Merge branch 'main' into feature/add-multi-variant

.github/workflows/ofl-ota-cronjob.yml

@@ -1,5 +1,7 @@
 name: Daily OFL OTA Update
 
+run-name: Daily OFL OTA Update [OFL barrier]
+
 # This workflow is intended for creating and publishing the OrcaFilamentLibrary (OFL) OPC package to
 # https://github.com/OrcaSlicer/orcaslicer-profiles, which generates an OTA update.
 # This cronjob runs daily at 00:00 UTC every day and scans main plus every release/vX.Y.Z branch for
@@ -12,9 +14,9 @@ name: Daily OFL OTA Update
 # vendor-dispatch path is also what makes post_merge_profiles.yml call the OTA auto-publish API after
 # uploading - see post_merge_profiles.yml for both sides of that contract.
 #
-# At the start of each run, the pending-publish table is cleared up to a captured
+# Each run captures a timestamp, dispatches the needed OFL publishers, waits for
-# timestamp (POST /api/v1/ota/ofl/pending/clear?timestamp=...). Changes merged after
+# all of them to finish, then clears the pending-publish table once. Changes merged
-# that timestamp remain pending for the next run.
+# after that timestamp remain pending for the next run.
 
 on:
   schedule:
@@ -34,32 +36,14 @@ jobs:
     if: ${{ github.repository == 'OrcaSlicer/OrcaSlicer' }}
     runs-on: ubuntu-24.04
     steps:
-      - name: Capture start timestamp and clear OFL pending queue
+      - name: Capture start timestamp
         id: start
         shell: bash
-        env:
-          OTA_API_BASE_URL: ${{ vars.OTA_API_BASE_URL }}
-          OTA_API_KEY: ${{ secrets.OFL_OTA_PUBLISH_KEY }}
         run: |
           set -euo pipefail
-          [ -n "$OTA_API_BASE_URL" ] || { echo "::error::vars.OTA_API_BASE_URL is not set"; exit 1; }
-          [ -n "$OTA_API_KEY" ] || { echo "::error::secrets.OFL_OTA_PUBLISH_KEY is not set"; exit 1; }
-
           timestamp="$(date -u +%s)"
           echo "timestamp=$timestamp" >> "$GITHUB_OUTPUT"
 
-          resp_file="$RUNNER_TEMP/ota-pending-clear-response.json"
-          status="$(curl -sS -o "$resp_file" -w '%{http_code}' -X POST \
-            "${OTA_API_BASE_URL%/}/api/v1/ota/ofl/pending/clear?timestamp=$timestamp" \
-            -H "Authorization: Bearer $OTA_API_KEY")"
-          body="$(cat "$resp_file")"
-          echo "$body"
-
-          if [ "$status" != "200" ]; then
-            echo "::error::OTA pending-clear call failed with HTTP $status"
-            exit 1
-          fi
-
       - name: Checkout repository
         uses: actions/checkout@v7
         with:
@@ -84,27 +68,21 @@ jobs:
               | grep -E '^(main|release/v[0-9]+\.[0-9]+\.[0-9]+)$' | sort -u
           )
 
+          # The cron run is the checkpoint: a successful run means every
+          # dispatched branch publisher completed and the pending queue was
+          # cleared. Manual or push-triggered post_merge_profiles runs are not
+          # checkpoints for this scan.
+          successful_cron_runs="$(gh api --method GET \
+            "repos/${{ github.repository }}/actions/workflows/ofl-ota-cronjob.yml/runs" \
+            -f status=success -f branch=main -f per_page=100 --paginate \
+            --jq '.workflow_runs[] | select((.display_title // "") | contains("[OFL barrier]"))')"
+          since="$(jq -rs 'sort_by(.run_started_at) | last.run_started_at // empty' <<< "$successful_cron_runs")"
+
           for branch in "${branches[@]}"; do
             echo "::group::$branch"
 
-            # post_merge_profiles.yml's own run history, not this workflow's: this
-            # workflow only ever runs against main (schedule, or workflow_dispatch
-            # --ref main), so its head branch never varies - filtering ITS history
-            # by $branch would never match anything except main. post_merge_profiles.yml
-            # genuinely runs per-branch (this dispatch below sets --ref "$branch"),
-            # so its history is the real per-branch checkpoint. It also means a
-            # failed publish naturally gets retried tomorrow: the checkpoint only
-            # advances on a run that actually succeeded.
-            # --method GET is required, not cosmetic: gh api defaults to POST
-            # whenever -f fields are present unless a method is given
-            # explicitly, and POST on this list-runs endpoint 404s - confirmed
-            # on real Actions infrastructure, not just reasoned about.
-            since="$(gh api --method GET "repos/${{ github.repository }}/actions/workflows/post_merge_profiles.yml/runs" \
-              -f status=success -f branch="$branch" -f per_page=1 \
-              --jq '.workflow_runs[0].run_started_at // empty')"
-
             if [ -z "$since" ]; then
-              echo "No prior successful run for $branch; checking OFL changes up to $SCAN_UNTIL."
+              echo "No prior successful OFL cron run; checking $branch through $SCAN_UNTIL."
               changed_files="$(git log --until="$SCAN_UNTIL" --name-only --pretty=format: "origin/$branch" -- \
                 resources/profiles/OrcaFilamentLibrary resources/profiles/OrcaFilamentLibrary.json \
                 | sed '/^$/d')"
@@ -124,16 +102,98 @@ jobs:
             fi
 
             if [ "$changed" = true ]; then
-              # Tolerate a per-branch failure (e.g. a pre-existing release branch
+              dispatch_id="${GITHUB_RUN_ID}-${branch//\//-}"
-              # whose post_merge_profiles.yml predates the vendor/auto_publish
+              # Record successful dispatches for the barrier step below.
-              # inputs) rather than aborting the whole scan under set -e.
+              # Branches whose workflow predates workflow_dispatch are skipped
-              if ! gh workflow run post_merge_profiles.yml \
+              # with a warning, as they were before the barrier was added.
+              if gh workflow run post_merge_profiles.yml \
                 --repo "${{ github.repository }}" \
                 --ref "$branch" \
-                -f vendor="$VENDOR" -f auto_publish=true; then
+                -f vendor="$VENDOR" -f auto_publish=true \
-                echo "::warning::failed to dispatch post_merge_profiles.yml for $branch - its post_merge_profiles.yml at this ref may predate the vendor/auto_publish inputs"
+                -f ofl_cron_dispatch_id="$dispatch_id"; then
+                printf '%s\t%s\n' "$branch" "$dispatch_id" >> "$RUNNER_TEMP/ofl-dispatches.tsv"
+              else
+                echo "::warning::skipping $branch because post_merge_profiles.yml could not be dispatched at that ref"
               fi
             fi
 
             echo "::endgroup::"
           done
+
+      - name: Wait for OFL publishers
+        id: wait
+        shell: bash
+        env:
+          GH_TOKEN: ${{ secrets.GITHUB_TOKEN }}
+          DISPATCHES_FILE: ${{ runner.temp }}/ofl-dispatches.tsv
+        run: |
+          set -euo pipefail
+
+          if [ ! -s "$DISPATCHES_FILE" ]; then
+            echo "No OFL publisher workflows were dispatched; pending queue will not be cleared."
+            echo "publishers_dispatched=false" >> "$GITHUB_OUTPUT"
+            exit 0
+          fi
+
+          : > "$RUNNER_TEMP/ofl-run-ids.tsv"
+          while IFS=$'\t' read -r branch dispatch_id; do
+            [ -n "$branch" ] || continue
+            echo "Waiting for OFL publisher on $branch ($dispatch_id)"
+
+            run_id=""
+            for _ in {1..120}; do
+              runs_json="$(gh api --method GET \
+                "repos/${{ github.repository }}/actions/workflows/post_merge_profiles.yml/runs" \
+                -f branch="$branch" -f event=workflow_dispatch -f per_page=100)"
+              run_id="$(jq -r --arg marker "[OFL cron $dispatch_id]" \
+                '[.workflow_runs[] | select((.display_title // "") | contains($marker))] \
+                | sort_by(.created_at) | last | .id // empty' <<< "$runs_json")"
+              [ -n "$run_id" ] && break
+              sleep 5
+            done
+
+            if [ -z "$run_id" ]; then
+              echo "::error::could not find dispatched post_merge_profiles run for $branch ($dispatch_id)"
+              exit 1
+            fi
+            printf '%s\t%s\n' "$branch" "$run_id" >> "$RUNNER_TEMP/ofl-run-ids.tsv"
+          done < "$DISPATCHES_FILE"
+
+          all_success=true
+          while IFS=$'\t' read -r branch run_id; do
+            [ -n "$run_id" ] || continue
+            echo "Watching OFL publisher run $run_id for $branch"
+            if ! gh run watch "$run_id" --repo "${{ github.repository }}" --exit-status; then
+              all_success=false
+            fi
+          done < "$RUNNER_TEMP/ofl-run-ids.tsv"
+
+          if [ "$all_success" != true ]; then
+            echo "::error::one or more OFL publisher workflows failed; pending queue will not be cleared"
+            exit 1
+          fi
+          echo "publishers_dispatched=true" >> "$GITHUB_OUTPUT"
+
+      - name: Clear OFL pending queue
+        if: steps.wait.outputs.publishers_dispatched == 'true'
+        shell: bash
+        env:
+          OTA_API_BASE_URL: ${{ vars.OTA_API_BASE_URL }}
+          OTA_API_KEY: ${{ secrets.OFL_OTA_PUBLISH_KEY }}
+          TIMESTAMP: ${{ steps.start.outputs.timestamp }}
+        run: |
+          set -euo pipefail
+          [ -n "$OTA_API_BASE_URL" ] || { echo "::error::vars.OTA_API_BASE_URL is not set"; exit 1; }
+          [ -n "$OTA_API_KEY" ] || { echo "::error::secrets.OFL_OTA_PUBLISH_KEY is not set"; exit 1; }
+
+          resp_file="$RUNNER_TEMP/ota-pending-clear-response.json"
+          status="$(curl -sS -o "$resp_file" -w '%{http_code}' -X POST \
+            "${OTA_API_BASE_URL%/}/api/v1/ota/ofl/pending/clear?timestamp=$TIMESTAMP" \
+            -H "Authorization: Bearer $OTA_API_KEY")"
+          body="$(cat "$resp_file")"
+          echo "$body"
+
+          if [ "$status" != "200" ]; then
+            echo "::error::OTA pending-clear call failed with HTTP $status"
+            exit 1
+          fi

.github/workflows/post_merge_profiles.yml

@@ -1,5 +1,14 @@
 name: Post-merge profiles
 
+run-name: >-
+  Post-merge profiles${{
+    inputs.ofl_cron_dispatch_id != '' &&
+    inputs.vendor == 'OrcaFilamentLibrary' &&
+    (inputs.auto_publish == true || inputs.auto_publish == 'true') &&
+    format(' [OFL cron {0}]', inputs.ofl_cron_dispatch_id) ||
+    ''
+  }}
+
 # Push-triggered counterpart to check_profiles.yml (which only gates PRs). When a
 # profile change lands on main or a release branch, rebuild the affected vendors'
 # binary preset caches (<vendor>.opc) and publish each as a versioned ZIP asset on
@@ -59,6 +68,12 @@ on:
         required: false
         type: boolean
         default: false
+      ofl_cron_dispatch_id:
+        description: >-
+          Unique marker supplied by the trusted OFL daily cron so it can find
+          and wait for this dispatched workflow run.
+        required: false
+        type: string
 
 permissions:
   contents: read

resources/profiles/OrcaFilamentLibrary/filament/Elegoo/Elegoo PLA @base.json

@@ -6,7 +6,7 @@
 	"filament_id": "OFvgE0Zh",
 	"instantiation": "false",
 	"fan_cooling_layer_time": [
-		"80"
+		"81"
 	],
 	"fan_min_speed": [
 		"50"

src/libslic3r/CAD/CadDocument.cpp

@@ -2673,10 +2673,10 @@ void CadDocument::apply_feature(TopoDS_Shape& result, bool& have_body,
                 ridge = pipe.Shape();
                 have_ridge = !ridge.IsNull();
             }
+        } catch (const Standard_Failure&) {
+            have_ridge = false; // OCCT failure — on OCCT >= 8 Standard_Failure derives from std::exception, so this handler must come first
         } catch (const std::exception&) {
             have_ridge = false; // fall back to the bare cylinder/bore below
-        } catch (const Standard_Failure&) {
-            have_ridge = false; // OCCT failure (not a std::exception) — must be caught here too
         }
 
         if (f.thread_internal) {

src/libslic3r/CAD/GeometryEngine.cpp

@@ -15,6 +15,8 @@
 #include <TopExp.hxx>
 #include <TopTools.hxx>
 #include <TopTools_IndexedMapOfShape.hxx>
+#include <TopTools_ListOfShape.hxx>
+#include <TopTools_IndexedDataMapOfShapeListOfShape.hxx>
 #include <Poly_Triangulation.hxx>
 #include <gp_Ax2.hxx>
 #include <gp_Dir.hxx>

src/libslic3r/Format/STEP.cpp

@@ -25,6 +25,7 @@
 #include "XCAFDoc_DocumentTool.hxx"
 #include "XCAFDoc_ShapeTool.hxx"
 #include "XCAFApp_Application.hxx"
+#include "TDF_LabelSequence.hxx"
 #include "TopoDS_Solid.hxx"
 #include "TopoDS_Compound.hxx"
 #include "TopoDS_Builder.hxx"

src/libslic3r/GCode.cpp

@@ -7969,6 +7969,20 @@ double GCode::calc_max_volumetric_speed(const double layer_height, const double
     return res;
 }
 
+// ORCA: Overlap at or below which the overhang fan switches on; negative when it does not depend on overlap
+// (Overhang_threshold_none cools every external perimeter).
+static float overhang_fan_overlap_threshold(int overhang_fan_threshold)
+{
+    switch (overhang_fan_threshold) {
+    case (int) Overhang_threshold_1_4: return 0.9f;
+    case (int) Overhang_threshold_2_4: return 0.75f;
+    case (int) Overhang_threshold_3_4: return 0.5f;
+    case (int) Overhang_threshold_4_4: return 0.25f;
+    case (int) Overhang_threshold_bridge: return 0.05f;
+    default: return -1.f;
+    }
+}
+
 std::string GCode::_extrude(const ExtrusionPath &path, std::string description, double speed)
 {
     std::string gcode;
@@ -8311,6 +8325,13 @@ std::string GCode::_extrude(const ExtrusionPath &path, std::string description,
             
             ConfigOptionPercents         overhang_overlap_levels({90, 75, 50, 25, 13, 0});
 
+            // ORCA: Lets the path be split where the overhang fan switches, not only where the speed changes.
+            // Bridges and overhang perimeters are cooled regardless of overlap.
+            float fan_overlap_threshold = -1.f;
+            if (FILAMENT_CONFIG(enable_overhang_bridge_fan) && m_enable_cooling_markers && path.role() != erBridgeInfill &&
+                path.role() != erOverhangPerimeter)
+                fan_overlap_threshold = overhang_fan_overlap_threshold(FILAMENT_CONFIG(overhang_fan_threshold));
+
             if (NOZZLE_CONFIG(slowdown_for_curled_perimeters)){
                 ConfigOptionFloatsOrPercents dynamic_overhang_speeds(
                     {FloatOrPercent{100, true},
@@ -8331,7 +8352,8 @@ std::string GCode::_extrude(const ExtrusionPath &path, std::string description,
                          FloatOrPercent{NOZZLE_CONFIG(overhang_4_4_speed).get_abs_value(ref_speed) * 100 / ref_speed, true}});
 
                 new_points = m_extrusion_quality_estimator.estimate_extrusion_quality(path, overhang_overlap_levels, dynamic_overhang_speeds,
-                                                                              ref_speed, speed, NOZZLE_CONFIG(slowdown_for_curled_perimeters));
+                                                                              ref_speed, speed, NOZZLE_CONFIG(slowdown_for_curled_perimeters),
+                                                                              fan_overlap_threshold);
         	}else{
                 ConfigOptionFloatsOrPercents dynamic_overhang_speeds(
                                                                      {FloatOrPercent{100, true},
@@ -8350,7 +8372,8 @@ std::string GCode::_extrude(const ExtrusionPath &path, std::string description,
                      FloatOrPercent{NOZZLE_CONFIG(bridge_speed) * 100 / ref_speed, true}});
 
                 new_points = m_extrusion_quality_estimator.estimate_extrusion_quality(path, overhang_overlap_levels, dynamic_overhang_speeds,
-                                                                              ref_speed, speed, NOZZLE_CONFIG(slowdown_for_curled_perimeters));
+                                                                              ref_speed, speed, NOZZLE_CONFIG(slowdown_for_curled_perimeters),
+                                                                              fan_overlap_threshold);
             }
             variable_speed = std::any_of(new_points.begin(), new_points.end(),
                                          [speed](const ProcessedPoint &p) { return fabs(double(p.speed) - speed) > 1; }); // Ignore small speed variations (under 1mm/sec)
@@ -8502,28 +8525,10 @@ std::string GCode::_extrude(const ExtrusionPath &path, std::string description,
       if (role == erBridgeInfill || role == erOverhangPerimeter) { // ORCA: Split out bridge infill to internal and external to apply separate fan settings
         return true;
       }
-      switch (overhang_fan_threshold) {
+      if (overhang_fan_threshold == Overhang_threshold_none)
-      case (int)Overhang_threshold_1_4:
-        return overlap <= 0.9f;
-        break;
-      case (int)Overhang_threshold_2_4:
-        return overlap <= 0.75f;
-        break;
-      case (int)Overhang_threshold_3_4:
-        return overlap <= 0.5f;
-        break;
-      case (int)Overhang_threshold_4_4:
-        return overlap <= 0.25f;
-        break;
-      case (int)Overhang_threshold_bridge:
-        return overlap <= 0.05f;
-        break;
-      case (int)Overhang_threshold_none:
         return is_external_perimeter(role);
-        break;
+      const float overlap_threshold = overhang_fan_overlap_threshold(overhang_fan_threshold);
-      default:
+      return overlap_threshold >= 0.f && overlap <= overlap_threshold;
-        return false;
-      }
     };
 
     std::string comment;

src/libslic3r/GCode/ExtrusionProcessor.hpp

@@ -41,10 +41,12 @@ std::vector<ExtendedPoint<L::Dim>> estimate_points_properties(const POINTS&
                                                               float                                   flow_width,
                                                               float                                   max_line_length = -1.0f,
                                                               float                                   min_distance    = -1.0f,
-                                                              // Maps an overhang distance onto the speed it will be printed at. Interior sampling
+                                                              // Speed an overhang distance prints at. Without it, interior sampling
-                                                              // needs it to tell which of the points it could add would change the G-code, and is
+                                                              // is skipped and every line over 4mm is split.
-                                                              // skipped without it.
+                                                              const std::function<float(float)>&      distance_to_speed = {},
-                                                              const std::function<float(float)>&      distance_to_speed = {})
+                                                              // Overlap (1 - distance / flow_width) at or below which the overhang
+                                                              // fan switches on; negative when the fan does not depend on overlap.
+                                                              float                                   fan_overlap_threshold = -1.0f)
 {
     bool   looped     = input_points.front() == input_points.back();
     std::function<size_t(size_t,size_t)> get_prev_index = [](size_t idx, size_t count) {
@@ -125,29 +127,43 @@ std::vector<ExtendedPoint<L::Dim>> estimate_points_properties(const POINTS&
         points.push_back(next_point);
     }
 
+    // ORCA: How an overhang distance prints, which is what the passes below compare. A segment is printed at the lower
+    // of the speeds at its two ends, and with the overhang fan on if the overlap at either end turns it on. A point
+    // added to a path can therefore only change the G-code where it prints at a different speed or fan state from the
+    // points either side of it, and the passes below add points there and nowhere else.
+    const float width_inv = 1.f / flow_width;
+    // Whether an overhang distance turns the overhang fan on. The overlap test check_overhang_fan applies in GCode.cpp.
+    auto fan_on = [fan_overlap_threshold, width_inv](float distance) {
+        return fan_overlap_threshold >= 0.f && 1.f - distance * width_inv <= fan_overlap_threshold;
+    };
+    // Whether two overhang distances are interchangeable ie have the same speed (beyond a 1mm/sec threshold that gcode.cpp filters out on) 
+    // and the same fan state.
+    auto same_speed_and_fan = [&distance_to_speed, &fan_on](float a, float b) {
+        return std::abs(distance_to_speed(a) - distance_to_speed(b)) <= 1.f && fan_on(a) == fan_on(b);
+    };
+    // Whether the first overhang distance prints slower than the second, beyond the 1mm/sec gcode.cpp tolerance, or turns the overhang
+    // fan on where the second does not. Against a supported point (overhang distance 0) it tells whether an end is
+    // affected by the overhang.
+    auto slower_or_cooled = [&distance_to_speed, &fan_on](float a, float b) {
+        return distance_to_speed(a) < distance_to_speed(b) - 1.f || (fan_on(a) && !fan_on(b));
+    };
+
     // ORCA: Interior sampling
-    // The passes below infer the support under a span from its endpoints alone, so an interior that is supported
+    // The passes below infer the support under a span from its endpoints alone, so a part that is supported
-    // differently from both ends is invisible to them: the outer perimeter of an overhang whose ends are caged by
+    // differently from both ends is invisible to them. The outer perimeter of an overhang whose ends are supported by
-    // full height walls reads as supported along its whole length. Probe the interior, keep the samples the
+    // reads as supported along its whole length. Probe the interior, keep the samples the endpoint interpolation fails to predict, 
-    // endpoint interpolation fails to predict, and bisect either side of each one, so a span that is only partly
+    // and bisect either side of each one, so a span that is only partly unsupported gets points where its support actually changes 
-    // unsupported gets points where its support actually changes instead of one reading spread across all of it.
+    // instead of one reading being spread across all of it.
-    if (PREV_LAYER_BOUNDARY_OFFSET && ADD_INTERSECTIONS && min_distance > 0 && distance_to_speed) {
+    // Skipped where there is nothing to find: min_distance <= 0 when no overhang can slow this path down, and
+    // fan_overlap_threshold < 0 when no overhang switches the fan on. It also needs distance_to_speed to tell which of
+    // the points it could add would change the G-code.
+    if (PREV_LAYER_BOUNDARY_OFFSET && ADD_INTERSECTIONS && distance_to_speed && (min_distance > 0 || fan_overlap_threshold >= 0.f)) {
         // Probe at least this densely before treating matching samples as evidence that a span is uniform. The
         // segmentation pass below only splits lines of 2mm or more, and every pass here drops points closer
-        // together than min_spacing, so finer discovery would not produce a more precise speed transition.
+        // together than min_spacing, so finer discovery would not produce a more precise transition.
         const double max_probe_spacing = std::max(2., 4. * min_spacing);
         // A backstop for that length test, which on a non-finite length would never be met.
         constexpr int max_bisection_depth = 10;
-        // Whether two readings are interchangeable. A segment is printed at the lower of the speeds its ends
-        // read, so a sample that agrees on speed with what is already known cannot change the G-code, whatever
-        // its distance says. The distances themselves are far too coarse a stand-in for this: the speed sections
-        // interpolate, so readings a small fraction of min_distance apart can still be tens of mm/s apart.
-        // The tolerance matches the one GCode.cpp applies when it decides a path has a variable speed at all.
-        auto same_speed = [&distance_to_speed](float a, float b) {
-            return std::abs(distance_to_speed(a) - distance_to_speed(b)) <= 1.f;
-        };
-        // Whether the first reading is printed slower than the second, once they are known to differ.
-        auto prints_slower = [&distance_to_speed](float a, float b) { return distance_to_speed(a) < distance_to_speed(b); };
 
         // Part of a segment still to bisect: its positions along the segment and bisections left.
         struct Subspan { double t0, t1; int depth; };
@@ -185,8 +201,8 @@ std::vector<ExtendedPoint<L::Dim>> estimate_points_properties(const POINTS&
             if (!interior.empty()) {
                 std::sort(interior.begin(), interior.end(),
                           [](const std::pair<double, float>& l, const std::pair<double, float>& r) { return l.first < r.first; });
-                // Coarse probing keeps every sample it took until this pass can see which ones bracket a speed
+                // Coarse probing keeps every sample it took until this pass can see which ones bracket a speed or
-                // transition. Matching samples cannot be discarded during discovery: one may be the last
+                // fan transition. Matching samples cannot be discarded during discovery: one may be the last
                 // supported point before a narrow unsupported pocket found by a later probe.
                 size_t kept = 0;
                 for (size_t i = 0; i < interior.size(); ++i) {
@@ -195,15 +211,15 @@ std::vector<ExtendedPoint<L::Dim>> estimate_points_properties(const POINTS&
                     const bool  at_end    = i + 1 == interior.size();      // And nothing follows the last sample but the segment's end
                     const float before    = at_start ? curr.distance : interior[kept - 1].second;
                     const float after     = at_end ? next.distance : interior[i + 1].second;
-                    // A sample is worth a point in the path only where it prints at a different speed from the
+                    // A sample is worth a point in the path only where it prints differently, in speed or fan state,
-                    // readings either side of it. Differing from one of the segment's own ends is not enough on
+                    // from the points either side of it. Differing from one of the segment's own ends is not enough on
-                    // its own where the sample is the faster of the two: the segmentation pass below already
+                    // its own where the sample is not the slower or cooled of the two: the segmentation pass below
-                    // ends the slowdown an end reads, at a distance taken from how far out that end is rather
+                    // already confines the slowdown and cooling at an end, at a distance taken from how far out that
-                    // than from wherever bisection happened to stop, and a point here would leave the span
+                    // end is rather than from wherever bisection happened to stop, and a point here would leave the
-                    // beside the end too short for that pass to run at all. Support an end cannot account for,
+                    // span beside the end too short for that pass to run at all. Support an end cannot account for,
-                    // where the interior is the slower reading, is exactly what this pass is here to find.
+                    // where the interior is the slower or cooled of the two, is exactly what this pass is here to find.
-                    const bool worth_before = !same_speed(sample, before) && (!at_start || prints_slower(sample, before));
+                    const bool worth_before = !same_speed_and_fan(sample, before) && (!at_start || slower_or_cooled(sample, before));
-                    const bool worth_after  = !same_speed(sample, after) && (!at_end || prints_slower(sample, after));
+                    const bool worth_after  = !same_speed_and_fan(sample, after) && (!at_end || slower_or_cooled(sample, after));
                     if (worth_before || worth_after)
                         interior[kept++] = interior[i];
                 }
@@ -239,51 +255,59 @@ std::vector<ExtendedPoint<L::Dim>> estimate_points_properties(const POINTS&
                 (next.distance > -boundary_offset && next.distance < boundary_offset + 2.0f)) {
                 double line_len = (next.position - curr.position).norm();
 
-                // ORCA: Segment path to smaller lines by adding additional points only if the path has an overhang that
+                // ORCA: A line prints as slow as its slower end and is cooled if either end is, so an overhang at one
-                // will trigger a slowdown and the path is also reasonably large, i.e. 2mm in length or more
+                // end would otherwise slow down or cool the whole line. Split the line so that only the part beside
-                // If there is no overhang in the start/end point, dont segment it.
+                // that end prints that way, if the line is reasonably long (2mm or more) and at least one end prints
-                // Ignore this check if the control of segmentation for overhangs is disabled (min_distance=-1)
+                // slower or cooled compared with a supported point (overhang distance 0). Deciding on how the end
-                if ((min_distance > 0 && ((std::abs(curr.distance) > min_distance) || (std::abs(next.distance) > min_distance)) && line_len >= 2.f) ||
+                // prints, rather than on its overhang distance against min_distance, also catches an end whose overhang
-                    (min_distance <= 0 && line_len > 4.0f)) {
+                // distance is exactly where the slowdown begins, such as an outline crossing at half a line width.
+                // Without distance_to_speed, split every line over 4mm.
+                const bool split_line = distance_to_speed ?
+                    line_len >= 2.f && (slower_or_cooled(curr.distance, 0.f) || slower_or_cooled(next.distance, 0.f)) :
+                    line_len > 4.0f;
+                if (split_line) {
+                    // Each end's piece is that end's overhang distance plus 1.5 line widths (3 * boundary_offset) long:
+                    // a0 ends the piece beside curr, a1 starts the piece beside next.
                     double a0 = std::clamp((curr.distance + 3 * boundary_offset) / line_len, 0.0, 1.0);
                     double a1 = std::clamp(1.0f - (next.distance + 3 * boundary_offset) / line_len, 0.0, 1.0);
                     double t0 = std::min(a0, a1);
                     double t1 = std::max(a0, a1);
 
-                    if (t0 < 1.0) {
+                    // Up to two cut points, in order along the line. Each takes its own overhang distance, so every
-                        Vec p0                          = curr.position + t0 * (next.position - curr.position);
+                    // piece prints by the overhang distances at its own two ends. t0 >= 1 or t1 <= 0 falls on the
-                        auto [p0_dist, p0_near_l, p0_x] = unscaled_prev_layer.template distance_from_lines_extra<SIGNED_DISTANCE>(
+                    // line's own end, so there is no cut. A cut closer than min_spacing to either end of the line is
-                            p0.template cast<AABBScalar>());
+                    // not meaningful and is filtered out (#6714).
-                        ExtendedPoint<L::Dim> new_p{};
+                    ExtendedPoint<L::Dim> cut[2]{};
-                        new_p.position = p0;
+                    bool                  keep[2] = {false, false};
-                        new_p.distance = float(p0_dist + boundary_offset);
+                    for (int k = 0; k < 2; ++k) {
-                        // ORCA: only create a new point in the path if the new point overhang distance will be used to generate a speed change
+                        const double t = k == 0 ? t0 : t1;
-                        // or if this option is disabled (min_distance<=0)
+                        if (k == 0 ? t >= 1.0 : t <= 0.0)
-                        if( (std::abs(p0_dist) > min_distance) || (min_distance<=0)){
+                            continue;
-                            // ORCA: also filter out points that are introduced to the start of the path when their distance from the start point is
+                        const Vec p                  = curr.position + t * (next.position - curr.position);
-                            // not meaningful
+                        auto [p_dist, p_near_l, p_x] = unscaled_prev_layer.template distance_from_lines_extra<SIGNED_DISTANCE>(
-                            if ((p0 - curr.position).norm() > min_spacing && (next.position - p0).norm() > min_spacing) {
+                            p.template cast<AABBScalar>());
-                                new_points.push_back(new_p);
+                        cut[k].position = p;
-                            }
+                        cut[k].distance = float(p_dist + boundary_offset);
-                        }
+                        keep[k] = (p - curr.position).norm() > min_spacing && (next.position - p).norm() > min_spacing;
-                    }
-                    if (t1 > 0.0) {
-                        Vec p1                          = curr.position + t1 * (next.position - curr.position);
-                        auto [p1_dist, p1_near_l, p1_x] = unscaled_prev_layer.template distance_from_lines_extra<SIGNED_DISTANCE>(
-                            p1.template cast<AABBScalar>());
-                        ExtendedPoint<L::Dim> new_p{};
-                        new_p.position = p1;
-                        new_p.distance = float(p1_dist + boundary_offset);
-                        // ORCA: only create a new point in the path if the new point overhang distance will be used to generate a speed change
-                        // or if this option is disabled (min_distance<=0)
-                        if( (std::abs(p1_dist) > min_distance) || (min_distance<=0)){
-                            // ORCA: filter out points that are introduced to the end of the path when their distance from the end point is
-                            // not meaningful
-                            if ((p1 - curr.position).norm() > min_spacing && (next.position - p1).norm() > min_spacing) {
-                                new_points.push_back(new_p);
-                            }
                     }
+                    if (distance_to_speed) {
+                        // Only keep a cut that changes the G-code: one that prints differently from at least one of the
+                        // points either side of it, which are the line's ends or the other cut where that is kept. A cut
+                        // that prints like both would only split a move into two identical ones.
+                        if (keep[0])
+                            keep[0] = !same_speed_and_fan(cut[0].distance, curr.distance) ||
+                                      !same_speed_and_fan(cut[0].distance, keep[1] ? cut[1].distance : next.distance);
+                        if (keep[1])
+                            keep[1] = !same_speed_and_fan(cut[1].distance, keep[0] ? cut[0].distance : curr.distance) ||
+                                      !same_speed_and_fan(cut[1].distance, next.distance);
+                        // Two cuts closer together than min_spacing would leave a micro segment between them, so only the
+                        // first is kept.
+                        if (keep[0] && keep[1] && (cut[1].position - cut[0].position).norm() <= min_spacing)
+                            keep[1] = false;
                     }
+                    for (int k = 0; k < 2; ++k)
+                        if (keep[k])
+                            new_points.push_back(cut[k]);
                 }
             }
             new_points.push_back(next);
@@ -423,7 +447,10 @@ public:
                                                            const ConfigOptionFloatsOrPercents &speeds,
                                                            float                               ext_perimeter_speed,
                                                            float                               original_speed,
-                                                           bool								   slowdown_for_curled_edges)
+                                                           bool								   slowdown_for_curled_edges,
+                                                           // Overlap at or below which the overhang fan switches on; negative when the fan
+                                                           // does not depend on overlap.
+                                                           float                               fan_overlap_threshold = -1.0f)
     {
         size_t                               speed_sections_count = std::min(overlaps.values.size(), speeds.values.size());
         std::vector<std::pair<float, float>> speed_sections;
@@ -463,7 +490,8 @@ public:
             }
         }
 
-        // If a meaningful (i.e. needing slowdown) overhang distance was not found, then we shouldn't split the lines
+        // If no overhang distance slows this path down, -1 turns interior sampling off unless the overhang fan can switch.
+        // Lines are only split where an end prints slower or cooled, so here only a fan switch splits them.
         if (!found)
             smallest_distance_with_lower_speed=-1.f;
 
@@ -487,9 +515,17 @@ public:
             return round(final_speed);
         };
 
+        // ORCA: The speed sections are built from ext_perimeter_speed, which can be above the speed this path prints at
+        // (original_speed, e.g. held down by resonance avoidance). Every segment is capped at original_speed below, so
+        // overhang distances whose speeds differ only above it print the same and must not count as a speed change when
+        // the path is split.
+        auto effective_speed = [&calculate_speed, original_speed](float distance) {
+            return std::min(calculate_speed(distance), original_speed);
+        };
+
         std::vector<ExtendedPoint<3>> extended_points =
             estimate_points_properties<true, true, true, true>(path.polyline.points, prev_layer_boundaries[current_object], path.width, -1,
-                                                               smallest_distance_with_lower_speed, calculate_speed);
+                                                               smallest_distance_with_lower_speed, effective_speed, fan_overlap_threshold);
         const auto width_inv = 1.0f / path.width;
         std::vector<ProcessedPoint> processed_points;
         processed_points.reserve(extended_points.size());

src/slic3r/GUI/CAD/DesignPanel.cpp

@@ -4862,13 +4862,13 @@ void DesignPanel::on_import_mesh()
     try {
         shape = GeometryEngine::mesh_to_brep(mesh.its, MESH_IMPORT_TOLERANCE,
                                              MESH_IMPORT_MERGE_ANGLE_DEG, stats);
-    } catch (const std::exception& e) {
+    } catch (const Standard_Failure& e) {   // on OCCT >= 8 Standard_Failure derives from std::exception — must precede that handler
-        fail(_L("Mesh conversion failed: ") + wxString::FromUTF8(e.what()));
-        return;
-    } catch (const Standard_Failure& e) {   // OCCT throws outside std::exception
         fail(_L("Mesh conversion failed: ") + wxString::FromUTF8(
                  e.GetMessageString() ? e.GetMessageString() : "OCCT error"));
         return;
+    } catch (const std::exception& e) {
+        fail(_L("Mesh conversion failed: ") + wxString::FromUTF8(e.what()));
+        return;
     }
     if (shape.IsNull()) { fail(_L("Mesh conversion produced no geometry")); return; }
 

src/slic3r/GUI/GCodeViewer.cpp

@@ -1443,6 +1443,7 @@ void GCodeViewer::load_as_gcode(const GCodeProcessorResult& gcode_result, const
             libvgcode::EGCodeExtrusionRole::SupportTransition, libvgcode::EGCodeExtrusionRole::Mixed
             });
     m_paths_bounding_box = BoundingBoxf3(libvgcode::convert(bbox[0]).cast<double>(), libvgcode::convert(bbox[1]).cast<double>());
+    m_max_bounding_box = m_paths_bounding_box;
 
     if (wxGetApp().is_editor())
         m_contained_in_bed = wxGetApp().plater()->build_volume().all_paths_inside(gcode_result, m_paths_bounding_box);

tests/fff_print/test_extrusion_processor.cpp

@@ -244,6 +244,44 @@ float furthest_reading(const std::vector<ExtendedPoint<2>>& points)
            })->distance;
 }
 
+// A wall along a supported edge of the previous layer, ending past or just short of the edge's end. Crossing the edge's
+// end reads half a line width out.
+constexpr double edge_run_length = 64.;   // mm, wall start, measured from the end of the previous layer's edge
+constexpr double edge_step       = 0.384; // mm, how far this layer's contour extends past the previous layer's end
+// The centreline is inset half a line width from the contour.
+constexpr double edge_wall_end_past  = edge_step - 0.5 * caged_wall_width;
+constexpr double edge_wall_end_short = 0.05; // mm short of the edge, reading 0.21 - 0.05 = 0.16mm out
+// Segmentation splits 1.5 line widths plus the end's reading from an end, so an end's slowdown and cooling stay within this.
+constexpr double edge_affected_length = 3. * caged_wall_width;
+
+std::vector<ExtendedPoint<2>> sampled_wall_along_edge(double                              wall_end_x,
+                                                      const std::function<float(float)>& distance_to_speed,
+                                                      float                               min_distance,
+                                                      float                               fan_overlap_threshold)
+{
+    const AABBTreeLines::LinesDistancer<Linef> prev_layer(std::vector<Linef>{
+        {{0., 0.}, {edge_run_length + 10., 0.}},
+        {{edge_run_length + 10., 0.}, {edge_run_length + 10., -10.}},
+        {{edge_run_length + 10., -10.}, {0., -10.}},
+        {{0., -10.}, {0., 0.}},
+    });
+    const double wall_y = -0.5 * caged_wall_width;
+    const Points wall{Point::new_scale(edge_run_length, wall_y), Point::new_scale(wall_end_x, wall_y)};
+
+    return estimate_points_properties<true, true, true, true>(wall, prev_layer, caged_wall_width, -1.f, min_distance,
+                                                              distance_to_speed, fan_overlap_threshold);
+}
+
+// Length printed with the overhang fan on: segments with either end's overlap at or below the threshold.
+double cooled_length(const std::vector<ExtendedPoint<2>>& points, float fan_overlap_threshold)
+{
+    double length = 0.;
+    for (size_t i = 0; i + 1 < points.size(); ++i)
+        if (1.f - std::max(points[i].distance, points[i + 1].distance) / float(caged_wall_width) <= fan_overlap_threshold)
+            length += (points[i + 1].position - points[i].position).norm();
+    return length;
+}
+
 DynamicPrintConfig caged_overhang_config(const char* wall_generator){
     DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
     config.set_deserialize_strict({
@@ -431,6 +469,61 @@ TEST_CASE("A supported wall between overhanging corners is slowed no further tha
     REQUIRE(sampled <= unsampled);
 }
 
+// Regression: the line up to a step past the previous layer was not split, so the step's slowdown and cooling covered the
+// whole wall. The split required an end reading beyond where the slowdown begins, and an edge crossing reads exactly
+// there when the wall speed is held below the reference speed (e.g. resonance avoidance).
+TEST_CASE("A wall stepping past the previous layer is slowed and cooled only beside the step", "[ExtrusionProcessor][Regression]")
+{
+    const float crossing_reading = 0.5f * float(caged_wall_width);
+    const std::function<float(float)> distance_to_speed = [crossing_reading](float distance) {
+        return distance < crossing_reading ? 70.f : 15.f;
+    };
+    const float fan_overlap_threshold = 0.75f; // The fan switches on at a 25% overhang
+
+    const std::vector<ExtendedPoint<2>> points = sampled_wall_along_edge(-edge_wall_end_past, distance_to_speed, crossing_reading,
+                                                                         fan_overlap_threshold);
+    const double slowed = slowed_length(points, distance_to_speed);
+    const double cooled = cooled_length(points, fan_overlap_threshold);
+
+    REQUIRE(slowed > 0.);
+    REQUIRE(cooled > 0.);
+    REQUIRE(slowed < edge_affected_length);
+    REQUIRE(cooled < edge_affected_length);
+}
+
+// Regression: the fan can switch on at a smaller overhang than the first slowdown. Splitting only on speed changes left
+// the whole wall cooled when its end read between the two.
+TEST_CASE("A wall is split where only the overhang fan changes", "[ExtrusionProcessor][Regression]")
+{
+    const float crossing_reading = 0.5f * float(caged_wall_width);
+    const std::function<float(float)> distance_to_speed = [crossing_reading](float distance) {
+        return distance < crossing_reading ? 70.f : 15.f;
+    };
+    // The end reads 0.16mm out (overlap 0.62): cooled at a 25% threshold, but not slowed.
+    const float fan_overlap_threshold = 0.75f;
+
+    const std::vector<ExtendedPoint<2>> points = sampled_wall_along_edge(edge_wall_end_short, distance_to_speed, crossing_reading,
+                                                                         fan_overlap_threshold);
+    const double cooled = cooled_length(points, fan_overlap_threshold);
+
+    REQUIRE_THAT(slowed_length(points, distance_to_speed), Catch::Matchers::WithinAbs(0., 1e-9));
+    REQUIRE(cooled > 0.);
+    REQUIRE(cooled < edge_affected_length);
+}
+
+// With one speed and a fan threshold no reading reaches, only the wall's ends and the edge crossing remain.
+TEST_CASE("A wall is left whole where neither its speed nor its cooling changes", "[ExtrusionProcessor]")
+{
+    const std::function<float(float)> distance_to_speed = [](float) { return 70.f; };
+    // 95% overhang; the step reads 0.384mm out (overlap 0.09).
+    const float fan_overlap_threshold = 0.05f;
+
+    const std::vector<ExtendedPoint<2>> points = sampled_wall_along_edge(-edge_wall_end_past, distance_to_speed, -1.f,
+                                                                         fan_overlap_threshold);
+
+    REQUIRE(points.size() == 3);
+}
+
 TEST_CASE("Benchmark caged overhang interior sampling", "[ExtrusionProcessor][!benchmark]"){
     const char* wall_generator = GENERATE("classic", "arachne");