std::set_union expects its inputs to be sorted. (#13928)

* Ensure spiral lift positive quadrant

* check for printable area

* clamp area

* simpler version

* Adjust printable area bounds with safety safety margin

Added safety margin to printable area bounds calculations.

* increase safety margin

* Refactor safety margin calculations in GCodeWriter

* New Logic

Co-Authored-By: Ian Bassi <12130714+ianalexis@users.noreply.github.com>

---------

Co-authored-by: Ian Bassi <12130714+ianalexis@users.noreply.github.com>

src/OrcaSlicer.cpp

@@ -24,6 +24,8 @@
 #include <iostream>
 #include <math.h>
 #include <csignal>
+#include <atomic>
+#include <new>
 
 #if defined(__linux__) || defined(__LINUX__)
 #include <condition_variable>
@@ -7608,6 +7610,9 @@ LONG WINAPI VectoredExceptionHandler(PEXCEPTION_POINTERS pExceptionInfo)
 }*/
 
 #if defined(_MSC_VER) || defined(__MINGW32__)
+// Guards against a failed allocation inside the dump re-entering the new-handler.
+static std::atomic<bool> g_dump_in_progress{false};
+
 extern "C" {
     __declspec(dllexport) int __stdcall orcaslicer_main(int argc, wchar_t **argv)
     {
@@ -7626,10 +7631,22 @@ extern "C" {
         //AddVectoredExceptionHandler(1, CBaseException::UnhandledExceptionFilter);
         SET_DEFULTER_HANDLER();
 #endif
+        // Dump before unwinding, while the stack still names what asked for the memory. Throwing
+        // std::bad_alloc is standard-permitted here and is what reaches generic_exception_handle().
         std::set_new_handler([]() {
-            int *a = nullptr;
-            *a     = 0;
-            });
+            if (!g_dump_in_progress.exchange(true)) {
+                try {
+                    // A null EXCEPTION_POINTERS walks the calling thread as it stands.
+                    CBaseException base(GetCurrentProcess(), GetCurrentProcessId(), NULL, nullptr);
+                    base.ShowCallstack();
+                } catch (...) {
+                    // A failed dump must not displace the std::bad_alloc owed to the caller.
+                }
+                // ObjParser recovers from std::bad_alloc, so let a later one dump again.
+                g_dump_in_progress = false;
+            }
+            throw std::bad_alloc();
+        });
         // Call the UTF8 main.
         return CLI().run(argc, argv_ptrs.data());
     }

src/libslic3r/GCodeWriter.cpp

@@ -2,6 +2,8 @@
 #include "CustomGCode.hpp"
 #include "I18N.hpp"
 #include "PrintConfig.hpp"
+#include "ClipperUtils.hpp"
+#include "Line.hpp"
 #include <algorithm>
 #include <iomanip>
 #include <iostream>
@@ -99,9 +101,87 @@ void GCodeWriter::apply_print_config(const PrintConfig &print_config)
     m_max_jerk_z = LIMITS(machine_max_jerk_z);
     m_max_jerk_e = LIMITS(machine_max_jerk_e);
     m_resolution = print_config.resolution.value;
-
 #undef LIMITS
 #undef LIMITS_UINT
+    // Orca: capture the printable area(s) so a spiral lift can be skipped when its
+    // circle would leave the boundary and collide with the print limits. Full polygons
+    // are stored (not a bounding box) so the check stays correct for non-rectangular
+    // beds, and per-extruder areas are kept so printers with different boundaries per
+    // extruder use the right limit for whichever extruder is active.
+    auto to_scaled_polygon = [](const Pointfs &pts) {
+        Polygon poly;
+        poly.points.reserve(pts.size());
+        for (const Vec2d &p : pts)
+            poly.points.emplace_back(coord_t(scale_(p.x())), coord_t(scale_(p.y())));
+        poly.make_counter_clockwise();
+        return poly;
+    };
+
+    m_bed_printable_area.points.clear();
+    m_extruder_printable_areas.clear();
+
+    if (print_config.printable_area.values.size() >= 3)
+        m_bed_printable_area = to_scaled_polygon(print_config.printable_area.values);
+
+    const std::vector<Pointfs> &extruder_areas = print_config.extruder_printable_area.values;
+    if (!extruder_areas.empty()) {
+        m_extruder_printable_areas.resize(extruder_areas.size());
+        for (size_t i = 0; i < extruder_areas.size(); ++i) {
+            if (extruder_areas[i].size() < 3) {
+                // No dedicated area for this extruder: it can reach the whole bed.
+                m_extruder_printable_areas[i] = m_bed_printable_area;
+                continue;
+            }
+            Polygon extruder_poly = to_scaled_polygon(extruder_areas[i]);
+            if (m_bed_printable_area.points.size() < 3) {
+                m_extruder_printable_areas[i] = std::move(extruder_poly);
+                continue;
+            }
+            // The reachable area is the extruder area clipped to the bed. Bed shapes are
+            // convex in practice, so keep the largest resulting contour.
+            Polygons clipped = intersection(extruder_poly, m_bed_printable_area);
+            const Polygon *largest = nullptr;
+            double          best_area = 0.;
+            for (const Polygon &p : clipped) {
+                double a = std::abs(p.area());
+                if (a > best_area) { best_area = a; largest = &p; }
+            }
+            m_extruder_printable_areas[i] = largest ? *largest : std::move(extruder_poly);
+        }
+    }
+}
+
+const Polygon *GCodeWriter::active_printable_area() const
+{
+    if (const Extruder *e = this->filament()) {
+        size_t id = e->extruder_id();
+        if (id < m_extruder_printable_areas.size() && m_extruder_printable_areas[id].points.size() >= 3)
+            return &m_extruder_printable_areas[id];
+    }
+    if (m_bed_printable_area.points.size() >= 3)
+        return &m_bed_printable_area;
+    return nullptr;
+}
+
+bool GCodeWriter::spiral_lift_fits_printable_area(const Vec2d &center, double radius) const
+{
+    const Polygon *area = this->active_printable_area();
+    if (area == nullptr)
+        return true; // Boundary unknown: don't restrict (preserve previous behavior).
+
+    const Point  c        = Point::new_scale(center.x(), center.y());
+    const double r_scaled = scale_(radius);
+    const double r2       = r_scaled * r_scaled;
+
+    // The spiral traces a full circle of `radius` around `center`, so the center must lie
+    // inside the printable area and every edge must be at least `radius` away from it.
+    if (!area->contains(c))
+        return false;
+    const Points &pts = area->points;
+    for (size_t i = 0, n = pts.size(); i < n; ++i)
+        if (Line::distance_to_squared(c, pts[i], pts[(i + 1) % n]) < r2)
+            return false;
+    return true;
 }
 
 void GCodeWriter::set_extruders(std::vector<unsigned int> extruder_ids)
@@ -731,14 +811,19 @@ std::string GCodeWriter::eager_lift(const LiftType type) {
     }
 
     // BBS: spiral lift only safe with known position
-    // TODO: check the arc will move within bed area
     if (type == LiftType::SpiralLift && this->is_current_position_clear()) {
         double radius = target_lift / (2 * PI * atan(filament()->travel_slope()));
         // static spiral alignment when no move in x,y plane.
-        // spiral centra is a radius distance to the right (y=0) 
+        // spiral centra is a radius distance to the right (y=0)
         Vec2d ij_offset = { radius, 0 };
-        if (target_lift > 0) {
+        // Orca: keep the spiral inside the active extruder's printable area, otherwise
+        // fall back to a normal lift to avoid colliding with the print boundary. m_pos
+        // includes the plate offset, so remove it to match the printable area coordinates.
+        const Vec2d spiral_center = { m_pos.x() - m_x_offset + ij_offset.x(), m_pos.y() - m_y_offset + ij_offset.y() };
+        if (target_lift > 0 && this->spiral_lift_fits_printable_area(spiral_center, radius)) {
             lift_move = this->_spiral_travel_to_z(m_pos(2) + target_lift, ij_offset, "spiral lift Z");
+        } else if (target_lift > 0) {
+            lift_move = _travel_to_z(m_pos(2) + target_lift, "normal lift Z");
         }
     }
     //BBS: if position is unknown use normal lift
@@ -793,7 +878,15 @@ std::string GCodeWriter::travel_to_xyz(const Vec3d &point, const std::string &co
                 double radius = delta(2) / (2 * PI * atan(this->filament()->travel_slope()));
                 Vec2d ij_offset = radius * delta_no_z.normalized();
                 ij_offset = { -ij_offset(1), ij_offset(0) };
-                slop_move = this->_spiral_travel_to_z(target(2), ij_offset, "spiral lift Z");
+                // Orca: only perform the spiral lift if its full circle stays inside the
+                // printable area of the active extruder, otherwise fall back to a normal
+                // lift to avoid colliding with the print boundary. `source` is already in
+                // bed coordinates (plate offset removed), matching the printable area.
+                const Vec2d spiral_center = { source.x() + ij_offset.x(), source.y() + ij_offset.y() };
+                if (this->spiral_lift_fits_printable_area(spiral_center, radius))
+                    slop_move = this->_spiral_travel_to_z(target(2), ij_offset, "spiral lift Z");
+                else
+                    slop_move = _travel_to_z(target.z(), "normal lift Z");
             }
             //BBS: SlopeLift
             else if (m_to_lift_type == LiftType::SlopeLift &&

src/libslic3r/GCodeWriter.hpp

@@ -6,6 +6,7 @@
 #include <charconv>
 #include "Extruder.hpp"
 #include "Point.hpp"
+#include "Polygon.hpp"
 #include "PrintConfig.hpp"
 #include "GCode/CoolingBuffer.hpp"
 
@@ -181,6 +182,14 @@ public:
 
     // Orca: slicing resolution in mm
     double          m_resolution = 0.01;
+    // Orca: printable area polygons (scaled, bed coordinates) used to keep spiral lifts
+    // from colliding with the print boundary. m_extruder_printable_areas holds the
+    // per-extruder reachable area (intersected with the bed) when a printer defines
+    // different boundaries per extruder; m_bed_printable_area is the global fallback.
+    // Storing full polygons (rather than a bounding box) keeps the check correct for
+    // non-rectangular beds such as delta/circular printers.
+    Polygon              m_bed_printable_area;
+    std::vector<Polygon> m_extruder_printable_areas;
     
     std::string m_gcode_label_objects_start;
     std::string m_gcode_label_objects_end;
@@ -197,6 +206,10 @@ public:
 
     std::string _travel_to_z(double z, const std::string &comment);
     std::string _spiral_travel_to_z(double z, const Vec2d &ij_offset, const std::string &comment);
+    // Orca: printable area of the active extruder (per-extruder when configured, otherwise the bed). Null when unknown.
+    const Polygon *active_printable_area() const;
+    // Orca: true if a full spiral-lift circle (center in bed coordinates, mm) fits inside the active printable area.
+    bool spiral_lift_fits_printable_area(const Vec2d &center, double radius) const;
     std::string _retract(double length, double restart_extra, const std::string &comment);
     std::string set_acceleration_internal(Acceleration type, unsigned int acceleration);
 

src/libslic3r/Preset.cpp

@@ -3504,7 +3504,7 @@ inline t_config_option_keys deep_diff(const ConfigBase &config_this, const Confi
         if (this_opt != nullptr && other_opt != nullptr && *this_opt != *other_opt)
         {
             //BBS: add bed_exclude_area
-            if (opt_key == "printable_area" || opt_key == "bed_exclude_area" || opt_key == "compatible_prints" || opt_key == "compatible_printers" || opt_key == "thumbnails" ||  opt_key == "wrapping_exclude_area", "slicing_pipeline_plugin") {
+            if (opt_key == "printable_area" || opt_key == "bed_exclude_area" || opt_key == "compatible_prints" || opt_key == "compatible_printers" || opt_key == "thumbnails" ||  opt_key == "wrapping_exclude_area" || opt_key == "slicing_pipeline_plugin") {
                 // Scalar variable, or a vector variable, which is independent from number of extruders,
                 // thus the vector is presented to the user as a single input.
                 diff.emplace_back(opt_key);

src/libslic3r/Print.cpp

@@ -3605,7 +3605,8 @@ std::vector<std::set<int>> Print::get_physical_unprintable_filaments(const std::
         return physical_unprintables;
 
     auto get_unprintable_extruder_id = [&](unsigned int filament_idx) -> int {
-        int status = m_config.filament_printable.values[filament_idx];
+        // filament_printable may be shorter than the filament count; get_at() clamps.
+        int status = m_config.filament_printable.get_at(filament_idx);
         for (int i = 0; i < extruder_num; ++i) {
             if (!(status >> i & 1)) {
                 return i;

src/libslic3r/calib.cpp

@@ -771,6 +771,7 @@ CustomGCode::Info CalibPressureAdvancePattern::generate_custom_gcodes(const Dyna
         }
     }
 
+    gcode << m_writer.reset_e();
     gcode << m_writer.set_pressure_advance(m_params.start);
     gcode << "; end pressure advance pattern for layer\n";
 

src/libslic3r/calib.hpp

@@ -35,10 +35,10 @@ struct Calib_Params
 {
     Calib_Params() : mode(CalibMode::Calib_None){};
     int extruder_id = 0;
-    double    start, end, step;
-    bool      print_numbers;
-    double freqStartX, freqEndX, freqStartY, freqEndY;
-    int test_model;
+    double    start = 0.0, end = 1.0, step = 0.1;
+    bool      print_numbers = false;
+    double freqStartX = 0.0, freqEndX = 1.0, freqStartY = 0.0, freqEndY = 1.0;
+    int test_model = 0;
     std::string shaper_type;
     std::vector<double> accelerations;
     std::vector<double> speeds;

src/slic3r/GUI/DeviceCore/DevManager.cpp

@@ -558,6 +558,7 @@ namespace Slic3r
             }
             else
             {
+                Slic3r::GUI::wxGetApp().reset_unsigned_plugin_warning();
                 if (m_agent)
                 {
                     if (it->second->connection_type() != "lan" || it->second->connection_type().empty())

src/slic3r/GUI/Field.cpp

@@ -1043,14 +1043,14 @@ void TextCtrl::propagate_value()
 
 void TextCtrl::set_value(const boost::any& value, bool change_event/* = false*/) {
     m_disable_change_event = !change_event;
+
     if (m_opt.nullable) {
         const bool m_is_na_val = value.empty() || (boost::any_cast<wxString>(value) == _(L("N/A")));
         if (!m_is_na_val)
             m_last_meaningful_value = value;
-        text_ctrl()->SetValue(boost::any_cast<wxString>(value)); // BBS
     }
-    else
-        text_ctrl()->SetValue(value.empty() ? "" : boost::any_cast<wxString>(value)); // BBS // BBS: null value
+
+    text_ctrl()->SetValue(value.empty() ? wxString() : boost::any_cast<wxString>(value));
     m_disable_change_event = false;
 
     if (!change_event) {
@@ -1187,18 +1187,24 @@ void CheckBox::set_value(const boost::any& value, bool change_event)
     m_disable_change_event = !change_event;
     if (m_opt.nullable) {
         const bool is_value_unsigned_char = value.type() == typeid(unsigned char);
+        bool bool_value = false;
+
         m_is_na_val = value.empty() || (is_value_unsigned_char &&
                       boost::any_cast<unsigned char>(value) == ConfigOptionBoolsNullable::nil_value());
-        if (!m_is_na_val)
-            m_last_meaningful_value = is_value_unsigned_char ? value : static_cast<unsigned char>(boost::any_cast<bool>(value));
 
-        const auto bool_value = is_value_unsigned_char ?
-                                    boost::any_cast<unsigned char>(value) != 0 :
-                                    boost::any_cast<bool>(value);
-        dynamic_cast<::CheckBox*>(window)->SetValue(m_is_na_val ? false : bool_value); // BBS
+        if (!m_is_na_val) {
+            bool_value = is_value_unsigned_char ?
+                            boost::any_cast<unsigned char>(value) != 0 :
+                            boost::any_cast<bool>(value);
+            m_last_meaningful_value = is_value_unsigned_char ? value : static_cast<unsigned char>(bool_value);
+        }
+
+        dynamic_cast<::CheckBox*>(window)->SetValue(bool_value);
     }
-    else if (!value.empty()) // BBS: null value
+    else if (!value.empty()){ // BBS: null value
         dynamic_cast<::CheckBox*>(window)->SetValue(boost::any_cast<bool>(value)); // BBS
+    }
+
     dynamic_cast<::CheckBox*>(window)->SetHalfChecked(value.empty());
     m_disable_change_event = false;
 }

src/slic3r/GUI/GUI_App.cpp

@@ -6127,18 +6127,23 @@ bool GUI_App::process_network_msg(std::string dev_id, std::string msg)
         }
         else if (msg == "unsigned_studio") {
             BOOST_LOG_TRIVIAL(info) << "process_network_msg, unsigned_studio";
-            MessageDialog
-                msg_dlg(nullptr,
-                        _L("To use OrcaSlicer with Bambu Lab printers, you need to enable LAN mode and Developer mode on your printer.\n\n"
-                           "Please go to your printer's settings and:\n"
-                           "1. Turn on LAN mode\n"
-                           "2. Enable Developer mode\n\n"
-                           "Developer mode allows the printer to work exclusively through local network access, "
-                           "enabling full functionality with OrcaSlicer."),
-                        _L("Network Plug-in Restriction"), wxAPPLY | wxOK);
-            m_show_error_msgdlg = true;
-            msg_dlg.ShowModal();
-            m_show_error_msgdlg = false;
+            // Plugin re-emits this on every subscribe retry; latch it so it shows
+            // once per connection episode.
+            if (!m_show_error_msgdlg && !m_unsigned_plugin_warning_shown) {
+                m_unsigned_plugin_warning_shown = true;
+                MessageDialog
+                    msg_dlg(nullptr,
+                            _L("To use OrcaSlicer with Bambu Lab printers, you need to enable LAN mode and Developer mode on your printer.\n\n"
+                               "Please go to your printer's settings and:\n"
+                               "1. Turn on LAN mode\n"
+                               "2. Enable Developer mode\n\n"
+                               "Developer mode allows the printer to work exclusively through local network access, "
+                               "enabling full functionality with OrcaSlicer."),
+                            _L("Network Plug-in Restriction"), wxAPPLY | wxOK);
+                m_show_error_msgdlg = true;
+                msg_dlg.ShowModal();
+                m_show_error_msgdlg = false;
+            }
             return true;
         }
     }

src/slic3r/GUI/GUI_App.hpp

@@ -343,6 +343,7 @@ private:
 public:
     //try again when subscription fails
     void            on_start_subscribe_again(std::string dev_id);
+    void            reset_unsigned_plugin_warning() { m_unsigned_plugin_warning_shown = false; }
     std::string     get_local_models_path();
     bool            OnInit() override;
     int             OnExit() override;

src/slic3r/GUI/Tab.cpp

@@ -3299,7 +3299,19 @@ static std::vector<std::string> intersect(std::vector<std::string> const& l, std
 static std::vector<std::string> concat(std::vector<std::string> const& l, std::vector<std::string> const& r)
 {
     std::vector<std::string> t;
-    std::set_union(l.begin(), l.end(), r.begin(), r.end(), std::back_inserter(t));
+    bool l_is_sorted = std::is_sorted(l.begin(), l.end());
+    bool r_is_sorted = std::is_sorted(r.begin(), r.end());
+
+    if (l_is_sorted && r_is_sorted) {
+        std::set_union(l.begin(), l.end(), r.begin(), r.end(), std::back_inserter(t));
+        return t;
+    }
+
+    std::vector<std::string> l_sorted = l;
+    std::vector<std::string> r_sorted = r;
+    std::sort(l_sorted.begin(), l_sorted.end());
+    std::sort(r_sorted.begin(), r_sorted.end());
+    std::set_union(l_sorted.begin(), l_sorted.end(), r_sorted.begin(), r_sorted.end(), std::back_inserter(t));
     return t;
 }
 

src/slic3r/GUI/TroubleshootDialog.cpp

@@ -186,7 +186,7 @@ TroubleshootDialog::TroubleshootDialog()
         Fit();
     });
 
-    auto link_wiki = new HyperLink(this, _L("Wiki Guide"));
+    auto link_wiki = new HyperLink(this, _L("Wiki Guide"), "https://www.orcaslicer.com/wiki/troubleshoot_center");
 
     // RIGHT SIZER //////////////////////
 

tests/libslic3r/test_calib.cpp

@@ -1,5 +1,9 @@
 #include <catch2/catch_all.hpp>
 
+#include <algorithm>
+#include <sstream>
+#include <string>
+
 #include "libslic3r/calib.hpp"
 #include "libslic3r/Model.hpp"
 #include "libslic3r/TriangleMesh.hpp"
@@ -38,3 +42,69 @@ TEST_CASE("Zero calibration line width resolves to a positive default", "[Calib]
     REQUIRE(pattern.line_width() > 0.);
     REQUIRE(pattern.line_width_first_layer() > 0.);
 }
+
+namespace {
+
+struct EndState { double final_e; double max_e; };
+
+EndState simulate_absolute_e(const std::string &gcode)
+{
+    double final_e = 0.;
+    double max_e   = 0.;
+
+    std::istringstream lines(gcode);
+    std::string        line;
+    while (std::getline(lines, line)) {
+        std::istringstream words(line);
+        std::string        op;
+        if (!(words >> op))
+            continue;
+        if (op != "G1" && op != "G0" && op != "G92")
+            continue;
+
+        std::string word;
+        while (words >> word) {
+            if (word.size() >= 2 && word[0] == 'E') {
+                final_e = std::stod(word.substr(1));
+                max_e   = std::max(max_e, final_e);
+                break;
+            }
+        }
+    }
+
+    return {final_e, max_e};
+}
+
+} // namespace
+
+TEST_CASE("PA pattern resets the extruder after the final layer in absolute E mode", "[Calib][Regression]")
+{
+    DynamicPrintConfig config = DynamicPrintConfig::full_print_config();
+    config.set_deserialize_strict({
+        {"use_relative_e_distances", "0"},
+        {"line_width", "0.45"},
+        {"initial_layer_line_width", "0.45"},
+    });
+
+    Model model;
+    model.add_object("cube", "", make_cube(20, 20, 20))->add_instance();
+
+    Calib_Params params;
+    params.mode  = CalibMode::Calib_PA_Pattern;
+    params.start = 0.;
+    params.end   = 0.08;
+    params.step  = 0.002;
+
+    CalibPressureAdvancePattern pattern(params, config, /* is_bbl_machine */ false, *model.objects.front(), Vec3d(0, 0, 0));
+    const CustomGCode::Info     info = pattern.generate_custom_gcodes(config, /* is_bbl_machine */ false, *model.objects.front(),
+                                                                      Vec3d(0, 0, 0));
+
+    std::string gcode;
+    for (const CustomGCode::Item &item : info.gcodes)
+        gcode += item.extra;
+
+    const EndState state = simulate_absolute_e(gcode);
+
+    REQUIRE(state.max_e > 1.);
+    REQUIRE_THAT(state.final_e, Catch::Matchers::WithinAbs(0., 1e-9));
+}