Safeguard CLI mode get_at() config functions to prevent crash from missing filament_id

src/OrcaSlicer.cpp

@@ -6516,10 +6516,20 @@ int CLI::run(int argc, char **argv)
                 plate_data->nozzle_diameters = nozzle_diameter_str;
 
             for (auto it = plate_data->slice_filaments_info.begin(); it != plate_data->slice_filaments_info.end(); it++) {
+                // ConfigOptionVector::get_at() falls back to values.front() when the index is out of
+                // range, but that is undefined behavior when values is empty outright (e.g. filament_ids
+                // is never populated on a from-scratch slice with no --load-filaments) - guard every
+                // get_at() here on the vector actually having an entry at it->id before calling it.
+                bool valid_id = it->id >= 0;
                 std::string display_filament_type;
-                it->type  = m_print_config.get_filament_type(display_filament_type, it->id);
+                if (valid_id && filament_types && static_cast<size_t>(it->id) < filament_types->values.size())
-                it->color = filament_color ? filament_color->get_at(it->id) : "#FFFFFF";
+                    it->type = m_print_config.get_filament_type(display_filament_type, it->id);
-                it->filament_id = filament_id?filament_id->get_at(it->id):"";
+                it->color       = (valid_id && filament_color && static_cast<size_t>(it->id) < filament_color->values.size()) ?
+                                      filament_color->get_at(it->id) :
+                                      "#FFFFFF";
+                it->filament_id = (valid_id && filament_id && static_cast<size_t>(it->id) < filament_id->values.size()) ?
+                                      filament_id->get_at(it->id) :
+                                      "";
             }
 
             if (!plate_data->plate_thumbnail.is_valid()) {
@@ -7311,6 +7321,10 @@ bool CLI::setup(int argc, char **argv)
             m_config.option(optdef.first, true);
 
     set_data_dir(m_config.opt_string("datadir"));
+    if (!data_dir().empty() && !boost::filesystem::exists(data_dir())) {
+        boost::nowide::cerr << "Could not create data directory: " << data_dir() << std::endl;
+        return false;
+    }
 
     //FIXME Validating at this stage most likely does not make sense, as the config is not fully initialized yet.
     if (!validity.empty()) {
@@ -7423,6 +7437,10 @@ bool CLI::export_models(IO::ExportFormat format, std::string path_dir)
                 for (ModelObject* model_object : model.objects)
                 {
                     const std::string path = this->output_filepath(*model_object, index++, format, path_dir);
+                    if (path.empty()) {
+                        boost::nowide::cerr << "Could not create output directory for STL export" << std::endl;
+                        return false;
+                    }
                     success = Slic3r::store_stl(path.c_str(), model_object, true);
                     if (success)
                         BOOST_LOG_TRIVIAL(info) << "Model successfully exported to " << path << std::endl;
@@ -7548,8 +7566,19 @@ std::string CLI::output_filepath(const ModelObject &object, unsigned int index,
     output_path = subdir + "/"+file_name;
 
     boost::filesystem::path subdir_path(subdir);
-    if (!boost::filesystem::exists(subdir_path))
+    if (!boost::filesystem::exists(subdir_path)) {
-        boost::filesystem::create_directory(subdir_path);
+        try {
+            boost::filesystem::create_directories(subdir_path);
+        } catch (const boost::filesystem::filesystem_error &ex) {
+            BOOST_LOG_TRIVIAL(error) << __FUNCTION__ << ": failed to create output directory " << subdir_path.string() << ": " << ex.what();
+        }
+        if (!boost::filesystem::exists(subdir_path)) {
+            // Directory creation failed and won't succeed on a retry (same path, same cause) -
+            // signal failure now instead of letting every object in the model repeat the same
+            // doomed attempt and fail with a less specific "export failed" error later.
+            return std::string();
+        }
+    }
     return output_path;
 }
 

src/libslic3r/utils.cpp

@@ -310,7 +310,11 @@ void set_data_dir(const std::string &dir)
 {
     g_data_dir = dir;
     if (!g_data_dir.empty() && !boost::filesystem::exists(g_data_dir)) {
-       boost::filesystem::create_directory(g_data_dir);
+        try {
+            boost::filesystem::create_directories(g_data_dir);
+        } catch (const boost::filesystem::filesystem_error &ex) {
+            BOOST_LOG_TRIVIAL(error) << "set_data_dir: failed to create data directory " << g_data_dir << ": " << ex.what();
+        }
     }
 }