Fix post-slice self-invalidation on custom multi-extruder printers

src/libslic3r/Config.hpp

@@ -2,6 +2,7 @@
 #define slic3r_Config_hpp_
 
 #include <assert.h>
+#include <algorithm>
 #include <map>
 #include <climits>
 #include <cfloat>
@@ -780,10 +781,14 @@ public:
                 this->values[i] = rhs_vec->values[i];
                 modified        = true;
             } else {
-                if ((i < default_index.size()) && (default_index[i] < default_value.size()))
+                // Orca: a negative slot (failed variant lookup) must not silently collapse the
+                // whole array to the first slot's value — the int-vs-size_t comparison used to
+                // promote -1 past the bounds check. Keep the slot's own value (get_at-style
+                // clamp) when no valid index is available.
+                if ((i < default_index.size()) && (default_index[i] >= 0) && (size_t(default_index[i]) < default_value.size()))
                     this->values[i] = default_value[default_index[i]];
                 else
-                    this->values[i] = default_value[0];
+                    this->values[i] = default_value[std::min(i, default_value.size() - 1)];
             }
         }
         return modified;
@@ -2106,6 +2111,11 @@ public:
             throw ConfigurationError("ConfigOptionEnumGeneric: Assigning an incompatible type");
         // rhs could be of the following type: ConfigOptionEnumGeneric or ConfigOptionEnum<T>
         this->value = rhs->getInt();
+        // Orca: options embedded in a StaticPrintConfig are constructed without a keys_map;
+        // adopt the source's so a later serialize() can emit names.
+        if (this->keys_map == nullptr)
+            if (auto rhs_generic = dynamic_cast<const ConfigOptionEnumGeneric *>(rhs))
+                this->keys_map = rhs_generic->keys_map;
     }
 
     std::string serialize() const override
@@ -2162,7 +2172,12 @@ public:
         if (rhs->type() != this->type())
             throw ConfigurationError("ConfigOptionEnumGeneric: Assigning an incompatible type");
         // rhs could be of the following type: ConfigOptionEnumsGeneric
-        this->values = dynamic_cast<const ConfigOptionEnumsGenericTempl *>(rhs)->values;
+        auto rhs_enums = dynamic_cast<const ConfigOptionEnumsGenericTempl *>(rhs);
+        this->values = rhs_enums->values;
+        // Orca: options embedded in a StaticPrintConfig are constructed without a keys_map;
+        // adopt the source's so a later serialize() emits names instead of empty tokens.
+        if (this->keys_map == nullptr)
+            this->keys_map = rhs_enums->keys_map;
     }
 
     std::string serialize() const override

src/libslic3r/Print.cpp

@@ -3409,7 +3409,11 @@ void Print::update_filament_maps_to_config(std::vector<int> f_maps, std::vector<
             }
             else if ((extruder_volume_type_count > extruder_count) && (m_config.filament_volume_map.values.size() > index))
                 nozzle_volume_type = (NozzleVolumeType)(m_config.filament_volume_map.values[index]);
-            m_config.filament_map_2.values[index] = m_ori_full_print_config.get_index_for_extruder(f_maps[index], "print_extruder_id", extruder_type, nozzle_volume_type, "print_extruder_variant");
+            // Orca: when the process variant columns cannot be matched (degenerate
+            // print_extruder_id), key the override by plain extruder index like the seeding
+            // above instead of poisoning the map with -1.
+            int slot_index = m_ori_full_print_config.get_index_for_extruder(f_maps[index], "print_extruder_id", extruder_type, nozzle_volume_type, "print_extruder_variant");
+            m_config.filament_map_2.values[index] = slot_index >= 0 ? slot_index : f_maps[index] - 1;
         }
 
         m_full_print_config = m_ori_full_print_config;

src/libslic3r/PrintApply.cpp

@@ -1355,7 +1355,11 @@ Print::ApplyStatus Print::apply(const Model &model, DynamicPrintConfig new_full_
         if ((extruder_volume_type_count > extruder_count) && opt_filament_volume_maps
             && opt_filament_volume_maps->values.size() == filament_maps.size())
             nozzle_volume_type = (NozzleVolumeType)(opt_filament_volume_maps->values[index]);
-        m_config.filament_map_2.values[index] = new_full_config.get_index_for_extruder(filament_maps[index], "print_extruder_id", extruder_type, nozzle_volume_type, "print_extruder_variant");
+        // Orca: when the process variant columns cannot be matched (degenerate
+        // print_extruder_id), key the override by plain extruder index like the seeding
+        // above instead of poisoning the map with -1.
+        int slot_index = new_full_config.get_index_for_extruder(filament_maps[index], "print_extruder_id", extruder_type, nozzle_volume_type, "print_extruder_variant");
+        m_config.filament_map_2.values[index] = slot_index >= 0 ? slot_index : filament_maps[index] - 1;
     }
 
     // Do not use the ApplyStatus as we will use the max function when updating apply_status.
@@ -1411,6 +1415,16 @@ Print::ApplyStatus Print::apply(const Model &model, DynamicPrintConfig new_full_
             num_extruders_changed  = true;
         }
     }
+    else if (! print_diff.empty()) {
+        // Orca: m_config can diverge from an unchanged full config (e.g. the in-slice retract
+        // override recompute writing different values than the apply-time computation). The
+        // invalidation above already fired for print_diff, so repair m_config here as well;
+        // otherwise the divergence is never corrected and every subsequent apply of the same
+        // config invalidates the result again, forever.
+        m_placeholder_parser.apply_config(filament_overrides);
+        m_config.apply_only(new_full_config, print_diff, true);
+        m_config.apply(filament_overrides);
+    }
 
     ModelObjectStatusDB model_object_status_db;
 

src/libslic3r/PrintConfig.cpp

@@ -10495,6 +10495,44 @@ int DynamicPrintConfig::get_extruder_nozzle_volume_count(int extruder_count, std
     return count;
 }
 
+// Orca: BBL system profiles ship full-width print_extruder_id/print_extruder_variant columns, but
+// custom multi-extruder printers only ever get the machine-scope columns synthesized for them (see
+// extend_extruder_variant); the process scope keeps the length-1 defaults, both in presets and in
+// 3mf project configs. Expanding with that degenerate map makes every per-extruder lookup fail, and
+// because both keys are themselves in print_options_with_variant, the expansion then latches a
+// full-width-but-wrong [1,1,...] map that also defeats the generated_extruder_id fallback in
+// get_index_for_extruder. Synthesize the process columns from the printer's extruder_variant_list
+// (same token walk as extend_extruder_variant) before expanding.
+static void ensure_process_variant_columns(DynamicPrintConfig &config, const DynamicPrintConfig &printer_config)
+{
+    auto id_opt      = dynamic_cast<ConfigOptionInts *>(config.option("print_extruder_id"));
+    auto variant_opt = dynamic_cast<ConfigOptionStrings *>(config.option("print_extruder_variant"));
+    auto list_opt    = dynamic_cast<const ConfigOptionStrings *>(printer_config.option("extruder_variant_list"));
+    if (!id_opt || !variant_opt || !list_opt)
+        return;
+    if (id_opt->values.size() != 1 || variant_opt->values.size() != 1)
+        return;
+
+    std::vector<int>         ids;
+    std::vector<std::string> variants;
+    for (int i = 0; i < int(list_opt->values.size()); ++i) {
+        std::vector<std::string> tokens;
+        boost::split(tokens, list_opt->get_at(i), boost::is_any_of(","), boost::token_compress_on);
+        for (std::string &token : tokens) {
+            boost::trim(token);
+            if (token.empty())
+                continue;
+            ids.push_back(i + 1);
+            variants.push_back(token);
+        }
+    }
+    // A single column is the legitimate single-extruder layout, not a degenerate one.
+    if (ids.size() <= 1)
+        return;
+    id_opt->values      = std::move(ids);
+    variant_opt->values = std::move(variants);
+}
+
 std::vector<int> DynamicPrintConfig::update_values_to_printer_extruders(DynamicPrintConfig& printer_config, int extruder_count, int extruder_nozzle_volume_count, std::vector<std::vector<NozzleVolumeType>>& nv_types,
     std::set<std::string>& key_set, std::string id_name, std::string variant_name, unsigned int stride, unsigned int extruder_id, NozzleVolumeType filament_nvt)
 {
@@ -10536,6 +10574,8 @@ std::vector<int> DynamicPrintConfig::update_values_to_printer_extruders(DynamicP
         variant_count = 1;
     }
     else {
+        if (id_name == "print_extruder_id")
+            ensure_process_variant_columns(*this, printer_config);
         // Orca: emit the slots first, then size variant_count from what was actually
         // emitted. extruder_nozzle_volume_count only equals the emitted total when every
         // extruder carries per-type stats; an extruder with an empty stats entry combined

tests/libslic3r/test_config_variant_expansion.cpp

@@ -43,18 +43,33 @@ TEST_CASE("apply_override fills nil entries from the 0-based default index", "[C
         REQUIRE(resolved.values == std::vector<double>({30., 42.}));
     }
 
-    SECTION("an index past the machine slots falls back to the first slot") {
+    SECTION("an index past the machine slots keeps the slot's own value") {
         std::vector<int> slot_index{5, 0};
         ConfigOptionFloats resolved(machine);
         REQUIRE(resolved.apply_override(&filament, slot_index));
         REQUIRE(resolved.values == std::vector<double>({10., 42.}));
     }
 
-    SECTION("a negative index (unresolved slot) falls back to the first slot") {
+    SECTION("a negative index (unresolved slot) keeps the slot's own value") {
-        std::vector<int> slot_index{-1, 0};
+        ConfigOptionFloatsNullable all_nil;
+        all_nil.values = {ConfigOptionFloatsNullable::nil_value(), ConfigOptionFloatsNullable::nil_value(),
+                          ConfigOptionFloatsNullable::nil_value()};
+        std::vector<int> slot_index{2, -1, 0};
         ConfigOptionFloats resolved(machine);
-        REQUIRE(resolved.apply_override(&filament, slot_index));
+        REQUIRE(!resolved.apply_override(&all_nil, slot_index));
-        REQUIRE(resolved.values == std::vector<double>({10., 42.}));
+        REQUIRE(resolved.values == std::vector<double>({30., 20., 10.}));
+    }
+
+    SECTION("all-nil overrides keyed by unresolved slots leave the machine values intact") {
+        // The failed-lookup map a degenerate print_extruder_id used to produce; the negative
+        // slots must not collapse the machine array to its first value.
+        ConfigOptionFloats per_extruder({100., 70., 70., 70., 100.});
+        ConfigOptionFloatsNullable all_nil;
+        all_nil.values.assign(5, ConfigOptionFloatsNullable::nil_value());
+        std::vector<int> slot_index{0, -1, -1, -1, 0};
+        ConfigOptionFloats resolved(per_extruder);
+        REQUIRE(!resolved.apply_override(&all_nil, slot_index));
+        REQUIRE(resolved.values == std::vector<double>({100., 70., 70., 70., 100.}));
     }
 }
 
@@ -238,6 +253,102 @@ TEST_CASE("update_values_to_printer_extruders expands one slot per (extruder x v
     }
 }
 
+TEST_CASE("update_values_to_printer_extruders synthesizes degenerate process variant columns", "[Config]")
+{
+    // Non-BBL process presets and 3mf project configs keep the length-1 defaults for
+    // print_extruder_id/print_extruder_variant; only BBL system presets ship full-width columns.
+    auto add_degenerate_print_columns = [](DynamicPrintConfig &config) {
+        config.option<ConfigOptionInts>("print_extruder_id", true)->values = {1};
+        config.option<ConfigOptionStrings>("print_extruder_variant", true)->values = {"Direct Drive Standard"};
+        config.option<ConfigOptionFloats>("outer_wall_speed", true)->values = {30.};
+    };
+
+    SECTION("a single-column pair on a multi-extruder machine expands to one column per extruder") {
+        DynamicPrintConfig config;
+        config.option<ConfigOptionEnumsGeneric>("extruder_type", true)->values = {etDirectDrive, etDirectDrive};
+        config.option<ConfigOptionEnumsGeneric>("nozzle_volume_type", true)->values = {nvtStandard, nvtStandard};
+        config.option<ConfigOptionStrings>("extruder_variant_list", true)->values = {"Direct Drive Standard", "Direct Drive Standard"};
+        add_degenerate_print_columns(config);
+
+        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);
+
+        std::vector<int> variant_index = config.update_values_to_printer_extruders(config, extruder_count, count, nozzle_volume_types,
+            print_options_with_variant, "print_extruder_id", "print_extruder_variant");
+
+        REQUIRE(variant_index == std::vector<int>({0, 1}));
+        REQUIRE(config.option<ConfigOptionInts>("print_extruder_id")->values == std::vector<int>({1, 2}));
+        REQUIRE(config.option<ConfigOptionStrings>("print_extruder_variant")->values ==
+                std::vector<std::string>({"Direct Drive Standard", "Direct Drive Standard"}));
+        // width-1 data arrays replicate their only column into every slot
+        REQUIRE(config.option<ConfigOptionFloats>("outer_wall_speed")->values == std::vector<double>({30., 30.}));
+    }
+
+    SECTION("a multi-variant list synthesizes one column per (extruder x variant)") {
+        DynamicPrintConfig config = make_hybrid_printer_config();
+        add_degenerate_print_columns(config);
+
+        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);
+        REQUIRE(count == 3);
+
+        std::vector<int> variant_index = config.update_values_to_printer_extruders(config, extruder_count, count, nozzle_volume_types,
+            print_options_with_variant, "print_extruder_id", "print_extruder_variant");
+
+        // same slot resolution as the explicit BBL-style 4-column layout
+        REQUIRE(variant_index == std::vector<int>({0, 2, 3}));
+        REQUIRE(config.option<ConfigOptionInts>("print_extruder_id")->values == std::vector<int>({1, 2, 2}));
+        REQUIRE(config.option<ConfigOptionStrings>("print_extruder_variant")->values ==
+                std::vector<std::string>({"Direct Drive Standard", "Direct Drive Standard", "Direct Drive High Flow"}));
+        REQUIRE(config.option<ConfigOptionFloats>("outer_wall_speed")->values == std::vector<double>({30., 30., 30.}));
+    }
+
+    SECTION("a single-extruder single-column layout is not treated as degenerate") {
+        DynamicPrintConfig config;
+        config.option<ConfigOptionEnumsGeneric>("extruder_type", true)->values = {etDirectDrive};
+        config.option<ConfigOptionEnumsGeneric>("nozzle_volume_type", true)->values = {nvtStandard};
+        config.option<ConfigOptionStrings>("extruder_variant_list", true)->values = {"Direct Drive Standard"};
+        add_degenerate_print_columns(config);
+
+        std::vector<std::vector<NozzleVolumeType>> nozzle_volume_types;
+        int extruder_count = 1;
+        int count = config.get_extruder_nozzle_volume_count(extruder_count, nozzle_volume_types);
+
+        config.update_values_to_printer_extruders(config, extruder_count, count, nozzle_volume_types,
+            print_options_with_variant, "print_extruder_id", "print_extruder_variant");
+
+        REQUIRE(config.option<ConfigOptionInts>("print_extruder_id")->values == std::vector<int>({1}));
+        REQUIRE(config.option<ConfigOptionFloats>("outer_wall_speed")->values == std::vector<double>({30.}));
+    }
+
+    SECTION("a second expansion leaves the synthesized layout unchanged") {
+        DynamicPrintConfig config;
+        config.option<ConfigOptionEnumsGeneric>("extruder_type", true)->values = {etDirectDrive, etDirectDrive};
+        config.option<ConfigOptionEnumsGeneric>("nozzle_volume_type", true)->values = {nvtStandard, nvtStandard};
+        config.option<ConfigOptionStrings>("extruder_variant_list", true)->values = {"Direct Drive Standard", "Direct Drive Standard"};
+        add_degenerate_print_columns(config);
+
+        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(config, extruder_count, count, nozzle_volume_types,
+            print_options_with_variant, "print_extruder_id", "print_extruder_variant");
+        DynamicPrintConfig once = config;
+        config.update_values_to_printer_extruders(config, extruder_count, count, nozzle_volume_types,
+            print_options_with_variant, "print_extruder_id", "print_extruder_variant");
+
+        REQUIRE(config.option<ConfigOptionInts>("print_extruder_id")->values ==
+                once.option<ConfigOptionInts>("print_extruder_id")->values);
+        REQUIRE(config.option<ConfigOptionStrings>("print_extruder_variant")->values ==
+                once.option<ConfigOptionStrings>("print_extruder_variant")->values);
+        REQUIRE(config.option<ConfigOptionFloats>("outer_wall_speed")->values ==
+                once.option<ConfigOptionFloats>("outer_wall_speed")->values);
+    }
+}
+
 TEST_CASE("update_values_to_printer_extruders_for_multiple_filaments resolves per-filament slots", "[Config]")
 {
     auto make_filament_arrays = [](DynamicPrintConfig &config) {

tests/libslic3r/test_toolordering_nozzle_group.cpp

@@ -500,6 +500,52 @@ TEST_CASE("Re-applying an unchanged config after slicing keeps the result valid"
     REQUIRE(print.is_step_done(psSlicingFinished));
 }
 
+TEST_CASE("A degenerate process variant map on a custom multi-extruder printer slices to a stable result", "[Print][Regression]")
+{
+    // Non-BBL multi-extruder printers get machine-scope variant columns synthesized on preset
+    // load (extend_extruder_variant), but nothing ships process-scope print_extruder_id /
+    // print_extruder_variant: presets and 3mf project configs carry the length-1 defaults. The
+    // apply-time expansion must synthesize the process columns from extruder_variant_list;
+    // otherwise the failed per-extruder lookups collapse the per-extruder retract overrides
+    // during slicing and the post-slice re-apply invalidates every fresh result, forever.
+    DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+    config.option<ConfigOptionFloats>("nozzle_diameter", true)->values = {0.4, 0.4, 0.4, 0.4, 0.4};
+    config.set_num_extruders(5);
+    // per-extruder machine values that a first-slot collapse would destroy
+    config.option<ConfigOptionPercents>("retract_before_wipe", true)->values = {100., 70., 70., 70., 100.};
+    config.option<ConfigOptionEnumsGeneric>("z_hop_types", true)->values = {zhtSlope, zhtNormal, zhtNormal, zhtNormal, zhtSlope};
+    // filament presets carry the nullable override twins (all-nil = "no override"); they are what
+    // routes the machine values through apply_override in the in-slice override recompute
+    config.option<ConfigOptionPercentsNullable>("filament_retract_before_wipe", true)->values =
+        std::vector<double>(5, ConfigOptionPercentsNullable::nil_value());
+    config.option<ConfigOptionEnumsGenericNullable>("filament_z_hop_types", true)->values =
+        std::vector<int>(5, ConfigOptionEnumsGenericNullable::nil_value());
+    config.option<ConfigOptionFloats>("filament_diameter", true)->values = std::vector<double>(5, 1.75);
+    config.option<ConfigOptionStrings>("filament_colour", true)->values = {"#FF0000", "#00FF00", "#0000FF", "#FFFF00", "#00FFFF"};
+    config.option<ConfigOptionInts>("filament_map", true)->values = {1, 2, 3, 4, 1};
+
+    Model model;
+    model.add_object("cube", "", make_cube(20, 20, 20))->add_instance()->set_offset(Vec3d(100., 100., 0.));
+
+    Print print;
+    print.apply(model, config);
+    print.process();
+    REQUIRE(print.is_step_done(psSlicingFinished));
+
+    // BackgroundSlicingProcess reads the engine-computed maps back into the plate config after
+    // slicing; the next apply overlays that written-back state.
+    config.option<ConfigOptionInts>("filament_map", true)->values = print.get_filament_maps();
+    config.option<ConfigOptionInts>("filament_volume_map", true)->values = print.get_filament_volume_maps();
+    config.option<ConfigOptionInts>("filament_nozzle_map", true)->values = print.get_filament_nozzle_maps();
+
+    auto status = print.apply(model, config);
+    REQUIRE(status == PrintBase::APPLY_STATUS_UNCHANGED);
+    REQUIRE(print.is_step_done(psSlicingFinished));
+    // the per-extruder machine values must survive the in-slice override recompute
+    REQUIRE(print.config().retract_before_wipe.values == std::vector<double>({100., 70., 70., 70., 100.}));
+    REQUIRE(print.config().z_hop_types.values == std::vector<int>({zhtSlope, zhtNormal, zhtNormal, zhtNormal, zhtSlope}));
+}
+
 TEST_CASE("normalize_nozzle_map_per_layer makes per-filament assignments gap-free", "[MultiNozzle][H2C][Dynamic]")
 {
     SECTION("gaps inherit the last used nozzle, entries on used layers stay untouched") {