fix(mixed): normalize incomplete mixed metadata before adding filaments (Orca #15728 adapt)

src/libslic3r/MixedFilament.cpp

@@ -2646,6 +2646,68 @@ void MixedFilamentManager::load_custom_entries(const std::string &serialized, co
                             << ", mixed_total=" << m_mixed.size();
 }
 
+std::string MixedFilamentManager::clamp_serialized_entries_to_physical_count(const std::string &serialized, size_t num_physical)
+{
+    if (serialized.empty() || num_physical < 2)
+        return {};
+
+    std::ostringstream out;
+    bool first = true;
+    size_t kept = 0;
+    size_t dropped = 0;
+    std::stringstream all(serialized);
+    std::string row;
+    while (std::getline(all, row, ';')) {
+        if (row.empty())
+            continue;
+
+        unsigned int a = 0;
+        unsigned int b = 0;
+        uint64_t stable_id = 0;
+        bool enabled = true;
+        bool custom = true;
+        bool origin_auto = false;
+        int mix = 50;
+        bool pointillism_all_filaments = false;
+        std::string gradient_component_ids;
+        std::string gradient_component_weights;
+        std::string manual_pattern;
+        int distribution_mode = int(MixedFilament::Simple);
+        int local_z_max_sublayers = 0;
+        float component_a_surface_offset = 0.f;
+        float component_b_surface_offset = 0.f;
+        bool deleted = false;
+        bool gradient_enabled = false;
+        float gradient_start = 0.8f;
+        float gradient_end   = 0.2f;
+        int   cm_mode = -1;
+        std::string image_fill_ref;
+        if (!parse_row_definition(row, a, b, stable_id, enabled, custom, origin_auto, mix, pointillism_all_filaments,
+                                  gradient_component_ids, gradient_component_weights, manual_pattern, distribution_mode,
+                                  local_z_max_sublayers, component_a_surface_offset, component_b_surface_offset, deleted,
+                                  gradient_enabled, gradient_start, gradient_end, cm_mode, image_fill_ref) ||
+            a == 0 || b == 0 || a > num_physical || b > num_physical || a == b ||
+            mixed_filament_references_exceed_physical(gradient_component_ids, manual_pattern, num_physical)) {
+            ++dropped;
+            continue;
+        }
+
+        if (!first)
+            out << ';';
+        first = false;
+        out << row;
+        ++kept;
+    }
+
+    if (dropped > 0)
+        BOOST_LOG_TRIVIAL(info) << "MixedFilamentManager::clamp_serialized_entries_to_physical_count"
+                                << ", physical_count=" << num_physical
+                                << ", kept_rows=" << kept
+                                << ", dropped_rows=" << dropped;
+
+    return out.str();
+}
+
 unsigned int MixedFilamentManager::resolve(unsigned int filament_id,
                                            size_t       num_physical,
                                            int          layer_index,

src/libslic3r/MixedFilament.hpp

@@ -291,6 +291,14 @@ class MixedFilamentManager
     std::string serialize_custom_entries();
     void load_custom_entries(const std::string &serialized, const std::vector<std::string> &filament_colours);
 
+    // Drop serialized mixed rows whose components (or gradient/pattern tokens)
+    // reference physical IDs beyond num_physical. Valid custom rows that still
+    // fit are kept verbatim. Empty input, or fewer than two physical slots,
+    // yields an empty string — mixed pairs cannot exist in that state.
+    // Edge analog of Orca #15728 resize_mixed_filament_metadata (truncate stale
+    // tails before grow); this project does not use filament_is_mixed arrays.
+    static std::string clamp_serialized_entries_to_physical_count(const std::string &serialized, size_t num_physical);
+
     // ---- Pattern string functions -------------------------------------------
     // Normalize a manual mixed-pattern string into canonical form.
     // Format: digits 1-9 for IDs 1-9, [N] for IDs >= 10, comma for group separator.

src/libslic3r/PresetBundle.cpp

@@ -178,6 +178,26 @@ void EraseFilamentColorFields(DynamicPrintConfig &config, size_t index)
     EnsureFilamentColorFieldsAligned(config);
 }
 
+// Clamp mixed_filament_definitions in project (and optional print) config to the
+// current physical slot count. Orphan tails that reference IDs beyond that count
+// are discarded so a later grow cannot resurrect them as phantom mixed rows.
+void normalize_mixed_filament_definitions(DynamicPrintConfig &project_config,
+                                          DynamicPrintConfig *print_cfg,
+                                          size_t              physical_count)
+{
+    auto clamp_opt = [physical_count](DynamicPrintConfig &cfg) {
+        if (ConfigOptionString *opt = cfg.option<ConfigOptionString>("mixed_filament_definitions")) {
+            const std::string clamped =
+                MixedFilamentManager::clamp_serialized_entries_to_physical_count(opt->value, physical_count);
+            if (clamped != opt->value)
+                opt->value = clamped;
+        }
+    };
+    clamp_opt(project_config);
+    if (print_cfg != nullptr)
+        clamp_opt(*print_cfg);
+}
+
 } // namespace
 
 static std::vector<std::string> s_project_options {
@@ -2178,8 +2198,18 @@ void PresetBundle::update_num_filaments(unsigned int to_del_filament_id)
     update_multi_material_filament_presets(to_del_filament_id, old_filament_count);
 }
 
+size_t PresetBundle::num_physical_filaments() const
+{
+    if (const auto *colors = project_config.option<ConfigOptionStrings>("filament_colour")) {
+        if (!colors->values.empty())
+            return colors->values.size();
+    }
+    return filament_presets.size();
+}
+
 void PresetBundle::set_num_filaments(unsigned int n, std::vector<std::string> new_colors) {
-    int old_filament_count = this->filament_presets.size();
+    const unsigned old_filament_count = unsigned(this->filament_presets.size());
+    const size_t   old_slot_count     = this->num_physical_filaments();
     if (n > old_filament_count && old_filament_count != 0)
         filament_presets.resize(n, filament_presets.back());
     else {
@@ -2190,21 +2220,27 @@ void PresetBundle::set_num_filaments(unsigned int n, std::vector<std::string> ne
     ams_multi_color_filment.resize(n);
     EnsureFilamentColorFieldsAligned(project_config);
     // BBS set new filament color to new_color
-    if (old_filament_count < n) {
+    if (old_slot_count < n) {
         if (!new_colors.empty()) {
             ConfigOptionStrings *multi_colors = project_config.option<ConfigOptionStrings>("filament_multi_colors", true);
-            for (int i = old_filament_count; i < n; i++) {
-                filament_color->values[i] = new_colors[i - old_filament_count];
-                multi_colors->values[i] = new_colors[i - old_filament_count];
+            for (size_t i = old_slot_count; i < n; i++) {
+                filament_color->values[i] = new_colors[i - old_slot_count];
+                multi_colors->values[i] = new_colors[i - old_slot_count];
             }
             EnsureFilamentColorFieldsAligned(project_config);
         }
     }
-    update_multi_material_filament_presets(size_t(-1), size_t(old_filament_count));
+    // Palette may already have been written (batch-match / #866); presets still hold the old
+    // physical count and must drive remap. Otherwise colours are the configured slot count.
+    const size_t remap_old = (old_slot_count > old_filament_count && old_filament_count != 0)
+        ? size_t(old_filament_count)
+        : old_slot_count;
+    update_multi_material_filament_presets(size_t(-1), remap_old);
 }
 void PresetBundle::set_num_filaments(unsigned int n, std::string new_color)
 {
-    int old_filament_count = this->filament_presets.size();
+    const unsigned old_filament_count = unsigned(this->filament_presets.size());
+    const size_t   old_slot_count     = this->num_physical_filaments();
     if (n > old_filament_count && old_filament_count != 0)
         filament_presets.resize(n, filament_presets.back());
     else {
@@ -2217,18 +2253,21 @@ void PresetBundle::set_num_filaments(unsigned int n, std::string new_color)
     EnsureFilamentColorFieldsAligned(project_config);
 
     //BBS set new filament color to new_color
-    if (old_filament_count < n) {
+    if (old_slot_count < n) {
         if (!new_color.empty()) {
             ConfigOptionStrings *multi_colors = project_config.option<ConfigOptionStrings>("filament_multi_colors", true);
-            for (int i = old_filament_count; i < n; i++) {
+            for (size_t i = old_slot_count; i < n; i++) {
                 filament_color->values[i] = new_color;
                 multi_colors->values[i] = new_color;
             }
             EnsureFilamentColorFieldsAligned(project_config);
         }
     }
 
-    update_multi_material_filament_presets(size_t(-1), size_t(old_filament_count));
+    const size_t remap_old = (old_slot_count > old_filament_count && old_filament_count != 0)
+        ? size_t(old_filament_count)
+        : old_slot_count;
+    update_multi_material_filament_presets(size_t(-1), remap_old);
 }
 
 unsigned int PresetBundle::sync_ams_list(unsigned int &unknowns)
@@ -3025,6 +3064,12 @@ void PresetBundle::load_config_file_config(const std::string &name_or_path, bool
         // 4) Load the project config values (the per extruder wipe matrix etc).
         this->project_config.apply_only(config, s_project_options);
         EnsureFilamentColorFieldsAligned(this->project_config);
+        // Older projects can carry mixed_filament_definitions that no longer match the
+        // physical colour slots (short, missing, or a stale tail from a larger slot count).
+        // Clamp now so a later add-filament grow cannot resurrect orphan mixed rows.
+        normalize_mixed_filament_definitions(this->project_config,
+                                             &this->prints.get_edited_preset().config,
+                                             num_filaments);
 
         break;
     }
@@ -3796,6 +3841,16 @@ void PresetBundle::update_multi_material_filament_presets(size_t to_delete_filam
             lower_bound = std::max(0.01f, lower_bound);
             upper_bound = std::max(lower_bound, upper_bound);
 
+            // Grow must clamp mixed defs to the *old* physical count first: a stale tail
+            // that named the not-yet-added slot would otherwise be accepted as a custom row.
+            // Shrink/same clamp to the current count so orphan IDs are dropped.
+            if (!deleting_filament) {
+                const size_t mixed_defs_limit = (num_filaments > old_num_filaments)
+                    ? old_num_filaments
+                    : num_filaments;
+                normalize_mixed_filament_definitions(this->project_config, &print_cfg, mixed_defs_limit);
+            }
+
             this->mixed_filaments.clear_custom_entries();
             this->mixed_filaments.load_custom_entries(
                 deleting_filament ? post_delete_mixed_defs : get_mixed_string("mixed_filament_definitions"),

src/libslic3r/PresetBundle.hpp

@@ -136,6 +136,9 @@ class PresetBundle
     void            set_num_filaments(unsigned int n, std::string new_col = "");
     void            set_num_filaments(unsigned int n, std::vector<std::string> new_colors);
     void            update_num_filaments(unsigned int to_del_filament_id);
+    // Physical slot count. filament_colour is the source of truth; mixed_filament_definitions
+    // and a topped-up filament_presets list must not invent extra slots (Orca #15728 adapt).
+    size_t          num_physical_filaments() const;
     unsigned int sync_ams_list(unsigned int & unknowns);
     //BBS: check whether this is the only edited filament
     bool is_the_only_edited_filament(unsigned int filament_index);

src/slic3r/GUI/Plater.cpp

@@ -3254,12 +3254,15 @@ Sidebar::Sidebar(Plater *parent)
     ScalableButton* add_btn = new ScalableButton(p->m_panel_physical_filaments_title, wxID_ANY, "add_filament");
     add_btn->SetToolTip(_L("Add one filament"));
     add_btn->Bind(wxEVT_BUTTON, [this](wxCommandEvent& e){
-        if (p->combos_filament.size() >= MAXIMUM_EXTRUDER_NUMBER)
-            return;
         PresetBundle* pb = wxGetApp().preset_bundle;
-        if (!pb || pb->mixed_filaments.total_filaments(p->combos_filament.size()) >= MAXIMUM_FILAMENT_NUMBER)
+        // Colour slots are the physical count; combos can lag the extruder-count spinner
+        // and mixed_filament_definitions must not invent extra slots (Orca #15728 adapt).
+        const size_t physical_count = pb ? pb->num_physical_filaments() : p->combos_filament.size();
+        if (physical_count >= MAXIMUM_EXTRUDER_NUMBER)
+            return;
+        if (!pb || pb->mixed_filaments.total_filaments(physical_count) >= MAXIMUM_FILAMENT_NUMBER)
             return;
-        int filament_count = p->combos_filament.size() + 1;
+        int filament_count = int(physical_count) + 1;
         wxGetApp().plater()->confirm_auto_generated_gradients(filament_count);
         wxColour new_col = Plater::get_next_color_for_filament();
         std::string new_color = new_col.GetAsString(wxC2S_HTML_SYNTAX).ToStdString();
@@ -8426,9 +8429,10 @@ PlaterPresetComboBox* Sidebar::combo_printer() { return p->combo_printer; }
 PlaterPresetComboBox* Sidebar::combo_print() { return p->combo_print; }
 
 void Sidebar::add_filament() {
-    if (p->combos_filament.size() >= MAXIMUM_EXTRUDER_NUMBER) return;
     PresetBundle* pb = wxGetApp().preset_bundle;
-    if (!pb || pb->mixed_filaments.total_filaments(p->combos_filament.size()) >= MAXIMUM_FILAMENT_NUMBER) return;
+    const size_t physical_count = pb ? pb->num_physical_filaments() : p->combos_filament.size();
+    if (physical_count >= MAXIMUM_EXTRUDER_NUMBER) return;
+    if (!pb || pb->mixed_filaments.total_filaments(physical_count) >= MAXIMUM_FILAMENT_NUMBER) return;
     wxColour    new_col        = Plater::get_next_color_for_filament();
     add_custom_filament(new_col);
     // Reveal the just-added filament: it is appended at the end of the (height-capped,
@@ -9319,11 +9323,14 @@ void Sidebar::cleanup_unused_filaments_after_batch_match(const BatchMatchResult
 }
 
 void Sidebar::add_custom_filament(wxColour new_col) {
-    if (p->combos_filament.size() >= MAXIMUM_EXTRUDER_NUMBER) return;
     PresetBundle* pb = wxGetApp().preset_bundle;
-    if (!pb || pb->mixed_filaments.total_filaments(p->combos_filament.size()) >= MAXIMUM_FILAMENT_NUMBER) return;
+    // Count configured colour slots, not the combo widgets or mixed definitions:
+    // the extruder-count spinner can reach this before the sidebar has rebuilt.
+    const size_t physical_count = pb ? pb->num_physical_filaments() : p->combos_filament.size();
+    if (physical_count >= MAXIMUM_EXTRUDER_NUMBER) return;
+    if (!pb || pb->mixed_filaments.total_filaments(physical_count) >= MAXIMUM_FILAMENT_NUMBER) return;
 
-    int         filament_count = p->combos_filament.size() + 1;
+    int         filament_count = int(physical_count) + 1;
     wxGetApp().plater()->confirm_auto_generated_gradients(filament_count);
     std::string new_color      = new_col.GetAsString(wxC2S_HTML_SYNTAX).ToStdString();
     pb->set_num_filaments(filament_count, new_color);