validator: detect ambiguous (duplicate) filament subtypes per printer (#14459)

* validator: detect duplicate filament subtype per printer (opt-in)

A filament is matched from the AMS by (filament_id + printer compatibility);
if two compatible filament presets for one printer share a filament_id, the
match is ambiguous and the runtime silently picks whichever loads first.

Add PresetBundle::check_duplicate_filament_subtypes(), gated behind a new
has_errors(check_duplicate_filament_subtypes) parameter and the validator's
-f/--check_filament_subtypes flag (off by default). For each system printer it
groups its vendor's compatible filament presets by filament_id and errors on
any group of 2+, reporting each preset as a clickable file:// URI with a single
"how to fix" hint. CI runs it for BBL only (-v BBL -f) until the other vendors'
profiles are cleaned up.

* profiles: fix ambiguous BBL filament matches

Resolve the duplicate-filament-subtype errors flagged by the validator:
- align compatible_printers with Bambu Studio where Orca over-claimed a nozzle
  that already has a dedicated preset (Bambu PLA Basic/Matte/ABS @BBL H2DP;
  Bambu ASA/PETG HF @BBL H2DP 0.6 nozzle; Fiberon PETG-ESD @BBL X1)
- fix a copy-pasted printer name in Overture Matte PLA @BBL A1M 0.2 nozzle
- fix a wrong inherits in Panchroma PLA Silk @BBL X1C 0.2 nozzle (was inheriting
  Panchroma PLA @base, giving it filament_id GFPM001 instead of GFPM004)

Bump BBL profile version.

* Potential fix for pull request finding

Co-authored-by: Copilot Autofix powered by AI <175728472+Copilot@users.noreply.github.com>

---------

Co-authored-by: Copilot Autofix powered by AI <175728472+Copilot@users.noreply.github.com>

.github/workflows/check_profiles.yml

@@ -49,6 +49,14 @@ jobs:
           set +e
           ./OrcaSlicer_profile_validator -p ${{ github.workspace }}/resources/profiles -l 2 2>&1 | tee ${{ runner.temp }}/validate_system.log
           exit ${PIPESTATUS[0]}
+      # For now run filament subtype check only for BBL profiles until we fix other vendors' profiles.
+      - name: validate filament subtype check for BBL profiles
+        id: validate_filament_subtypes
+        continue-on-error: true
+        run: |
+          set +e
+          ./OrcaSlicer_profile_validator -p ${{ github.workspace }}/resources/profiles -l 2 -v BBL -f 2>&1 | tee ${{ runner.temp }}/validate_filament_subtypes.log
+          exit ${PIPESTATUS[0]}
 
       - name: validate custom presets
         id: validate_custom
@@ -68,7 +76,7 @@ jobs:
           echo "${{ github.event.pull_request.number }}" > ${{ runner.temp }}/profile-check-results/pr_number.txt
 
       - name: Prepare comment artifact
-        if: ${{ always() && github.event_name == 'pull_request' && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
+        if: ${{ always() && github.event_name == 'pull_request' && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_filament_subtypes.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
         run: |
           {
             # Marker matched by check_profiles_comment.yml to delete prior comments.
@@ -94,6 +102,15 @@ jobs:
               echo ""
             fi
 
+            if [ "${{ steps.validate_filament_subtypes.outcome }}" = "failure" ]; then
+              echo "### BBL Filament Subtype Validation Failed"
+              echo ""
+              echo '```'
+              head -c 30000 ${{ runner.temp }}/validate_filament_subtypes.log || echo "No output captured"
+              echo '```'
+              echo ""
+            fi
+
             if [ "${{ steps.validate_custom.outcome }}" = "failure" ]; then
               echo "### Custom Preset Validation Failed"
               echo ""
@@ -116,7 +133,7 @@ jobs:
           retention-days: 1
 
       - name: Fail if any check failed
-        if: ${{ always() && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
+        if: ${{ always() && (steps.extra_json_check.outcome == 'failure' || steps.validate_system.outcome == 'failure' || steps.validate_filament_subtypes.outcome == 'failure' || steps.validate_custom.outcome == 'failure') }}
         run: |
           echo "One or more profile checks failed. See above for details."
           exit 1

resources/profiles/BBL.json

@@ -1,7 +1,7 @@
 {
 	"name": "Bambulab",
 	"url": "http://www.bambulab.com/Parameters/vendor/BBL.json",
-	"version": "02.01.00.17",
+	"version": "02.01.00.18",
 	"force_update": "0",
 	"description": "BBL configurations",
 	"machine_model_list": [

resources/profiles/BBL/filament/Bambu ABS @BBL H2DP.json

@@ -123,8 +123,7 @@
 		"0 0 0 0 0 0"
 	],
 	"compatible_printers": [
-		"Bambu Lab H2D Pro 0.4 nozzle",
+		"Bambu Lab H2D Pro 0.4 nozzle"
-		"Bambu Lab H2D Pro 0.6 nozzle"
 	],
 	"filament_start_gcode": [
 		"; filament start gcode\n"

resources/profiles/BBL/filament/Bambu ASA @BBL H2DP 0.6 nozzle.json

@@ -117,8 +117,7 @@
 		"0 0 0 0 0 0"
 	],
 	"compatible_printers": [
-		"Bambu Lab H2D Pro 0.6 nozzle",
+		"Bambu Lab H2D Pro 0.6 nozzle"
-		"Bambu Lab H2D Pro 0.8 nozzle"
 	],
 	"filament_start_gcode": [
 		"; filament start gcode\n"

resources/profiles/BBL/filament/Bambu PETG HF @BBL H2DP 0.6 nozzle.json

@@ -132,8 +132,7 @@
 		"0 0 0 0 0 0"
 	],
 	"compatible_printers": [
-		"Bambu Lab H2D Pro 0.6 nozzle",
+		"Bambu Lab H2D Pro 0.6 nozzle"
-		"Bambu Lab H2D Pro 0.8 nozzle"
 	],
 	"filament_start_gcode": [
 		"; filament start gcode\n"

resources/profiles/BBL/filament/Bambu PLA Basic @BBL H2DP.json

@@ -144,8 +144,7 @@
 		"0 0 0 0 0 0"
 	],
 	"compatible_printers": [
-		"Bambu Lab H2D Pro 0.4 nozzle",
+		"Bambu Lab H2D Pro 0.4 nozzle"
-		"Bambu Lab H2D Pro 0.6 nozzle"
 	],
 	"filament_start_gcode": [
 		"; filament start gcode\n"

resources/profiles/BBL/filament/Bambu PLA Matte @BBL H2DP.json

@@ -150,8 +150,7 @@
 		"0 0 0 0 0 0"
 	],
 	"compatible_printers": [
-		"Bambu Lab H2D Pro 0.4 nozzle",
+		"Bambu Lab H2D Pro 0.4 nozzle"
-		"Bambu Lab H2D Pro 0.6 nozzle"
 	],
 	"filament_start_gcode": [
 		"; filament start gcode\n"

resources/profiles/BBL/filament/Overture/Overture Matte PLA @BBL A1M 0.2 nozzle.json

@@ -9,6 +9,6 @@
 		"1.8"
 	],
 	"compatible_printers": [
-		"Bambu Lab P1P 0.2 nozzle"
+		"Bambu Lab A1 mini 0.2 nozzle"
 	]
 }

resources/profiles/BBL/filament/Polymaker/Fiberon PETG-ESD @BBL X1.json

@@ -7,8 +7,6 @@
 	"instantiation": "true",
 	"compatible_printers": [
 		"Bambu Lab X1 0.4 nozzle",
-		"Bambu Lab X1 Carbon 0.4 nozzle",
-		"Bambu Lab P1S 0.4 nozzle",
 		"Bambu Lab X1E 0.4 nozzle"
 	],
 	"overhang_fan_speed": [

resources/profiles/BBL/filament/Polymaker/Panchroma PLA Silk @BBL X1C 0.2 nozzle.json

@@ -1,7 +1,7 @@
 {
 	"type": "filament",
 	"name": "Panchroma PLA Silk @BBL X1C 0.2 nozzle",
-	"inherits": "Panchroma PLA @base",
+	"inherits": "Panchroma PLA Silk @base",
 	"from": "system",
 	"setting_id": "GFSPM004_09",
 	"instantiation": "true",

src/dev-utils/OrcaSlicer_profile_validator.cpp

@@ -95,6 +95,7 @@ int main(int argc, char* argv[])
 #endif
     ("vendor,v", po::value<std::string>()->default_value(""), "Vendor name. Optional, all profiles present in the folder will be validated if not specified")
     ("generate_presets,g", po::value<bool>()->default_value(false), "Generate user presets for mock test")
+    ("check_filament_subtypes,f", po::bool_switch()->default_value(false), "Also flag printers with duplicate (ambiguous) filament subtypes. Off unless this flag is present.")
     ("log_level,l", po::value<int>()->default_value(2), "Log level. Optional, default is 2 (warning). Higher values produce more detailed logs.");
     // clang-format on
 
@@ -118,6 +119,7 @@ int main(int argc, char* argv[])
     std::string vendor               = vm["vendor"].as<std::string>();
     int         log_level            = vm["log_level"].as<int>();
     bool        generate_user_preset = vm["generate_presets"].as<bool>();
+    bool        check_filament_subtypes = vm["check_filament_subtypes"].as<bool>();
 
     //  check if path is valid, and return error if not
     if (!fs::exists(path) || !fs::is_directory(path)) {
@@ -164,7 +166,7 @@ int main(int argc, char* argv[])
         return 0;
     }
 
-    if (preset_bundle->has_errors()) {
+    if (preset_bundle->has_errors(check_filament_subtypes)) {
         std::cout << "Validation failed" << std::endl;
         return 1;
     }

src/libslic3r/PresetBundle.cpp

@@ -5471,7 +5471,7 @@ void PresetBundle::set_default_suppressed(bool default_suppressed)
     printers.set_default_suppressed(default_suppressed);
 }
 
-bool PresetBundle::has_errors() const
+bool PresetBundle::has_errors(bool check_duplicate_filament_subtypes) const
 {
     if (m_errors != 0 || printers.m_errors != 0 || filaments.m_errors != 0 || prints.m_errors != 0)
         return true;
@@ -5491,9 +5491,106 @@ bool PresetBundle::has_errors() const
         }
     }
 
+    if (check_duplicate_filament_subtypes && this->check_duplicate_filament_subtypes())
+        has_errors = true;
+
     return has_errors;
 }
 
+// Orca: turn a preset file path into an absolute file:// URI for log messages.
+// Printed unquoted on its own line, this is the one format clickable in both the
+// VS Code integrated terminal (Cmd/Ctrl+click) and macOS Terminal.app
+// (Cmd+double-click); quotes or literal spaces break link detection in both, so
+// the characters that would terminate the URI token are percent-encoded.
+static std::string preset_file_uri(const std::string &file)
+{
+    std::string path;
+    try {
+        path = boost::filesystem::canonical(file).generic_string();
+    } catch (...) {
+        path = file;
+    }
+    std::string uri = "file://";
+    if (path.empty() || path.front() != '/')
+        uri += '/'; // Windows drive paths (e.g. C:/...) need the extra leading slash
+    for (char c : path) {
+        switch (c) {
+        case ' ': uri += "%20"; break;
+        case '#': uri += "%23"; break;
+        case '%': uri += "%25"; break;
+        default:  uri += c;
+        }
+    }
+    return uri;
+}
+
+// Orca: a filament is matched from the AMS by (filament_id + printer compatibility).
+// For any one printer, at most one instantiated filament preset with a given
+// filament_id may be compatible - otherwise the AMS match is ambiguous and the
+// runtime silently picks whichever loads first. This validator-only check flags
+// any printer that has two or more compatible filament presets sharing a filament_id.
+bool PresetBundle::check_duplicate_filament_subtypes() const
+{
+    // Pre-collect system filament presets (each carries its effective filament_id,
+    // inherited from its @base at load time), grouped by vendor so we only test a
+    // printer against its own vendor's filaments. A vendor's compatible_printers
+    // only names that vendor's printers, so same-vendor scoping is correctness
+    // preserving and avoids an O(all printers x all filaments) sweep.
+    std::map<std::string, std::vector<const Preset *>> filaments_by_vendor;
+    for (const auto &preset : filaments) {
+        if (!preset.is_system || preset.filament_id.empty() || preset.vendor == nullptr)
+            continue;
+        filaments_by_vendor[preset.vendor->name].push_back(&preset);
+    }
+
+    bool found_duplicates = false;
+    for (const auto &printer : printers) {
+        if (!printer.is_system || printer.vendor == nullptr)
+            continue;
+        auto vendor_it = filaments_by_vendor.find(printer.vendor->name);
+        if (vendor_it == filaments_by_vendor.end())
+            continue;
+
+        const PresetWithVendorProfile active_printer = printers.get_preset_with_vendor_profile(printer);
+        // std::map keeps the reported errors in a deterministic (sorted) order.
+        std::map<std::string, std::vector<const Preset *>> by_filament_id;
+        for (const Preset *fil : vendor_it->second)
+            if (is_compatible_with_printer(filaments.get_preset_with_vendor_profile(*fil), active_printer))
+                by_filament_id[fil->filament_id].push_back(fil);
+
+        for (const auto &entry : by_filament_id) {
+            if (entry.second.size() < 2)
+                continue;
+            found_duplicates = true;
+            // List each conflicting preset with a clickable file:// URI on its own
+            // line, so the profile author can jump straight to the files to fix.
+            std::string presets;
+            for (const Preset *p : entry.second)
+                presets += "\n    - " + p->name + "\n      " + preset_file_uri(p->file);
+            BOOST_LOG_TRIVIAL(error)
+                << "Ambiguous AMS filament match: " << entry.second.size()
+                << " filament presets share filament_id \"" << entry.first
+                << "\" and are all compatible with printer \"" << printer.name
+                << "\". When matching an AMS spool the slicer cannot tell them apart and"
+                   " silently picks whichever loads first." << presets;
+        }
+    }
+
+    // Print the troubleshooting guidance once, not per error, to keep the log readable.
+    if (found_duplicates)
+        BOOST_LOG_TRIVIAL(error) << "\n========================================\n"
+            << "How to fix \"Ambiguous AMS filament match\" errors: make sure only ONE filament"
+               " preset with a given filament_id is compatible with each printer. Either"
+               "\n    (a) remove the overlapping printer from a preset's \"compatible_printers\""
+               " list (e.g. a '@printer' preset over-claiming a nozzle that already has its own"
+               " '@printer 0.x nozzle' preset), or"
+               "\n    (b) if these are genuinely different materials, give each its own"
+               " \"filament_id\" - a common cause is a wrong \"inherits\" pointing at another"
+               " material's @base preset.";
+
+    return found_duplicates;
+}
+
 // Orca: BundleMetadata method implementations
 bool BundleMetadata::load_from_json(const std::string& path)
 {

src/libslic3r/PresetBundle.hpp

@@ -480,10 +480,14 @@ public:
         return      { Preset::TYPE_PRINTER, Preset::TYPE_SLA_PRINT, Preset::TYPE_SLA_MATERIAL };
     }
 
-    // Orca: for validation only
+    // Orca: for validation only. The duplicate filament subtype check is opt-in for now
-    bool has_errors() const;
+    bool has_errors(bool check_duplicate_filament_subtypes = false) const;
 
 private:
+    // Orca: validation only - flag any printer with two or more compatible
+    // filament presets sharing one filament_id (ambiguous AMS subtype match).
+    bool check_duplicate_filament_subtypes() const;
+
     //std::pair<PresetsConfigSubstitutions, std::string> load_system_presets(ForwardCompatibilitySubstitutionRule compatibility_rule);
     //BBS: add json related logic
     std::pair<PresetsConfigSubstitutions, std::string> load_system_presets_from_json(ForwardCompatibilitySubstitutionRule compatibility_rule);