fix: exporting a sliced print again gives different G-code (#16025)

extrude_infill() and extrude_support() reversed the layer's extrusion
entities in place while chaining them, so each export started from the
previous one's reversed toolpaths, and each copy of an object from the
copy before it. The export-time region lists now hold const pointers,
and chaining reverses a clone instead.

src/libslic3r/Color.hpp

@@ -6,8 +6,6 @@
 #include <array>
 #include <algorithm>
 
-#include <cassert>
-
 namespace Slic3r {
 using RGB = std::array<float, 3>;
 using RGBA = std::array<float, 4>;

src/libslic3r/Fill/Fill.cpp

@@ -1692,9 +1692,9 @@ void Layer::make_ironing()
 				ironing_params.just_infill 	= false;
 				// ORCA: Get filament-specific overrides if configured, otherwise use process values
 				size_t extruder_idx = ironing_params.extruder - 1;
-				ironing_params.line_spacing = (!config.filament_ironing_spacing.is_nil(extruder_idx)
+				ironing_params.line_spacing = std::max(IRONING_SPACING_MIN, !config.filament_ironing_spacing.is_nil(extruder_idx)
 					? config.filament_ironing_spacing.get_at(extruder_idx)
-					: config.ironing_spacing);
+					: config.ironing_spacing.value);
                 ironing_params.inset = (!config.filament_ironing_inset.is_nil(extruder_idx)
 					? config.filament_ironing_inset.get_at(extruder_idx)
 					: config.ironing_inset);

src/libslic3r/Fill/FillConcentric.cpp

@@ -22,6 +22,9 @@ void FillConcentric::_fill_surface_single(
     
     coord_t min_spacing = scale_(this->spacing) * params.multiline;
     coord_t distance = coord_t(min_spacing / params.density);
+    // A non-positive step never shrinks the region, so the inset loop below would not end.
+    if (min_spacing <= 0 || distance <= 0)
+        return;
     
     if (params.density > 0.9999f && !params.dont_adjust) {
         distance = this->_adjust_solid_spacing(bounding_box.size()(0), distance);
@@ -108,6 +111,8 @@ void FillConcentric::_fill_surface_single(const FillParams& params,
     // no rotation is supported for this infill pattern
     Point   bbox_size = expolygon.contour.bounding_box().size();
     coord_t min_spacing = scaled<coord_t>(this->spacing);
+    if (min_spacing <= 0)
+        return;
 
     if (params.density > 0.9999f && !params.dont_adjust) {
         coord_t                loops_count = std::max(bbox_size.x(), bbox_size.y()) / min_spacing + 1;

src/libslic3r/GCode.cpp

@@ -7313,7 +7313,7 @@ static std::unique_ptr<EdgeGrid::Grid> calculate_layer_edge_grid(const Layer& la
 std::string GCode::extrude_loop(const ExtrusionLoop&                       loop_ref,
                                 const std::string&                         description,
                                 double                                     speed,
-                                const ExtrusionEntitiesPtr& region_perimeters,
+                                const std::vector<const ExtrusionEntity*>& region_perimeters,
                                 const Point*                               start_point,
                                 const WipeInwardSupport*                   wipe_support)
 {
@@ -7662,7 +7662,7 @@ std::string GCode::extrude_multi_path(const ExtrusionMultiPath& multipath, const
 std::string GCode::extrude_entity(const ExtrusionEntity&                     entity,
                                   const std::string&                         description,
                                   double                                     speed,
-                                  const ExtrusionEntitiesPtr& region_perimeters,
+                                  const std::vector<const ExtrusionEntity*>& region_perimeters,
                                   const WipeInwardSupport*                   wipe_support)
 {
     if (const ExtrusionPath* path = dynamic_cast<const ExtrusionPath*>(&entity))
@@ -7755,22 +7755,31 @@ std::string GCode::extrude_perimeters(const Print &print, const std::vector<Obje
 std::string GCode::extrude_infill(const Print &print, const std::vector<ObjectByExtruder::Island::Region> &by_region, bool ironing)
 {
     std::string                                   gcode;
-    ExtrusionEntitiesPtr extrusions;
+    std::vector<const ExtrusionEntity*>           extrusions;
+    std::vector<std::unique_ptr<ExtrusionEntity>> reversed;
     const char*                                   extrusion_name = ironing ? "ironing" : "infill";
     for (const ObjectByExtruder::Island::Region &region : by_region)
         if (! region.infills.empty()) {
             extrusions.clear();
             extrusions.reserve(region.infills.size());
-            for (ExtrusionEntity *ee : region.infills)
+            for (const ExtrusionEntity *ee : region.infills)
                 if ((ee->role() == erIroning) == ironing)
                     extrusions.emplace_back(ee);
             if (! extrusions.empty()) {
                 m_config.apply(print.get_print_region(&region - &by_region.front()).config());
-                chain_and_reorder_extrusion_entities(extrusions, m_last_pos.to_point());
+                reversed.clear();
+                chain_and_reorder_extrusion_entities(extrusions, m_last_pos.to_point(), reversed);
+                // The reversed copies are in chain order.
+                auto next_reversed = reversed.begin();
                 for (const ExtrusionEntity *fill : extrusions) {
+                    ExtrusionEntity *own_copy = next_reversed != reversed.end() && next_reversed->get() == fill ? (next_reversed++)->get() : nullptr;
                     auto *eec = dynamic_cast<const ExtrusionEntityCollection*>(fill);
                     if (eec) {
-                        for (ExtrusionEntity *ee : eec->chained_path_from(m_last_pos.to_point()).entities)
+                        // A reversed copy is owned here and can be moved from.
+                        ExtrusionEntityCollection chained = own_copy ? std::move(static_cast<ExtrusionEntityCollection&>(*own_copy)) : ExtrusionEntityCollection(*eec);
+                        if (!chained.no_sort)
+                            chain_and_reorder_extrusion_entities(chained.entities, m_last_pos.to_point());
+                        for (ExtrusionEntity *ee : chained.entities)
                             gcode += this->extrude_entity(*ee, extrusion_name);
                     } else
                         gcode += this->extrude_entity(*fill, extrusion_name);
@@ -7808,9 +7817,9 @@ std::string GCode::extrude_support(const ExtrusionEntityCollection &support_fill
     std::string gcode;
     if (!support_fills.entities.empty()) {
 
-        ExtrusionEntitiesPtr extrusions;
+        std::vector<const ExtrusionEntity*> extrusions;
         extrusions.reserve(support_fills.entities.size());
-        for (ExtrusionEntity* ee : support_fills.entities) {
+        for (const ExtrusionEntity* ee : support_fills.entities) {
             const auto role = ee->role();
             if ((role == support_extrusion_role) || (support_extrusion_role == erMixed && role != erIroning)) {
                 extrusions.emplace_back(ee);
@@ -7819,9 +7828,10 @@ std::string GCode::extrude_support(const ExtrusionEntityCollection &support_fill
         if (extrusions.empty())
             return gcode;
 
+        std::vector<std::unique_ptr<ExtrusionEntity>> reversed;
         //ORCA: Respect no_sort to preserve support base outline->fill order.
         if (!support_fills.no_sort)
-            chain_and_reorder_extrusion_entities(extrusions, m_last_pos.to_point());
+            chain_and_reorder_extrusion_entities(extrusions, m_last_pos.to_point(), reversed);
 
         for (const ExtrusionEntity *ee : extrusions) {
             ExtrusionRole role = ee->role();
@@ -10054,8 +10064,8 @@ const std::vector<GCode::ObjectByExtruder::Island::Region>& GCode::ObjectByExtru
         // Now we are going to iterate through perimeters and infills and pick ones that are supposed to be printed
         // References are used so that we don't have to repeat the same code
         for (int iter = 0; iter < 2; ++iter) {
-            const ExtrusionEntitiesPtr&										entities    = (iter ? reg.infills : reg.perimeters);
-            ExtrusionEntitiesPtr&   										target_eec  = (iter ? by_region_per_copy_cache.back().infills : by_region_per_copy_cache.back().perimeters);
+            const std::vector<const ExtrusionEntity*>&						entities    = (iter ? reg.infills : reg.perimeters);
+            std::vector<const ExtrusionEntity*>&							target_eec  = (iter ? by_region_per_copy_cache.back().infills : by_region_per_copy_cache.back().perimeters);
             const std::vector<const WipingExtrusions::ExtruderPerCopy*>& 	overrides   = (iter ? reg.infills_overrides : reg.perimeters_overrides);
 
             // Now the most important thing - which extrusion should we print.
@@ -10090,7 +10100,7 @@ const std::vector<GCode::ObjectByExtruder::Island::Region>& GCode::ObjectByExtru
 void GCode::ObjectByExtruder::Island::Region::append(const Type type, const ExtrusionEntityCollection* eec, const WipingExtrusions::ExtruderPerCopy* copies_extruder)
 {
     // We are going to manipulate either perimeters or infills, exactly in the same way. Let's create pointers to the proper structure to not repeat ourselves:
-    ExtrusionEntitiesPtr*									perimeters_or_infills;
+    std::vector<const ExtrusionEntity*>*					perimeters_or_infills;
     std::vector<const WipingExtrusions::ExtruderPerCopy*>* 	perimeters_or_infills_overrides;
 
     switch (type) {
@@ -10114,7 +10124,7 @@ void GCode::ObjectByExtruder::Island::Region::append(const Type type, const Extr
         for (auto* ee : eec->entities)
             perimeters_or_infills->emplace_back(ee);
     } else
-        perimeters_or_infills->emplace_back(const_cast<ExtrusionEntityCollection*>(eec));
+        perimeters_or_infills->emplace_back(eec);
 
     if (copies_extruder != nullptr) {
         // Don't reallocate overrides if not needed.

src/libslic3r/GCode.hpp

@@ -453,14 +453,14 @@ private:
     std::string extrude_entity(const ExtrusionEntity&                     entity,
                                const std::string&                         description       = "",
                                double                                     speed             = -1.,
-                               const ExtrusionEntitiesPtr& region_perimeters = ExtrusionEntitiesPtr(),
+                               const std::vector<const ExtrusionEntity*>& region_perimeters = {},
                                const WipeInwardSupport*                   wipe_support      = nullptr);
     // Orca: pass the complete collection of region perimeters to the extrude loop to check whether the wipe before external loop
     // should be executed
     std::string extrude_loop(const ExtrusionLoop&                       loop,
                              const std::string&                         description,
                              double                                     speed             = -1.,
-                             const ExtrusionEntitiesPtr& region_perimeters = ExtrusionEntitiesPtr(),
+                             const std::vector<const ExtrusionEntity*>& region_perimeters = {},
                              const Point*                               start_point       = nullptr,
                              const WipeInwardSupport*                   wipe_support      = nullptr);
     std::string extrude_multi_path(const ExtrusionMultiPath& multipath, const std::string& description = "", double speed = -1.);
@@ -493,10 +493,9 @@ private:
         {
             struct Region {
             	// Non-owned references to LayerRegion::perimeters::entities
-            	// std::vector<const ExtrusionEntity*> would be better here, but there is no way in C++ to convert from std::vector<T*> std::vector<const T*> without copying.
-                ExtrusionEntitiesPtr perimeters;
+                std::vector<const ExtrusionEntity*> perimeters;
             	// Non-owned references to LayerRegion::fills::entities
-                ExtrusionEntitiesPtr infills;
+                std::vector<const ExtrusionEntity*> infills;
 
                 std::vector<const WipingExtrusions::ExtruderPerCopy*> infills_overrides;
                 std::vector<const WipingExtrusions::ExtruderPerCopy*> perimeters_overrides;

src/libslic3r/PrintConfig.hpp

@@ -180,6 +180,10 @@ enum class IroningType {
     Count,
 };
 
+// Smallest usable ironing line spacing. Anything tighter yields an unprintable number of lines,
+// and zero stops the fillers from making progress.
+constexpr double IRONING_SPACING_MIN = 0.05;
+
 //BBS
 enum class WallInfillOrder {
     InnerOuterInfill,

src/libslic3r/ShortestPath.cpp

@@ -1024,13 +1024,14 @@ std::vector<std::pair<size_t, bool>> chain_segments_greedy2(SegmentEndPointFunc
 	return chain_segments_greedy_constrained_reversals2_<PointType, SegmentEndPointFunc, false, decltype(could_reverse_func)>(end_point_func, could_reverse_func, num_segments, start_near);
 }
 
-std::vector<std::pair<size_t, bool>> chain_extrusion_entities(std::vector<ExtrusionEntity*> &entities, const Point *start_near)
+template<typename EntityPtr>
+static std::vector<std::pair<size_t, bool>> chain_extrusion_entities_impl(const std::vector<EntityPtr> &entities, const Point *start_near)
 {
 	auto segment_end_point = [&entities](size_t idx, bool first_point) -> Point { return first_point ? entities[idx]->first_point() : entities[idx]->last_point(); };
 	auto could_reverse = [&entities](size_t idx) { const ExtrusionEntity *ee = entities[idx]; return ee->is_loop() || ee->can_reverse(); };
 	std::vector<std::pair<size_t, bool>> out = chain_segments_greedy_constrained_reversals<Point, decltype(segment_end_point), decltype(could_reverse)>(segment_end_point, could_reverse, entities.size(), start_near);
 	for (std::pair<size_t, bool> &segment : out) {
-		ExtrusionEntity *ee = entities[segment.first];
+		const ExtrusionEntity *ee = entities[segment.first];
 		if (ee->is_loop())
 			// Ignore reversals for loops, as the start point equals the end point.
 			segment.second = false;
@@ -1040,6 +1041,20 @@ std::vector<std::pair<size_t, bool>> chain_extrusion_entities(std::vector<Extrus
 	return out;
 }
 
+std::vector<std::pair<size_t, bool>> chain_extrusion_entities(std::vector<ExtrusionEntity*> &entities, const Point *start_near)
+{
+	return chain_extrusion_entities_impl(entities, start_near);
+}
+
+// Orca: Reordering queries first_point() / last_point(); drop entities that cannot provide valid endpoints.
+template<typename EntityPtr>
+static void remove_entities_without_endpoints(std::vector<EntityPtr> &entities)
+{
+    entities.erase(std::remove_if(entities.begin(), entities.end(),
+                                  [](const ExtrusionEntity *entity) { return !extrusion_entity_has_endpoints(entity); }),
+                   entities.end());
+}
+
 void reorder_extrusion_entities(std::vector<ExtrusionEntity*> &entities, const std::vector<std::pair<size_t, bool>> &chain)
 {
 	assert(entities.size() == chain.size());
@@ -1061,14 +1076,27 @@ void chain_and_reorder_extrusion_entities(std::vector<ExtrusionEntity*> &entitie
 
 void chain_and_reorder_extrusion_entities(std::vector<ExtrusionEntity*> &entities, const Point *start_near)
 {
-    // Orca: Reordering queries first_point() / last_point(); drop entities that cannot provide valid endpoints.
-    entities.erase(std::remove_if(entities.begin(), entities.end(), [](ExtrusionEntity *entity) {
-        return !extrusion_entity_has_endpoints(entity);
-    }),
-                   entities.end());
+    remove_entities_without_endpoints(entities);
 	reorder_extrusion_entities(entities, chain_extrusion_entities(entities, start_near));
 }
 
+void chain_and_reorder_extrusion_entities(std::vector<const ExtrusionEntity*> &entities, const Point &start_near,
+                                          std::vector<std::unique_ptr<ExtrusionEntity>> &reversed_clones)
+{
+    remove_entities_without_endpoints(entities);
+    std::vector<const ExtrusionEntity*> out;
+    out.reserve(entities.size());
+    for (const auto &[idx, reverse] : chain_extrusion_entities_impl(entities, &start_near)) {
+        if (reverse) {
+            ExtrusionEntity *clone = reversed_clones.emplace_back(entities[idx]->clone()).get();
+            clone->reverse();
+            out.emplace_back(clone);
+        } else
+            out.emplace_back(entities[idx]);
+    }
+    entities.swap(out);
+}
+
 std::vector<std::pair<size_t, bool>> chain_extrusion_paths(std::vector<ExtrusionPath> &extrusion_paths, const Point *start_near)
 {
 	auto segment_end_point = [&extrusion_paths](size_t idx, bool first_point) -> Point { return first_point ? extrusion_paths[idx].first_point() : extrusion_paths[idx].last_point(); };

src/libslic3r/ShortestPath.hpp

@@ -5,6 +5,7 @@
 #include "ExtrusionEntity.hpp"
 #include "Point.hpp"
 
+#include <memory>
 #include <utility>
 #include <vector>
 
@@ -24,6 +25,9 @@ std::vector<std::pair<size_t, bool>> chain_extrusion_entities(std::vector<Extrus
 void                                 reorder_extrusion_entities(std::vector<ExtrusionEntity*> &entities, const std::vector<std::pair<size_t, bool>> &chain);
 void                                 chain_and_reorder_extrusion_entities(std::vector<ExtrusionEntity*> &entities, const Point &start_near);
 void                                 chain_and_reorder_extrusion_entities(std::vector<ExtrusionEntity*> &entities, const Point *start_near = nullptr);
+// Each entity the chain reverses is replaced by a reversed clone that reversed_clones owns, so the originals stay unchanged.
+void                                 chain_and_reorder_extrusion_entities(std::vector<const ExtrusionEntity*> &entities, const Point &start_near,
+                                                                          std::vector<std::unique_ptr<ExtrusionEntity>> &reversed_clones);
 
 std::vector<std::pair<size_t, bool>> chain_extrusion_paths(std::vector<ExtrusionPath> &extrusion_paths, const Point *start_near = nullptr);
 void                                 reorder_extrusion_paths(std::vector<ExtrusionPath> &extrusion_paths, std::vector<std::pair<size_t, bool>> &chain);

src/libslic3r/Support/SupportParameters.hpp

@@ -64,7 +64,7 @@ struct SupportParameters {
 
         this->ironing = object_config.support_ironing;
         this->ironing_flow = support_material_interface_flow.with_height(support_material_interface_flow.height() * 0.01 * object_config.support_ironing_flow.value);
-        this->ironing_spacing = object_config.support_ironing_spacing;
+        this->ironing_spacing = std::max(IRONING_SPACING_MIN, object_config.support_ironing_spacing.value);
         this->ironing_pattern = object_config.support_ironing_pattern;
 
         // Calculate a minimum support layer height as a minimum over all extruders, but not smaller than 10um.

src/slic3r/GUI/ConfigManipulation.cpp

@@ -212,6 +212,30 @@ void ConfigManipulation::check_filament_max_volumetric_speed(DynamicPrintConfig
 
 }
 
+void ConfigManipulation::check_filament_ironing_spacing(DynamicPrintConfig *config)
+{
+    const auto *opt = config->option<ConfigOptionFloatsNullable>("filament_ironing_spacing");
+    if (opt == nullptr)
+        return;
+    std::vector<double> values = opt->values;
+    bool                reset  = false;
+    for (size_t i = 0; i < values.size(); ++i)
+        if (!opt->is_nil(i) && values[i] < IRONING_SPACING_MIN) {
+            values[i] = 0.1;
+            reset     = true;
+        }
+    if (!reset)
+        return;
+    const wxString     msg_text = _(L("Ironing spacing too small\nIt has been reset to 0.1"));
+    MessageDialog      dialog(nullptr, msg_text, "", wxICON_WARNING | wxOK);
+    DynamicPrintConfig new_conf = *config;
+    is_msg_dlg_already_exist    = true;
+    dialog.ShowModal();
+    new_conf.set_key_value("filament_ironing_spacing", new ConfigOptionFloatsNullable(values));
+    apply(config, &new_conf);
+    is_msg_dlg_already_exist = false;
+}
+
 void ConfigManipulation::check_chamber_temperature(DynamicPrintConfig* config)
 {
    bool support_chamber_temp_control=GUI::wxGetApp().preset_bundle->printers.get_selected_preset().config.opt_bool("support_chamber_temp_control");
@@ -334,7 +358,7 @@ void ConfigManipulation::update_print_fff_config(DynamicPrintConfig* config, con
     }
 
     //BBS: ironing_spacing shouldn't be too small or equal to zero
-    if (config->opt_float("ironing_spacing") < 0.05)
+    if (config->opt_float("ironing_spacing") < IRONING_SPACING_MIN)
     {
         const wxString msg_text = _(L("Ironing spacing too small\nIt has been reset to 0.1"));
         MessageDialog dialog(nullptr, msg_text, "", wxICON_WARNING | wxOK);
@@ -345,7 +369,7 @@ void ConfigManipulation::update_print_fff_config(DynamicPrintConfig* config, con
         apply(config, &new_conf);
         is_msg_dlg_already_exist = false;
     }
-    if (config->opt_float("support_ironing_spacing") < 0.05)
+    if (config->opt_float("support_ironing_spacing") < IRONING_SPACING_MIN)
     {
         const wxString msg_text = _(L("Ironing spacing too small\nIt has been reset to 0.1"));
         MessageDialog dialog(nullptr, msg_text, "", wxICON_WARNING | wxOK);

src/slic3r/GUI/ConfigManipulation.hpp

@@ -84,6 +84,7 @@ public:
     void    check_nozzle_temperature_initial_layer_range(DynamicPrintConfig* config, unsigned int variant_index);
     void    check_adaptive_pressure_advance_model(DynamicPrintConfig* config);
     void    check_filament_max_volumetric_speed(DynamicPrintConfig *config);
+    void    check_filament_ironing_spacing(DynamicPrintConfig *config);
     void    check_chamber_temperature(DynamicPrintConfig* config);
     void    check_chamber_minimal_temperature(DynamicPrintConfig* config);
     bool    check_layer_height(DynamicPrintConfig* config);

src/slic3r/GUI/Tab.cpp

@@ -4911,6 +4911,7 @@ void TabFilament::update()
         return; // ys_FIXME
 
     m_config_manipulation.check_filament_max_volumetric_speed(m_config);
+    m_config_manipulation.check_filament_ironing_spacing(m_config);
 
     m_update_cnt++;
 

tests/fff_print/test_fill.cpp

@@ -748,6 +748,61 @@ TEST_CASE("A region with ironing turned off is never ironed", "[Fill]")
     REQUIRE(Layer::choose_ironing_extruder(cfg, spiral_mode, /*is_topmost_layer=*/true) == -1);
 }
 
+// Ironing path count and total length in mm, over the whole object.
+static std::pair<size_t, double> ironing_extent(const Print &print)
+{
+    size_t paths  = 0;
+    double length = 0.;
+    for (const Layer *layer : print.objects().front()->layers())
+        for (const LayerRegion *region : layer->regions())
+            for (const ExtrusionEntity *entity : region->fills.flatten().entities)
+                if (ironing_role(entity->role())) {
+                    ++paths;
+                    length += unscale<double>(entity->length());
+                }
+    return {paths, length};
+}
+
+TEST_CASE("Ironing spacing below the minimum irons at the minimum spacing", "[Fill]")
+{
+    const std::string pattern      = GENERATE("rectilinear", "concentric");
+    const bool        via_filament = GENERATE(false, true);
+    const double      spacing      = GENERATE(0., 0.001);
+    CAPTURE(pattern, via_filament, spacing);
+
+    auto ironing_for = [&pattern, via_filament](double spacing) {
+        DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+        config.set_deserialize_strict({{"ironing_type", "top"},
+                                       {"ironing_pattern", pattern},
+                                       {"layer_height", 0.2}});
+        // The filament override replaces the process spacing, which stays at a usable value.
+        if (via_filament)
+            config.set_deserialize_strict({{"ironing_spacing", 0.1}, {"filament_ironing_spacing", spacing}});
+        else
+            config.set_deserialize_strict({{"ironing_spacing", spacing}});
+        Print print;
+        Slic3r::Test::init_and_process_print({Slic3r::Test::cube(20)}, print, config);
+        return ironing_extent(print);
+    };
+
+    const std::pair<size_t, double> clamped = ironing_for(spacing);
+    const std::pair<size_t, double> minimum = ironing_for(IRONING_SPACING_MIN);
+    REQUIRE(minimum.first > 0);
+    CHECK(clamped.first == minimum.first);
+    CHECK_THAT(clamped.second, Catch::Matchers::WithinRel(minimum.second, 1e-9));
+}
+
+TEST_CASE("Concentric fill at zero spacing returns without paths", "[Fill]")
+{
+    std::unique_ptr<Fill> filler(Fill::new_from_type(ipConcentric));
+    filler->spacing      = 0.;
+    filler->bounding_box = BoundingBox(Point(0, 0), Point::new_scale(10, 10));
+    FillParams params;
+    params.density = 1.f;
+    Surface surface(stTop, ExPolygon({Point(0, 0), Point::new_scale(10, 0), Point::new_scale(10, 10), Point::new_scale(0, 10)}));
+    CHECK(filler->fill_surface(&surface, params).empty());
+}
+
 TEST_CASE("Solid infill direction offsets every layer when no template is set", "[Fill]")
 {
     auto angles_for = [](int direction) {

tests/fff_print/test_helpers.cpp

@@ -225,7 +225,7 @@ DynamicPrintConfig multifilament_config(unsigned int filaments, std::initializer
 }
 
 void init_print(std::vector<TriangleMesh> &&meshes, Slic3r::Print &print, Slic3r::Model &model, const DynamicPrintConfig &config_in,
-                const std::vector<std::vector<ConfigBase::SetDeserializeItem>> *per_object_overrides, bool arrange)
+                const std::vector<std::vector<ConfigBase::SetDeserializeItem>> *per_object_overrides, bool arrange, size_t instances)
 {
 	DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
     config.apply(config_in);
@@ -236,6 +236,7 @@ void init_print(std::vector<TriangleMesh> &&meshes, Slic3r::Print &print, Slic3r
 		ModelObject *object = model.add_object();
 		object->name += "object.stl";
 		object->add_volume(std::move(t));
+		for (size_t i = 0; i < instances; ++i)
 			object->add_instance();
 
 		if (per_object_overrides && object_idx < per_object_overrides->size() && !(*per_object_overrides)[object_idx].empty()) {

tests/fff_print/test_helpers.hpp

@@ -72,9 +72,11 @@ Slic3r::Model model(const std::string& model_name, TriangleMesh&& _mesh);
 DynamicPrintConfig multifilament_config(unsigned int filaments,
     std::initializer_list<Slic3r::ConfigBase::SetDeserializeItem> extra = {});
 
-// Apply `meshes` and config to `print`/`model`; optional per-object overrides, auto-arranged unless `arrange` is false.
+// Apply `meshes` and config to `print`/`model`, each object with `instances` copies; optional per-object overrides,
+// auto-arranged unless `arrange` is false.
 void init_print(std::vector<TriangleMesh> &&meshes, Slic3r::Print &print, Slic3r::Model &model, const DynamicPrintConfig &config_in,
-    const std::vector<std::vector<Slic3r::ConfigBase::SetDeserializeItem>> *per_object_overrides = nullptr, bool arrange = true);
+    const std::vector<std::vector<Slic3r::ConfigBase::SetDeserializeItem>> *per_object_overrides = nullptr, bool arrange = true,
+    size_t instances = 1);
 void init_print(std::initializer_list<TestMesh> meshes, Slic3r::Print &print, Slic3r::Model &model, const Slic3r::DynamicPrintConfig &config_in = Slic3r::DynamicPrintConfig::full_print_config());
 void init_print(std::initializer_list<TriangleMesh> meshes, Slic3r::Print &print, Slic3r::Model &model, const Slic3r::DynamicPrintConfig &config_in = Slic3r::DynamicPrintConfig::full_print_config());
 void init_print(std::initializer_list<TestMesh> meshes, Slic3r::Print &print, Slic3r::Model &model, std::initializer_list<Slic3r::ConfigBase::SetDeserializeItem> config_items);

tests/fff_print/test_print.cpp

@@ -561,6 +561,40 @@ TEST_CASE("export_gcode writes G-code without a result pointer", "[Print][export
     REQUIRE_FALSE(gcode.empty());
 }
 
+TEST_CASE("Exporting a sliced print again gives the same G-code", "[Print][export_gcode][Regression]")
+{
+    const int instances = GENERATE(1, 3);
+    CAPTURE(instances);
+    DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+    TestMesh           mesh   = TestMesh::ipadstand;
+    SECTION("infill reversed by chaining") { config.set_deserialize_strict({{"sparse_infill_pattern", "gyroid"}}); }
+    SECTION("support reversed by chaining") {
+        mesh = TestMesh::overhang;
+        config.set_deserialize_strict({{"enable_support", true}, {"support_interface_pattern", "concentric"}});
+    }
+    Print print;
+    Model model;
+    Slic3r::Test::init_print({Slic3r::Test::mesh(mesh)}, print, model, config, nullptr, true, instances);
+
+    const auto export_without_timestamp = [&print]() {
+        std::string gcode = Slic3r::Test::gcode(print);
+        const size_t line = gcode.find("; generated by ");
+        REQUIRE(line != std::string::npos);
+        gcode.erase(line, gcode.find('\n', line) - line);
+        return gcode;
+    };
+    const std::string first  = export_without_timestamp();
+    const std::string second = export_without_timestamp();
+
+    // Shows the first differing line on failure.
+    const size_t diff       = std::mismatch(first.begin(), first.end(), second.begin(), second.end()).first - first.begin();
+    const size_t line_start = diff == 0 ? 0 : first.rfind('\n', diff - 1) + 1;
+    INFO("first export:  " << first.substr(line_start, first.find('\n', diff) - line_start));
+    INFO("second export: " << second.substr(line_start, second.find('\n', diff) - line_start));
+    CHECK(diff == first.size());
+    CHECK(first.size() == second.size());
+}
+
 TEST_CASE("Sequential printing follows model order", "[Print]")
 {
     // Two objects of different heights, taller one added first. Orca prints

tests/slic3rutils/slic3rutils_tests_main.cpp

@@ -1,39 +1,6 @@
 #include <catch2/catch_all.hpp>
 
 #include "slic3r/Utils/Http.hpp"
-#include "slic3r/Utils/OrcaCloudServiceAgent.hpp"
-
-namespace {
-
-nlohmann::json flat_session_json(const nlohmann::json& fields)
-{
-    nlohmann::json session = {
-        {"access_token", "test-token"},
-        {"user_id", "test-user-id"}
-    };
-    session.update(fields);
-    return session;
-}
-
-nlohmann::json nested_session_json(const nlohmann::json& metadata)
-{
-    return {
-        {"access_token", "test-token"},
-        {"user", {
-            {"id", "test-user-id"},
-            {"user_metadata", metadata}
-        }}
-    };
-}
-
-std::string resolved_display_name(const nlohmann::json& session)
-{
-    Slic3r::OrcaCloudServiceAgent agent("");
-    REQUIRE(agent.set_user_session(session, false));
-    return agent.get_user_nickname();
-}
-
-} // namespace
 
 TEST_CASE("Check SSL certificates paths", "[Http][NotWorking]") {
     
@@ -53,62 +20,6 @@ TEST_CASE("Check SSL certificates paths", "[Http][NotWorking]") {
     REQUIRE(status == 200);
 }
 
-TEST_CASE("Orca cloud flat session resolves display name consistently", "[OrcaCloudServiceAgent]")
-{
-    CHECK(resolved_display_name(flat_session_json({
-        {"username", "orca_username"},
-        {"display_name", "Display Name"},
-        {"nickname", "Nickname"}
-    })) == "Display Name");
-
-    CHECK(resolved_display_name(flat_session_json({
-        {"username", "orca_username"},
-        {"nickname", "Nickname"}
-    })) == "Nickname");
-
-    CHECK(resolved_display_name(flat_session_json({
-        {"username", "orca_username"},
-        {"full_name", "Full Name"}
-    })) == "Full Name");
-
-    CHECK(resolved_display_name(flat_session_json({
-        {"username", "orca_username"},
-        {"name", "Provider Name"}
-    })) == "Provider Name");
-
-    CHECK(resolved_display_name(flat_session_json({
-        {"username", "orca_username"}
-    })) == "orca_username");
-}
-
-TEST_CASE("Orca cloud nested session resolves display name consistently", "[OrcaCloudServiceAgent]")
-{
-    CHECK(resolved_display_name(nested_session_json({
-        {"username", "orca_username"},
-        {"display_name", "Display Name"},
-        {"nickname", "Nickname"}
-    })) == "Display Name");
-
-    CHECK(resolved_display_name(nested_session_json({
-        {"username", "orca_username"},
-        {"nickname", "Nickname"}
-    })) == "Nickname");
-
-    CHECK(resolved_display_name(nested_session_json({
-        {"username", "orca_username"},
-        {"full_name", "Full Name"}
-    })) == "Full Name");
-
-    CHECK(resolved_display_name(nested_session_json({
-        {"username", "orca_username"},
-        {"name", "Provider Name"}
-    })) == "Provider Name");
-
-    CHECK(resolved_display_name(nested_session_json({
-        {"username", "orca_username"}
-    })) == "orca_username");
-}
-
 TEST_CASE("Http digest authentication", "[Http][NotWorking]") {
     Slic3r::Http g = Slic3r::Http::get("https://httpbingo.org/digest-auth/auth/guest/guest");
 

tests/slic3rutils/test_orca_cloud_agent.cpp

@@ -27,6 +27,37 @@ std::unique_ptr<OrcaCloudServiceAgent> make_file_backed_agent(const fs::path& di
 
 fs::path secret_file(const fs::path& dir) { return dir / secret_constants::USER_SECRET_FILENAME; }
 
+nlohmann::json flat_session_json(const nlohmann::json& fields)
+{
+    nlohmann::json session = {
+        {"access_token", "test-token"},
+        {"user_id", "test-user-id"}
+    };
+    session.update(fields);
+    return session;
+}
+
+nlohmann::json nested_session_json(const nlohmann::json& metadata)
+{
+    return {
+        {"access_token", "test-token"},
+        {"user", {
+            {"id", "test-user-id"},
+            {"user_metadata", metadata}
+        }}
+    };
+}
+
+// set_user_session() persists the session, so it goes to a throwaway token file rather than the
+// system keychain of whoever runs the tests.
+std::string resolved_display_name(const nlohmann::json& session)
+{
+    ScopedTemporaryDir dir("orca-secret");
+    auto               agent = make_file_backed_agent(dir.path());
+    REQUIRE(agent->set_user_session(session, false));
+    return agent->get_user_nickname();
+}
+
 } // namespace
 
 TEST_CASE("Logging out removes the secret this instance saved", "[OrcaCloudServiceAgent]")
@@ -84,3 +115,59 @@ TEST_CASE("Logging out leaves a secret this instance could not read alone", "[Or
     agent->user_logout(false);
     CHECK(fs::exists(secret_file(dir.path())));
 }
+
+TEST_CASE("Orca cloud flat session resolves display name consistently", "[OrcaCloudServiceAgent]")
+{
+    CHECK(resolved_display_name(flat_session_json({
+        {"username", "orca_username"},
+        {"display_name", "Display Name"},
+        {"nickname", "Nickname"}
+    })) == "Display Name");
+
+    CHECK(resolved_display_name(flat_session_json({
+        {"username", "orca_username"},
+        {"nickname", "Nickname"}
+    })) == "Nickname");
+
+    CHECK(resolved_display_name(flat_session_json({
+        {"username", "orca_username"},
+        {"full_name", "Full Name"}
+    })) == "Full Name");
+
+    CHECK(resolved_display_name(flat_session_json({
+        {"username", "orca_username"},
+        {"name", "Provider Name"}
+    })) == "Provider Name");
+
+    CHECK(resolved_display_name(flat_session_json({
+        {"username", "orca_username"}
+    })) == "orca_username");
+}
+
+TEST_CASE("Orca cloud nested session resolves display name consistently", "[OrcaCloudServiceAgent]")
+{
+    CHECK(resolved_display_name(nested_session_json({
+        {"username", "orca_username"},
+        {"display_name", "Display Name"},
+        {"nickname", "Nickname"}
+    })) == "Display Name");
+
+    CHECK(resolved_display_name(nested_session_json({
+        {"username", "orca_username"},
+        {"nickname", "Nickname"}
+    })) == "Nickname");
+
+    CHECK(resolved_display_name(nested_session_json({
+        {"username", "orca_username"},
+        {"full_name", "Full Name"}
+    })) == "Full Name");
+
+    CHECK(resolved_display_name(nested_session_json({
+        {"username", "orca_username"},
+        {"name", "Provider Name"}
+    })) == "Provider Name");
+
+    CHECK(resolved_display_name(nested_session_json({
+        {"username", "orca_username"}
+    })) == "orca_username");
+}