bambu-printer-mcp 1.0.8 → 1.1.2

package/src/slicer/profile-flatten.ts

@@ -0,0 +1,562 @@
+/**
+ * BambuStudio CLI profile flattener.
+ *
+ * Background: BambuStudio's bundled profile JSONs (Resources/profiles/BBL/...)
+ * use an `inherits` chain that the GUI resolves at runtime but the CLI does
+ * not. Passing a leaf profile straight to `--load-settings` / `--load-filaments`
+ * yields a partial config and the slicer asserts (e.g. `nozzle_volume_type
+ * not found` -> SIGSEGV / assertion in MutablePolygon.cpp / Geometry.hpp).
+ * See https://github.com/bambulab/BambuStudio/issues/9636 and #9968.
+ *
+ * This module:
+ *   1. Indexes every BBL profile JSON by its `name` field.
+ *   2. Recursively walks `inherits`, deep-merging parent into child.
+ *   3. Derives `nozzle_volume_type` from `default_nozzle_volume_type[0]`
+ *      (the GUI does this implicitly; the CLI doesn't).
+ *   4. Merges CLI-specific machine_limits from `BBL/cli_config.json` so the
+ *      printer doesn't run unsafe accelerations / jerks.
+ *   5. Writes the flattened JSON to a temp file the caller passes to
+ *      BambuStudio CLI.
+ *
+ * BBL only. Other vendors are out of scope and rejected explicitly so we
+ * fail loud rather than producing dangerous gcode for hardware we don't own.
+ */
+
+import fs from "node:fs/promises";
+import path from "node:path";
+import crypto from "node:crypto";
+
+export type ProfileKind = "machine" | "process" | "filament";
+
+export interface FlattenedProfiles {
+  machinePath: string;
+  processPath: string;
+  filamentPaths: string[];
+  /** Diagnostics for callers / logs. Not part of the slicer invocation. */
+  meta: {
+    profilesRoot: string;
+    machineLeafName: string;
+    processLeafName: string;
+    filamentLeafNames: string[];
+    cliOverlayApplied: boolean;
+  };
+}
+
+export interface FlattenOptions {
+  /** e.g. "Bambu Lab H2S 0.4 nozzle" */
+  machineLeaf: string;
+  /** e.g. "0.20mm Standard @BBL H2S" */
+  processLeaf: string;
+  /** e.g. ["Bambu PLA Basic @BBL H2S"] */
+  filamentLeaves: string[];
+  /** Absolute path to `.../Resources/profiles`. */
+  profilesRoot: string;
+  /** Where to write flattened temp files. */
+  tempDir: string;
+  /** Vendor subdir under profilesRoot. Currently only "BBL" supported. */
+  vendor?: string;
+  /**
+   * Override for installed nozzle flow type. The printer reports this on
+   * boot from its physical nozzle scan; both nozzles always match (you
+   * can't mix Standard + High Flow, just like you can't mix 0.2 + 0.4).
+   * If omitted we use `default_nozzle_volume_type` from the profile tree
+   * (= "Standard" on stock BBL machines). Pass "High Flow" when HF
+   * nozzles are installed.
+   */
+  nozzleVolumeType?: "Standard" | "High Flow";
+  /** BambuStudio display name, e.g. "Textured PEI Plate" or "Cool Plate". */
+  bedType?: string;
+}
+
+interface IndexedProfile {
+  filePath: string;
+  data: Record<string, unknown>;
+}
+
+type NameIndex = Map<string, IndexedProfile>;
+
+/* -------------------------------------------------------------------------- */
+/* Indexing                                                                    */
+/* -------------------------------------------------------------------------- */
+
+/**
+ * Build a name -> {filePath, data} map for every JSON in
+ * <profilesRoot>/<vendor>/{machine,process,filament}/.
+ *
+ * The `name` field inside each JSON is the lookup key (this is what
+ * `inherits` references). We index every file, including non-instantiable
+ * abstract bases like `fdm_machine_common` and `fdm_bbl_3dp_001_common`,
+ * because those are the parents we'll walk to.
+ */
+async function buildNameIndex(
+  profilesRoot: string,
+  vendor: string
+): Promise<NameIndex> {
+  const index: NameIndex = new Map();
+  const subdirs: ProfileKind[] = ["machine", "process", "filament"];
+
+  for (const sub of subdirs) {
+    const dir = path.join(profilesRoot, vendor, sub);
+    let entries: string[];
+    try {
+      entries = await fs.readdir(dir);
+    } catch {
+      // Vendor or subdir missing -- skip silently; flatten will fail later
+      // with a precise "name not found" error.
+      continue;
+    }
+    for (const entry of entries) {
+      if (!entry.endsWith(".json")) continue;
+      const filePath = path.join(dir, entry);
+      let raw: string;
+      try {
+        raw = await fs.readFile(filePath, "utf8");
+      } catch {
+        continue;
+      }
+      let data: Record<string, unknown>;
+      try {
+        data = JSON.parse(raw) as Record<string, unknown>;
+      } catch {
+        // Malformed profile -- skip, don't poison the index.
+        continue;
+      }
+      const name = data["name"];
+      if (typeof name !== "string" || name.length === 0) continue;
+      // First-write wins. BBL doesn't have name collisions in practice;
+      // log if it ever does so we notice.
+      if (!index.has(name)) {
+        index.set(name, { filePath, data });
+      }
+    }
+  }
+
+  return index;
+}
+
+/* -------------------------------------------------------------------------- */
+/* Inheritance walk + merge                                                    */
+/* -------------------------------------------------------------------------- */
+
+/**
+ * Resolve the full inheritance chain for `leafName` and return a single
+ * deep-merged object. Child wins on key collision.
+ *
+ * Throws on:
+ *   - Unknown name (broken `inherits` reference).
+ *   - Cycles (A -> B -> A).
+ */
+function flattenByName(leafName: string, index: NameIndex): Record<string, unknown> {
+  const chain: Record<string, unknown>[] = [];
+  const visited = new Set<string>();
+  let cursor: string | undefined = leafName;
+
+  while (cursor) {
+    if (visited.has(cursor)) {
+      throw new Error(
+        `Profile inheritance cycle detected at "${cursor}" (chain: ${[...visited].join(" -> ")})`
+      );
+    }
+    visited.add(cursor);
+
+    const entry = index.get(cursor);
+    if (!entry) {
+      throw new Error(
+        `Profile "${cursor}" not found in index. ` +
+          `Inherits chain so far: ${[...visited].join(" -> ")}. ` +
+          `This usually means the leaf name is misspelled or the profile tree is incomplete.`
+      );
+    }
+
+    chain.push(entry.data);
+    const parent = entry.data["inherits"];
+    cursor = typeof parent === "string" && parent.length > 0 ? parent : undefined;
+  }
+
+  // Merge root-most parent first, leaf last (so leaf wins).
+  const merged: Record<string, unknown> = {};
+  for (let i = chain.length - 1; i >= 0; i--) {
+    Object.assign(merged, chain[i]);
+  }
+  return merged;
+}
+
+/* -------------------------------------------------------------------------- */
+/* CLI post-processing                                                         */
+/* -------------------------------------------------------------------------- */
+
+/**
+ * Bambu's CLI looks up `nozzle_volume_type`, but the profile tree only
+ * defines `default_nozzle_volume_type`. The GUI propagates the latter
+ * (or the value reported by the printer's nozzle scan on boot) into the
+ * former at runtime. We do the same.
+ *
+ * Shape: array of strings, one entry per physical nozzle. Hardware
+ * invariant from Bambu: BOTH nozzles must match (same diameter, same
+ * flow type) -- you cannot install 0.2 + 0.4, and you cannot install
+ * Standard + High Flow. So the array always contains identical entries.
+ *
+ * Verified against a GUI-sliced H2D project_settings.config:
+ *   ["High Flow", "High Flow"]   (dual-nozzle, HF installed)
+ *   ["Standard", "Standard"]     (dual-nozzle, stock)
+ *   ["Standard"]                 (single-extruder default)
+ *
+ * Override priority:
+ *   1. Caller-supplied `nozzleVolumeType` (e.g. printer reported HF).
+ *   2. Existing `nozzle_volume_type` already in the flattened profile.
+ *   3. `default_nozzle_volume_type` from the profile tree.
+ *   4. ["Standard"] x extruder count.
+ */
+function deriveNozzleVolumeType(
+  flat: Record<string, unknown>,
+  override?: "Standard" | "High Flow"
+): void {
+  if (override) {
+    const count = inferExtruderCount(flat);
+    flat["nozzle_volume_type"] = Array(count).fill(override);
+    return;
+  }
+
+  if (Array.isArray(flat["nozzle_volume_type"])) {
+    enforceMatchingNozzles(flat["nozzle_volume_type"] as unknown[]);
+    return;
+  }
+
+  const def = flat["default_nozzle_volume_type"];
+  if (Array.isArray(def) && def.every((v) => typeof v === "string")) {
+    enforceMatchingNozzles(def);
+    flat["nozzle_volume_type"] = [...def];
+    return;
+  }
+
+  const extruderCount = inferExtruderCount(flat);
+  flat["nozzle_volume_type"] = Array(extruderCount).fill("Standard");
+}
+
+/**
+ * Hardware invariant: all nozzles on a Bambu printer have identical flow
+ * type (and diameter). If a profile somehow declares mixed types it's
+ * either bad input or a future mistake -- fail loud so we don't ship
+ * gcode that could damage the printer.
+ */
+function enforceMatchingNozzles(arr: unknown[]): void {
+  if (arr.length <= 1) return;
+  const first = arr[0];
+  for (let i = 1; i < arr.length; i++) {
+    if (arr[i] !== first) {
+      throw new Error(
+        `nozzle_volume_type entries must all match (Bambu hardware invariant). ` +
+          `Got: ${JSON.stringify(arr)}. ` +
+          `Both nozzles on H2-series printers always have identical flow type.`
+      );
+    }
+  }
+}
+
+/** Best-effort extruder count for fallback nozzle_volume_type sizing. */
+function inferExtruderCount(flat: Record<string, unknown>): number {
+  for (const key of ["nozzle_diameter", "extruder_type", "extruder_variant_list"]) {
+    const v = flat[key];
+    if (Array.isArray(v) && v.length > 0) return v.length;
+  }
+  return 1;
+}
+
+/**
+ * Bambu ships `BBL/cli_config.json` with per-printer overlays containing
+ * machine_limits keys (cli_safe_acceleration_*, cli_safe_jerk_*,
+ * cli_safe_speed_*). Without these the slicer can emit movements faster
+ * than the printer's safe envelope -- dangerous on real hardware.
+ *
+ * The overlay keys are scoped under printer.<printer_name>.machine_limits.
+ * We look up by the leaf machine's `printer_model` or `name` and merge
+ * those keys into the flattened machine profile.
+ *
+ * Returns true if an overlay was found and applied, false otherwise.
+ */
+async function applyCliOverlay(
+  flat: Record<string, unknown>,
+  profilesRoot: string,
+  vendor: string
+): Promise<boolean> {
+  const cliConfigPath = path.join(profilesRoot, vendor, "cli_config.json");
+  let raw: string;
+  try {
+    raw = await fs.readFile(cliConfigPath, "utf8");
+  } catch {
+    return false;
+  }
+  let cliConfig: Record<string, unknown>;
+  try {
+    cliConfig = JSON.parse(raw) as Record<string, unknown>;
+  } catch {
+    return false;
+  }
+
+  const printerSection = cliConfig["printer"];
+  if (!printerSection || typeof printerSection !== "object") return false;
+
+  // Match key: cli_config.json keys are bare printer names like
+  // "Bambu Lab H2D" / "Bambu Lab A1". Try, in order: explicit printer_model,
+  // printer_settings_id with the " 0.4 nozzle" suffix stripped, raw name
+  // with that suffix stripped, raw name as-is.
+  const candidates = [
+    flat["printer_model"],
+    typeof flat["printer_settings_id"] === "string"
+      ? stripNozzleSuffix(flat["printer_settings_id"])
+      : undefined,
+    typeof flat["name"] === "string" ? stripNozzleSuffix(flat["name"]) : undefined,
+    flat["name"],
+  ].filter((v): v is string => typeof v === "string" && v.length > 0);
+
+  for (const key of candidates) {
+    const block = (printerSection as Record<string, unknown>)[key];
+    if (!block || typeof block !== "object") continue;
+    const mlimits = (block as Record<string, unknown>)["machine_limits"];
+    if (!mlimits || typeof mlimits !== "object") continue;
+    // Merge machine_limits into the flat profile. These are CLI-only safety
+    // values; they should never be overridden by the leaf.
+    Object.assign(flat, mlimits as Record<string, unknown>);
+    return true;
+  }
+
+  return false;
+}
+
+/**
+ * Ensure the chosen machine is in the process/filament's
+ * `compatible_printers` list. This mirrors what the GUI does when you
+ * save a project with a printer/process combo that wasn't in the
+ * shipped compat list.
+ */
+function ensureMachineInCompatList(
+  flat: Record<string, unknown>,
+  machineLeaf: string
+): void {
+  const list = flat["compatible_printers"];
+  if (!Array.isArray(list)) {
+    flat["compatible_printers"] = [machineLeaf];
+    return;
+  }
+  if (!list.includes(machineLeaf)) {
+    list.push(machineLeaf);
+  }
+}
+
+function stripNozzleSuffix(name: string): string {
+  return name.replace(/\s+\d+\.\d+\s+nozzle.*$/, "");
+}
+
+/**
+ * Adjust fields for CLI consumption.
+ *
+ * - Strip `inherits` and `instantiation` (chain marker, abstract-base flag).
+ *   The GUI consumes them; the CLI treats anything still present as part of
+ *   the merged config.
+ * - Rewrite `from`. Leaf BBL profiles ship with `"from": "system"`, which
+ *   the CLI rejects when loaded via `--load-settings` (system presets
+ *   aren't supposed to be loaded that way). The GUI rewrites this to
+ *   `"from": "project"` when it embeds the merged config in a 3MF. We do
+ *   the same so the CLI accepts our flattened temp file.
+ * - Strip `setting_id` / `is_custom_defined` (user-registry markers that
+ *   make no sense on a transient flattened file).
+ */
+function normalizeForCli(
+  flat: Record<string, unknown>,
+  kind: ProfileKind,
+  leafName: string
+): void {
+  // Set inherits to the leaf name BEFORE we delete it below, so the
+  // CLI's system_name resolution lands on the right value.
+  // (See note further down for why this matters.)
+  flat["inherits"] = leafName;
+  // Identity field. The CLI sets this internally, but we mirror it for
+  // consistency with what the GUI's project_settings.config emits.
+  switch (kind) {
+    case "machine":
+      flat["printer_settings_id"] = leafName;
+      break;
+    case "process":
+      flat["print_settings_id"] = leafName;
+      break;
+    case "filament":
+      flat["filament_settings_id"] = [leafName];
+      break;
+  }
+
+  // CRITICAL: when from=="User", the CLI computes `system_name = inherits`
+  // and the compatibility check compares the *other* configs'
+  // `compatible_printers` list against that system_name. The leaf
+  // profiles' compat lists contain the leaf machine name (e.g.
+  // "Bambu Lab H2S 0.4 nozzle"), so we must set `inherits` on the
+  // flattened machine to that same leaf name. For process/filament,
+  // `inherits` doesn't drive the compat check we hit, but we set it for
+  // symmetry so any future check succeeds the same way.
+  // Source: BambuStudio.cpp ~line 2222 (from!="system" -> system_name = inherits).
+  // NOTE: do NOT delete inherits -- we just set it above. The CLI uses
+  // its value (when from=="User") for the system_name compat check.
+  delete flat["instantiation"];
+  delete flat["setting_id"];
+  delete flat["is_custom_defined"];
+  // Always rewrite `from` to "User". "Project" is what the GUI uses when
+  // embedding in a 3MF, but the CLI accepts "User" for --load-settings
+  // paths and that's semantically what we are.
+  flat["from"] = "User";
+  // Mirror the GUI's behavior of clearing compatibility constraints in the
+  // merged project config. The leaf process/filament profiles ship with
+  // `compatible_printers: ["Bambu Lab H2S 0.4 nozzle"]` etc., and the CLI
+  // re-validates that list against our flattened machine config -- which
+  // has had `from` rewritten and inheritance collapsed, so the equality
+  // check fails. The GUI's project_settings.config has these set to null
+  // because at that point compatibility is already established by the
+  // user. We do the same.
+  // Leave compatible_printers / compatible_prints as the leaf declared
+  // them. The GUI nulls these in embedded project configs, but the CLI's
+  // --load-settings path requires a non-empty list and matches against
+  // the machine's `name` / `printer_settings_id`. The leaves ship with
+  // the correct list ([machine_leaf_name]) so just preserve.
+  // _condition fields can stay null (string-typed, tolerated as null).
+}
+
+function applyBedType(processFlat: Record<string, unknown>, bedType?: string): void {
+  if (!bedType) return;
+  processFlat.curr_bed_type = bedType;
+}
+
+function applyMachineModelBedMetadata(
+  machineFlat: Record<string, unknown>,
+  index: NameIndex
+): void {
+  const modelName = machineFlat.printer_model;
+  if (typeof modelName !== "string") return;
+
+  const model = index.get(modelName)?.data;
+  if (!model) return;
+
+  for (const key of ["default_bed_type", "image_bed_type", "not_support_bed_type"]) {
+    if (!(key in machineFlat) && key in model) {
+      machineFlat[key] = model[key];
+    }
+  }
+}
+
+/* -------------------------------------------------------------------------- */
+/* Public entry point                                                          */
+/* -------------------------------------------------------------------------- */
+
+/**
+ * Flatten the leaf profiles, post-process for CLI, and write to temp files.
+ *
+ * Throws on unknown leaf names, missing profilesRoot, or cycles.
+ */
+export async function flattenForCli(opts: FlattenOptions): Promise<FlattenedProfiles> {
+  const vendor = opts.vendor ?? "BBL";
+  if (vendor !== "BBL") {
+    throw new Error(
+      `profile-flatten: only BBL vendor is supported (got "${vendor}"). ` +
+        `Other vendors are out of scope -- contributions welcome but untested.`
+    );
+  }
+
+  // Confirm the profiles root looks plausible before doing real work.
+  const probe = path.join(opts.profilesRoot, vendor, "machine");
+  try {
+    await fs.access(probe);
+  } catch {
+    throw new Error(
+      `profile-flatten: profilesRoot "${opts.profilesRoot}" does not contain "${vendor}/machine". ` +
+        `Set BAMBU_PROFILES_ROOT or check your BambuStudio install.`
+    );
+  }
+
+  const index = await buildNameIndex(opts.profilesRoot, vendor);
+
+  // Flatten each leaf.
+  const machineFlat = flattenByName(opts.machineLeaf, index);
+  const processFlat = flattenByName(opts.processLeaf, index);
+  const filamentFlats = opts.filamentLeaves.map((n) => flattenByName(n, index));
+
+  // CLI-specific post-processing on machine profile only.
+  deriveNozzleVolumeType(machineFlat, opts.nozzleVolumeType);
+  applyMachineModelBedMetadata(machineFlat, index);
+  const cliOverlayApplied = await applyCliOverlay(machineFlat, opts.profilesRoot, vendor);
+
+  // Normalize each flattened profile for CLI consumption.
+  normalizeForCli(machineFlat, "machine", opts.machineLeaf);
+  normalizeForCli(processFlat, "process", opts.processLeaf);
+  filamentFlats.forEach((f, i) => normalizeForCli(f, "filament", opts.filamentLeaves[i]));
+  applyBedType(processFlat, opts.bedType);
+
+  // Mirror the GUI's auto-extend behavior: when the caller explicitly
+  // chose a process or filament that wasn't pre-declared compatible with
+  // the chosen machine (e.g. "0.20mm Standard @BBL P1P" used on a P1S),
+  // add the machine name to the process/filament compat list. The GUI
+  // does this implicitly when saving a project.
+  ensureMachineInCompatList(processFlat, opts.machineLeaf);
+  filamentFlats.forEach((f) => ensureMachineInCompatList(f, opts.machineLeaf));
+
+  // Write temp files. Hash the leaf name into the filename so concurrent
+  // slices for different printers don't collide.
+  await fs.mkdir(opts.tempDir, { recursive: true });
+  const machinePath = await writeTemp(opts.tempDir, "machine", opts.machineLeaf, machineFlat);
+  const processPath = await writeTemp(opts.tempDir, "process", opts.processLeaf, processFlat);
+  const filamentPaths: string[] = [];
+  for (let i = 0; i < filamentFlats.length; i++) {
+    filamentPaths.push(
+      await writeTemp(opts.tempDir, `filament-${i}`, opts.filamentLeaves[i], filamentFlats[i])
+    );
+  }
+
+  return {
+    machinePath,
+    processPath,
+    filamentPaths,
+    meta: {
+      profilesRoot: opts.profilesRoot,
+      machineLeafName: opts.machineLeaf,
+      processLeafName: opts.processLeaf,
+      filamentLeafNames: opts.filamentLeaves,
+      cliOverlayApplied,
+    },
+  };
+}
+
+async function writeTemp(
+  tempDir: string,
+  kind: string,
+  leafName: string,
+  data: Record<string, unknown>
+): Promise<string> {
+  const hash = crypto.createHash("sha1").update(leafName).digest("hex").slice(0, 8);
+  const safe = leafName.replace(/[^a-zA-Z0-9._-]+/g, "_").slice(0, 64);
+  const filename = `flat-${kind}-${safe}-${hash}.json`;
+  const out = path.join(tempDir, filename);
+  await fs.writeFile(out, JSON.stringify(data, null, 2), "utf8");
+  return out;
+}
+
+/* -------------------------------------------------------------------------- */
+/* Profile root detection                                                      */
+/* -------------------------------------------------------------------------- */
+
+/**
+ * Given the SLICER_PATH (path to BambuStudio executable), walk up to the
+ * Resources/profiles directory. Falls back to common platform paths.
+ *
+ * Override via BAMBU_PROFILES_ROOT env.
+ */
+export function detectProfilesRoot(slicerPath?: string): string {
+  if (process.env["BAMBU_PROFILES_ROOT"]) {
+    return process.env["BAMBU_PROFILES_ROOT"];
+  }
+
+  if (slicerPath) {
+    // macOS: /Applications/BambuStudio.app/Contents/MacOS/BambuStudio
+    //  -> /Applications/BambuStudio.app/Contents/Resources/profiles
+    const macGuess = path.resolve(path.dirname(slicerPath), "..", "Resources", "profiles");
+    return macGuess;
+  }
+
+  // Default macOS install.
+  return "/Applications/BambuStudio.app/Contents/Resources/profiles";
+}