Belt: size the purge prism against physical filaments, not mixed slots

A mixed filament slot is virtual: ToolOrdering::resolve_mixed_filaments()
replaces it with its physical components before any G-code is emitted, so
the toolchanges the prism has to absorb are between those components.
ensure_belt_purge_tower() counted the slot as a filament of its own,
provisioning one island per mixed slot that no swap can ever reach -- the
"extra purge tower" on MCTEST5, where filament 5 is a 50/50 blend of 2
and 4 and the G-code reports 0.00 g of it used.

Expand the assigned set with the same expand_mixed_filaments() the
backend uses, so the GUI sizes the prism against the filament set the
slicer actually produces. No-op when nothing is mixed. Test covers the
MCTEST5 shape, a mixed slot whose components are otherwise unused, and
the no-mixing case.

Co-Authored-By: Claude Fable 5.1 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01SsuY8Laiyh7q2zPVVKV3HZ

src/slic3r/GUI/BeltPurgeTower.cpp

@@ -9,6 +9,7 @@
 #include "libslic3r/Preset.hpp"
 #include "libslic3r/PresetBundle.hpp"
 #include "libslic3r/PrintConfig.hpp"
+#include "libslic3r/FilamentMixer.hpp"
 #include "libslic3r/TriangleMesh.hpp"
 #include "libslic3r/Geometry.hpp"
 #include "libslic3r/BoundingBox.hpp"
@@ -131,6 +132,39 @@ bool ensure_belt_purge_tower(Model &model, PartPlateList &partplate_list, Object
         }
     }
 
+    // A mixed filament slot is VIRTUAL: it never reaches a nozzle. At slice time
+    // ToolOrdering::resolve_mixed_filaments() replaces it with its physical
+    // components, so the toolchanges the prism has to absorb are between those
+    // components, not to the mixed slot itself. Counting the slot as a filament
+    // of its own therefore over-provisions the prism by one island per mixed slot
+    // -- the "extra purge tower" -- and, when every component is already used by
+    // another object, by an island that can never be reached at all.
+    //
+    // Expand here with the same helper the backend uses (Print.cpp's sequential
+    // path), so the GUI sizes the prism against the same filament set the slicer
+    // will actually produce. No-op when no filament is mixed.
+    {
+        // Copies, not references: a ternary with an empty-vector fallback would bind
+        // a reference to a temporary.
+        std::vector<unsigned char> is_mixed;
+        std::vector<std::string>   comp_strs;
+        if (const auto *o = full_cfg.option<ConfigOptionBools>("filament_is_mixed"))
+            is_mixed = o->values;
+        if (const auto *o = full_cfg.option<ConfigOptionStrings>("filament_mixed_components"))
+            comp_strs = o->values;
+        if (has_any_mixed_filament(is_mixed)) {
+            std::vector<unsigned int> zero_based;
+            zero_based.reserve(filaments.size());
+            for (int f : filaments)
+                if (f > 0)
+                    zero_based.push_back((unsigned int) (f - 1));
+            zero_based = expand_mixed_filaments(zero_based, is_mixed, comp_strs);
+            filaments.clear();
+            for (unsigned int f : zero_based)
+                filaments.insert((int) f + 1);
+        }
+    }
+
     const bool wanted = belt && prime_tower_enabled && !by_object && have_objects && filaments.size() > 1;
     if (!wanted) {
         sig = BeltPurgeSignature{};

tests/libslic3r/test_filament_mixer.cpp

@@ -57,6 +57,50 @@ TEST_CASE("expand_mixed_filaments replaces mixed slots with their components", "
     }
 }
 
+TEST_CASE("belt purge tower island count ignores virtual mixed slots", "[FilamentMixer][belt]")
+{
+    // Regression for the "extra purge tower" on a belt printer with a mixed
+    // filament (MCTEST5). The belt purge prism is sized as
+    //   n_islands = used_filaments.size() - 1
+    // and GUI::ensure_belt_purge_tower() collected those filaments straight off
+    // the model objects' extruder assignments. A mixed slot is VIRTUAL -- no
+    // nozzle carries it, and ToolOrdering::resolve_mixed_filaments() replaces it
+    // with its components before any G-code is emitted -- so counting it as a
+    // filament of its own provisions one island that can never be reached.
+    //
+    // MCTEST5: five cubes on extruders 1..5, where filament 5 is a 50/50 blend of
+    // filaments 2 and 4. The G-code uses only T0..T3 and reports
+    // "filament used [g] = 53.35, 141.11, 40.84, 107.23, 0.00" -- filament 5
+    // consumes nothing, exactly as a virtual slot should.
+    const std::vector<unsigned char> is_mixed  = {0, 0, 0, 0, 1};
+    const std::vector<std::string>   comp_strs = {"", "", "", "", "2,4"};
+
+    // The set the sizer used to see: slots 0..4 (filaments 1..5).
+    const std::vector<unsigned int> assigned = {0, 1, 2, 3, 4};
+    const auto physical = expand_mixed_filaments(assigned, is_mixed, comp_strs);
+
+    // Slot 4 dissolves into 1 and 3, which are already present.
+    REQUIRE(physical == std::vector<unsigned int>({0, 1, 2, 3}));
+
+    // Four physical filaments => three transitions => three islands, not four.
+    REQUIRE(int(physical.size()) - 1 == 3);
+    REQUIRE(int(assigned.size()) - 1 == 4);   // what it produced before the fix
+
+    SECTION("A mixed slot whose components are otherwise unused still counts them") {
+        // Only the mixed slot is assigned: it must still yield its two components,
+        // i.e. one island, rather than collapsing to zero.
+        const auto only_mixed = expand_mixed_filaments({4}, is_mixed, comp_strs);
+        REQUIRE(only_mixed == std::vector<unsigned int>({1, 3}));
+        REQUIRE(int(only_mixed.size()) - 1 == 1);
+    }
+
+    SECTION("No mixed filaments anywhere leaves the set untouched") {
+        const std::vector<unsigned char> none_mixed = {0, 0, 0, 0, 0};
+        REQUIRE_FALSE(has_any_mixed_filament(none_mixed));
+        REQUIRE(expand_mixed_filaments(assigned, none_mixed, {"", "", "", "", ""}) == assigned);
+    }
+}
+
 TEST_CASE("check_mixed_filament_integrity flags dangling component references", "[FilamentMixer]")
 {
     const std::vector<unsigned char> is_mixed  = {0, 0, 1};