to create output directory " << subdir_path.string() << ": " << ex.what();
+        }
+        if (!boost::filesystem::exists(subdir_path)) {
+            // Directory creation failed and won't succeed on a retry (same path, same cause) -
+            // signal failure now instead of letting every object in the model repeat the same
+            // doomed attempt and fail with a less specific "export failed" error later.
+            return std::string();
+        }
+    }
     return output_path;
 }
 
diff --git a/src/libslic3r/utils.cpp b/src/libslic3r/utils.cpp
index 58ec8318a6..5f4baac951 100644
--- a/src/libslic3r/utils.cpp
+++ b/src/libslic3r/utils.cpp
@@ -310,7 +310,11 @@ void set_data_dir(const std::string &dir)
 {
     g_data_dir = dir;
     if (!g_data_dir.empty() && !boost::filesystem::exists(g_data_dir)) {
-       boost::filesystem::create_directory(g_data_dir);
+        try {
+            boost::filesystem::create_directories(g_data_dir);
+        } catch (const boost::filesystem::filesystem_error &ex) {
+            BOOST_LOG_TRIVIAL(error) << "set_data_dir: failed to create data directory " << g_data_dir << ": " << ex.what();
+        }
     }
 }