bambu-printer-mcp 1.1.15 → 1.1.17

package/dist/index.js

@@ -497,6 +497,30 @@ function parseBooleanEnv(rawValue, fallback) {
         return false;
     return fallback;
 }
+// Someone confirming a hardware action may have to walk to the printer, so the
+// SDK's 60-second request default is too short for human confirmation.
+const DEFAULT_CONFIRMATION_TIMEOUT_MS = 600000;
+const MIN_CONFIRMATION_TIMEOUT_MS = 1000;
+const MAX_CONFIRMATION_TIMEOUT_MS = 3600000;
+/** Out-of-range values fall back to the default; Node clamps huge timer delays to 1 ms. */
+function parseConfirmationTimeout(value) {
+    const parsed = Number(value?.trim() || NaN);
+    return Number.isInteger(parsed) && parsed >= MIN_CONFIRMATION_TIMEOUT_MS && parsed <= MAX_CONFIRMATION_TIMEOUT_MS
+        ? parsed
+        : DEFAULT_CONFIRMATION_TIMEOUT_MS;
+}
+function describeDuration(ms) {
+    return ms >= 60000 ? `${Math.round(ms / 6000) / 10} minute(s)` : `${Math.round(ms / 100) / 10} second(s)`;
+}
+function isElicitationTimeout(error) {
+    return error?.code === ErrorCode.RequestTimeout;
+}
+/** Only a missing method or capability means the client cannot show the prompt. */
+function isElicitationUnsupported(error) {
+    const message = String(error?.message ?? error);
+    return error?.code === ErrorCode.MethodNotFound || error?.code === ErrorCode.InvalidRequest ||
+        /does not support (form |url )?elicitation/i.test(message);
+}
 function parsePort(value, fallback) {
     if (!value)
         return fallback;
@@ -822,6 +846,7 @@ class BambuPrinterMCPServer {
     constructor() {
         this.blender = new BlenderMcpBridge();
         this.shuttingDown = false;
+        this.confirmationTimeoutMs = parseConfirmationTimeout(process.env.BAMBU_CONFIRMATION_TIMEOUT_MS);
         this.runtimeConfig = readRuntimeConfig();
         this.server = new Server({
             name: "bambu-printer-mcp",
@@ -842,11 +867,17 @@ class BambuPrinterMCPServer {
                         properties: { confirmed: { type: "boolean", title: "I checked the printer and confirm this operation", default: false } },
                         required: ["confirmed"],
                     },
-                });
+                }, { timeout: this.confirmationTimeoutMs });
                 return response.action === "accept" && response.content?.confirmed === true;
             }
-            catch {
-                throw new Error("Human hardware confirmation requires an MCP client with elicitation support. For deliberately headless operation, BAMBU_REQUIRE_CONFIRMATION=0 disables ordinary print/heat prompts; finished-bed clearance and hardware-error confirmation still require elicitation.");
+            catch (error) {
+                if (isElicitationTimeout(error)) {
+                    throw new Error(`No hardware confirmation within ${describeDuration(this.confirmationTimeoutMs)}; nothing was sent to the printer. Retry when someone can check the printer, or raise BAMBU_CONFIRMATION_TIMEOUT_MS.`);
+                }
+                if (isElicitationUnsupported(error)) {
+                    throw new Error("Human hardware confirmation requires an MCP client with elicitation support. For deliberately headless operation, BAMBU_REQUIRE_CONFIRMATION=0 disables ordinary print/heat prompts; finished-bed clearance and hardware-error confirmation still require elicitation.");
+                }
+                throw new Error(`Human hardware confirmation failed: ${error?.message ?? error}. Nothing was sent to the printer.`);
             }
         });
         this.bambuNetwork = new BambuNetworkBridge();
@@ -902,17 +933,19 @@ class BambuPrinterMCPServer {
                     },
                     required: ["bambu_model"],
                 },
-            });
+            }, { timeout: this.confirmationTimeoutMs });
             if (result.action === "accept" && result.content?.bambu_model) {
                 return validateBambuModel(String(result.content.bambu_model));
             }
             throw new Error("Printer model selection was cancelled. Cannot proceed without knowing the printer model.");
         }
         catch (elicitError) {
+            if (isElicitationTimeout(elicitError)) {
+                throw new Error(`No printer model was selected within ${describeDuration(this.confirmationTimeoutMs)}; nothing was sent to the printer. ` +
+                    "Set BAMBU_MODEL or pass bambu_model in the tool call.");
+            }
             // Elicitation not supported by this client — fall back to a clear error
-            const msg = elicitError?.message || String(elicitError);
-            if (elicitError?.code === -32601 || elicitError?.code === -32600 ||
-                msg.includes("does not support") || msg.includes("elicitation")) {
+            if (isElicitationUnsupported(elicitError)) {
                 throw new Error("bambu_model is required but your MCP client does not support elicitation. " +
                     `Set the BAMBU_MODEL environment variable or pass bambu_model in the tool call. ` +
                     `Valid models: ${VALID_BAMBU_MODELS.join(", ")}`);

package/dist/slicer/profile-flatten.js

@@ -41,6 +41,7 @@ import crypto from "node:crypto";
  */
 async function buildNameIndex(profilesRoot, vendor, userProfileRoots = []) {
     const index = new Map();
+    index.malformed = [];
     const subdirs = ["machine", "process", "filament"];
     const directories = [
         ...subdirs.map(sub => path.join(profilesRoot, vendor, sub)),
@@ -72,11 +73,15 @@ async function buildNameIndex(profilesRoot, vendor, userProfileRoots = []) {
                 data = JSON.parse(raw);
             }
             catch {
-                // Malformed profile -- skip, don't poison the index.
+                // Malformed profile -- skip, don't poison the index. A reference to
+                // it still fails, and the error names the skipped file.
+                index.malformed.push(filePath);
                 continue;
             }
-            if (!data || typeof data !== 'object' || Array.isArray(data))
+            if (!data || typeof data !== 'object' || Array.isArray(data)) {
+                index.malformed.push(filePath);
                 continue;
+            }
             const name = data["name"];
             if (typeof name !== "string" || name.length === 0)
                 continue;
@@ -106,7 +111,7 @@ function flattenByName(leafName, index, visiting = new Set()) {
     }
     const entry = index.get(leafName);
     if (!entry) {
-        throw new Error(`Profile "${leafName}" not found in index. The profile tree is incomplete or the name is misspelled.`);
+        throw new Error(`Profile "${leafName}" not found in index. The profile tree is incomplete or the name is misspelled.${describeMalformed(index)}`);
     }
     visiting.add(leafName);
     try {
@@ -116,6 +121,13 @@ function flattenByName(leafName, index, visiting = new Set()) {
         visiting.delete(leafName);
     }
 }
+function describeMalformed(index) {
+    const malformed = index.malformed ?? [];
+    if (malformed.length === 0)
+        return "";
+    const shown = malformed.slice(0, 5).map((file) => path.basename(file)).join(", ");
+    return ` Skipped ${malformed.length} unreadable or malformed profile file(s): ${shown}${malformed.length > 5 ? ", ..." : ""}.`;
+}
 function flattenData(data, index, visiting = new Set()) {
     const parent = data["inherits"];
     const merged = typeof parent === "string" && parent.length > 0
@@ -157,7 +169,7 @@ function applyIncludes(target, profile, index, visiting) {
         const entry = index.get(name);
         if (!entry) {
             throw new Error(`Profile "${String(profile["name"])}" includes "${name}", which is not in the index. ` +
-                `Refusing to fall back to inherited defaults (wrong G-code for this printer).`);
+                `Refusing to fall back to inherited defaults (wrong G-code for this printer).${describeMalformed(index)}`);
         }
         for (const [key, value] of Object.entries(flattenByName(name, index, visiting))) {
             if (!INCLUDE_METADATA_KEYS.has(key))

package/dist/stl/stl-manipulator.d.ts

@@ -62,10 +62,20 @@ export declare class STLManipulator extends EventEmitter {
     private readJsonFile;
     private stripAbsoluteExtruderResets;
     private sanitizeProcessForOrca;
+    /** Orca slices with absolute E distances; per-layer `G92 E0` resets would break them. */
+    private useAbsoluteExtrusionForOrca;
     private writeTempJson;
     private resolveBambuLikeSettingsBundle;
     /** Resolve BBL dependencies before invoking the CLI; failures stop the slice. */
     private maybeFlattenBundle;
+    /**
+     * The CLI applies every key in every --load-settings/--load-filaments file,
+     * so machine settings carried by a process or filament file (for example a
+     * template 3MF's project_settings from another printer) would replace the
+     * selected preset's start G-code, model, and bed geometry. The machine
+     * preset owns those keys; drop them from the other profiles.
+     */
+    private isolateMachineSettings;
     /** --load-filaments is positional; a single override must cover every project slot. */
     private expandProjectFilaments;
     private resolveBambuStudioBedType;

package/dist/stl/stl-manipulator.js

@@ -100,6 +100,11 @@ function configuredBambuProfileDirs() {
     ];
     return roots.flatMap((root) => appNames.map((appName) => path.join(root, appName, 'system', 'BBL')));
 }
+/** Keys every profile kind carries; they describe the file, not machine hardware. */
+const PROFILE_METADATA_KEYS = new Set([
+    'name', 'type', 'from', 'inherits', 'instantiation', 'setting_id', 'version', 'is_custom_defined',
+    'compatible_printers', 'compatible_printers_condition', 'compatible_prints', 'compatible_prints_condition',
+]);
 export class STLManipulator extends EventEmitter {
     constructor(tempDir = path.join(process.cwd(), 'temp')) {
         super();
@@ -193,11 +198,16 @@ export class STLManipulator extends EventEmitter {
         else if (sanitized.prime_tower_brim_width !== undefined) {
             sanitized.prime_tower_brim_width = String(sanitized.prime_tower_brim_width);
         }
-        sanitized.use_relative_e_distances = '0';
-        sanitized.before_layer_change_gcode = this.stripAbsoluteExtruderResets(sanitized.before_layer_change_gcode);
-        sanitized.layer_gcode = this.stripAbsoluteExtruderResets(sanitized.layer_gcode);
-        sanitized.layer_change_gcode = this.stripAbsoluteExtruderResets(sanitized.layer_change_gcode);
-        return sanitized;
+        return this.useAbsoluteExtrusionForOrca(sanitized);
+    }
+    /** Orca slices with absolute E distances; per-layer `G92 E0` resets would break them. */
+    useAbsoluteExtrusionForOrca(config) {
+        const normalized = { ...config };
+        normalized.use_relative_e_distances = '0';
+        normalized.before_layer_change_gcode = this.stripAbsoluteExtruderResets(normalized.before_layer_change_gcode);
+        normalized.layer_gcode = this.stripAbsoluteExtruderResets(normalized.layer_gcode);
+        normalized.layer_change_gcode = this.stripAbsoluteExtruderResets(normalized.layer_change_gcode);
+        return normalized;
     }
     writeTempJson(outputBase, suffix, value) {
         const serialized = JSON.stringify(value, null, 2);
@@ -426,6 +436,36 @@ export class STLManipulator extends EventEmitter {
                 : withCliFields(bundle.filamentPaths[i], profile, flat.filamentPaths[i], ['filament_colour'])),
         };
     }
+    /**
+     * The CLI applies every key in every --load-settings/--load-filaments file,
+     * so machine settings carried by a process or filament file (for example a
+     * template 3MF's project_settings from another printer) would replace the
+     * selected preset's start G-code, model, and bed geometry. The machine
+     * preset owns those keys; drop them from the other profiles.
+     */
+    isolateMachineSettings(bundle) {
+        const [machinePath, processPath] = bundle.settingsArg?.split(';') ?? [];
+        if (!machinePath || !processPath)
+            return bundle;
+        const machineKeys = Object.keys(this.readJsonFile(machinePath)).filter(key => !PROFILE_METADATA_KEYS.has(key));
+        const isolate = (filePath, label) => {
+            const profile = this.readJsonFile(filePath);
+            const foreign = machineKeys.filter(key => Object.prototype.hasOwnProperty.call(profile, key));
+            if (foreign.length === 0)
+                return filePath;
+            const isolated = { ...profile };
+            for (const key of foreign)
+                delete isolated[key];
+            console.error(`Ignoring ${foreign.length} machine setting(s) in ${label} profile ${filePath} ` +
+                `(the selected machine preset owns them): ${foreign.slice(0, 8).join(', ')}${foreign.length > 8 ? ', ...' : ''}`);
+            return this.writeTempJson(path.basename(filePath, '.json'), `${label}_without_machine`, isolated);
+        };
+        return {
+            ...bundle,
+            settingsArg: [machinePath, isolate(processPath, 'process')].join(';'),
+            filamentPaths: bundle.filamentPaths.map(filePath => isolate(filePath, 'filament')),
+        };
+    }
     /** --load-filaments is positional; a single override must cover every project slot. */
     async expandProjectFilaments(inputPath, bundle) {
         if (!inputPath.toLowerCase().endsWith('.3mf') || bundle.filamentPaths.length === 0)
@@ -1244,17 +1284,23 @@ export class STLManipulator extends EventEmitter {
                         const settingsBundle = await this.maybeFlattenBundle(await this.expandProjectFilaments(stlFilePath, rawBundle), bambuOptions, profilesRoot);
                         // Inherited process G-code is now present; apply Orca's existing
                         // absolute-extrusion normalization after resolving those ancestors.
+                        // The machine owns the extrusion mode and layer G-code once process
+                        // files lose machine keys, so normalize it there as well.
                         if (slicerType === 'orcaslicer' && settingsBundle.settingsArg) {
                             const [machinePath, processPath] = settingsBundle.settingsArg.split(';');
-                            settingsBundle.settingsArg = [machinePath, this.writeTempJson(outputBase, 'process_orca_resolved', this.sanitizeProcessForOrca(this.readJsonFile(processPath), printerPreset))].join(';');
+                            settingsBundle.settingsArg = [
+                                this.writeTempJson(outputBase, 'machine_orca_resolved', this.useAbsoluteExtrusionForOrca(this.readJsonFile(machinePath))),
+                                this.writeTempJson(outputBase, 'process_orca_resolved', this.sanitizeProcessForOrca(this.readJsonFile(processPath), printerPreset)),
+                            ].join(';');
                         }
+                        const cliBundle = this.isolateMachineSettings(settingsBundle);
                         args = [
                             '--slice', String(bambuOptions?.slicePlate ?? 0),
                             '--outputdir', outputDir,
                             '--export-3mf', path.basename(bambuOutputPath),
                         ];
-                        if (settingsBundle.settingsArg) {
-                            args.push('--load-settings', settingsBundle.settingsArg);
+                        if (cliBundle.settingsArg) {
+                            args.push('--load-settings', cliBundle.settingsArg);
                         }
                         // Always allow newer-version 3MF files (the CLI rejects them by default)
                         args.push('--allow-newer-file');
@@ -1289,8 +1335,8 @@ export class STLManipulator extends EventEmitter {
                             args.push('--clone-objects', bambuOptions.cloneObjects);
                         if (bambuOptions?.skipObjects)
                             args.push('--skip-objects', bambuOptions.skipObjects);
-                        if (settingsBundle.filamentPaths.length > 0) {
-                            args.push('--load-filaments', settingsBundle.filamentPaths.join(';'));
+                        if (cliBundle.filamentPaths.length > 0) {
+                            args.push('--load-filaments', cliBundle.filamentPaths.join(';'));
                             args.push('--load-defaultfila');
                         }
                         if (bambuOptions?.loadFilamentIds)

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "bambu-printer-mcp",
-  "version": "1.1.15",
+  "version": "1.1.17",
   "description": "MCP server for Bambu Lab 3D printers with STL manipulation, slicing, and print management",
   "main": "dist/index.js",
   "repository": {

package/src/index.ts

@@ -689,6 +689,35 @@ function parseBooleanEnv(rawValue: string | undefined, fallback: boolean): boole
   return fallback;
 }
 
+// Someone confirming a hardware action may have to walk to the printer, so the
+// SDK's 60-second request default is too short for human confirmation.
+const DEFAULT_CONFIRMATION_TIMEOUT_MS = 600_000;
+const MIN_CONFIRMATION_TIMEOUT_MS = 1_000;
+const MAX_CONFIRMATION_TIMEOUT_MS = 3_600_000;
+
+/** Out-of-range values fall back to the default; Node clamps huge timer delays to 1 ms. */
+function parseConfirmationTimeout(value: string | undefined): number {
+  const parsed = Number(value?.trim() || NaN);
+  return Number.isInteger(parsed) && parsed >= MIN_CONFIRMATION_TIMEOUT_MS && parsed <= MAX_CONFIRMATION_TIMEOUT_MS
+    ? parsed
+    : DEFAULT_CONFIRMATION_TIMEOUT_MS;
+}
+
+function describeDuration(ms: number): string {
+  return ms >= 60_000 ? `${Math.round(ms / 6_000) / 10} minute(s)` : `${Math.round(ms / 100) / 10} second(s)`;
+}
+
+function isElicitationTimeout(error: any): boolean {
+  return error?.code === ErrorCode.RequestTimeout;
+}
+
+/** Only a missing method or capability means the client cannot show the prompt. */
+function isElicitationUnsupported(error: any): boolean {
+  const message = String(error?.message ?? error);
+  return error?.code === ErrorCode.MethodNotFound || error?.code === ErrorCode.InvalidRequest ||
+    /does not support (form |url )?elicitation/i.test(message);
+}
+
 function parsePort(value: string | undefined, fallback: number): number {
   if (!value) return fallback;
   const parsed = Number(value);
@@ -1105,6 +1134,7 @@ class BambuPrinterMCPServer {
   private readonly runtimeConfig: RuntimeConfig;
   private httpRuntime?: { transport: StreamableHTTPServerTransport; httpServer: HttpServer };
   private shuttingDown = false;
+  private readonly confirmationTimeoutMs = parseConfirmationTimeout(process.env.BAMBU_CONFIRMATION_TIMEOUT_MS);
 
   constructor() {
     this.runtimeConfig = readRuntimeConfig();
@@ -1131,10 +1161,16 @@ class BambuPrinterMCPServer {
             properties: { confirmed: { type: "boolean", title: "I checked the printer and confirm this operation", default: false } },
             required: ["confirmed"],
           },
-        });
+        }, { timeout: this.confirmationTimeoutMs });
         return response.action === "accept" && response.content?.confirmed === true;
-      } catch {
-        throw new Error("Human hardware confirmation requires an MCP client with elicitation support. For deliberately headless operation, BAMBU_REQUIRE_CONFIRMATION=0 disables ordinary print/heat prompts; finished-bed clearance and hardware-error confirmation still require elicitation.");
+      } catch (error: any) {
+        if (isElicitationTimeout(error)) {
+          throw new Error(`No hardware confirmation within ${describeDuration(this.confirmationTimeoutMs)}; nothing was sent to the printer. Retry when someone can check the printer, or raise BAMBU_CONFIRMATION_TIMEOUT_MS.`);
+        }
+        if (isElicitationUnsupported(error)) {
+          throw new Error("Human hardware confirmation requires an MCP client with elicitation support. For deliberately headless operation, BAMBU_REQUIRE_CONFIRMATION=0 disables ordinary print/heat prompts; finished-bed clearance and hardware-error confirmation still require elicitation.");
+        }
+        throw new Error(`Human hardware confirmation failed: ${error?.message ?? error}. Nothing was sent to the printer.`);
       }
     });
     this.bambuNetwork = new BambuNetworkBridge();
@@ -1196,7 +1232,7 @@ class BambuPrinterMCPServer {
           },
           required: ["bambu_model"],
         },
-      });
+      }, { timeout: this.confirmationTimeoutMs });
 
       if (result.action === "accept" && result.content?.bambu_model) {
         return validateBambuModel(String(result.content.bambu_model));
@@ -1206,12 +1242,14 @@ class BambuPrinterMCPServer {
         "Printer model selection was cancelled. Cannot proceed without knowing the printer model."
       );
     } catch (elicitError: any) {
+      if (isElicitationTimeout(elicitError)) {
+        throw new Error(
+          `No printer model was selected within ${describeDuration(this.confirmationTimeoutMs)}; nothing was sent to the printer. ` +
+          "Set BAMBU_MODEL or pass bambu_model in the tool call."
+        );
+      }
       // Elicitation not supported by this client — fall back to a clear error
-      const msg = elicitError?.message || String(elicitError);
-      if (
-        elicitError?.code === -32601 || elicitError?.code === -32600 ||
-        msg.includes("does not support") || msg.includes("elicitation")
-      ) {
+      if (isElicitationUnsupported(elicitError)) {
         throw new Error(
           "bambu_model is required but your MCP client does not support elicitation. " +
           `Set the BAMBU_MODEL environment variable or pass bambu_model in the tool call. ` +

package/src/slicer/profile-flatten.ts

@@ -95,7 +95,8 @@ interface IndexedProfile {
   data: Record<string, unknown>;
 }
 
-type NameIndex = Map<string, IndexedProfile>;
+/** Name index plus unreadable JSON files, reported when a name is missing. */
+type NameIndex = Map<string, IndexedProfile> & { malformed?: string[] };
 
 /* -------------------------------------------------------------------------- */
 /* Indexing                                                                    */
@@ -116,6 +117,7 @@ async function buildNameIndex(
   userProfileRoots: string[] = []
 ): Promise<NameIndex> {
   const index: NameIndex = new Map();
+  index.malformed = [];
   const subdirs: ProfileKind[] = ["machine", "process", "filament"];
 
   const directories = [
@@ -144,10 +146,15 @@ async function buildNameIndex(
       try {
         data = JSON.parse(raw) as Record<string, unknown>;
       } catch {
-        // Malformed profile -- skip, don't poison the index.
+        // Malformed profile -- skip, don't poison the index. A reference to
+        // it still fails, and the error names the skipped file.
+        index.malformed!.push(filePath);
+        continue;
+      }
+      if (!data || typeof data !== 'object' || Array.isArray(data)) {
+        index.malformed!.push(filePath);
         continue;
       }
-      if (!data || typeof data !== 'object' || Array.isArray(data)) continue;
       const name = data["name"];
       if (typeof name !== "string" || name.length === 0) continue;
       // First-write wins. BBL doesn't have name collisions in practice;
@@ -183,7 +190,7 @@ function flattenByName(
   }
   const entry = index.get(leafName);
   if (!entry) {
-    throw new Error(`Profile "${leafName}" not found in index. The profile tree is incomplete or the name is misspelled.`);
+    throw new Error(`Profile "${leafName}" not found in index. The profile tree is incomplete or the name is misspelled.${describeMalformed(index)}`);
   }
   visiting.add(leafName);
   try {
@@ -193,6 +200,13 @@ function flattenByName(
   }
 }
 
+function describeMalformed(index: NameIndex): string {
+  const malformed = index.malformed ?? [];
+  if (malformed.length === 0) return "";
+  const shown = malformed.slice(0, 5).map((file) => path.basename(file)).join(", ");
+  return ` Skipped ${malformed.length} unreadable or malformed profile file(s): ${shown}${malformed.length > 5 ? ", ..." : ""}.`;
+}
+
 function flattenData(
   data: Record<string, unknown>,
   index: NameIndex,
@@ -249,7 +263,7 @@ function applyIncludes(
     if (!entry) {
       throw new Error(
         `Profile "${String(profile["name"])}" includes "${name}", which is not in the index. ` +
-          `Refusing to fall back to inherited defaults (wrong G-code for this printer).`
+          `Refusing to fall back to inherited defaults (wrong G-code for this printer).${describeMalformed(index)}`
       );
     }
     for (const [key, value] of Object.entries(flattenByName(name, index, visiting))) {

package/src/stl/stl-manipulator.ts

@@ -186,6 +186,12 @@ interface BambuSettingsBundle {
   processSource?: { filePath: string; profile: Record<string, unknown> };
 }
 
+/** Keys every profile kind carries; they describe the file, not machine hardware. */
+const PROFILE_METADATA_KEYS = new Set([
+  'name', 'type', 'from', 'inherits', 'instantiation', 'setting_id', 'version', 'is_custom_defined',
+  'compatible_printers', 'compatible_printers_condition', 'compatible_prints', 'compatible_prints_condition',
+]);
+
 export class STLManipulator extends EventEmitter {
   private tempDir: string;
   private activeOperations: Map<string, boolean> = new Map();
@@ -304,16 +310,22 @@ export class STLManipulator extends EventEmitter {
       sanitized.prime_tower_brim_width = String(sanitized.prime_tower_brim_width);
     }
 
-    sanitized.use_relative_e_distances = '0';
-    sanitized.before_layer_change_gcode = this.stripAbsoluteExtruderResets(
-      sanitized.before_layer_change_gcode
+    return this.useAbsoluteExtrusionForOrca(sanitized);
+  }
+
+  /** Orca slices with absolute E distances; per-layer `G92 E0` resets would break them. */
+  private useAbsoluteExtrusionForOrca(config: any): any {
+    const normalized = { ...config };
+    normalized.use_relative_e_distances = '0';
+    normalized.before_layer_change_gcode = this.stripAbsoluteExtruderResets(
+      normalized.before_layer_change_gcode
     );
-    sanitized.layer_gcode = this.stripAbsoluteExtruderResets(sanitized.layer_gcode);
-    sanitized.layer_change_gcode = this.stripAbsoluteExtruderResets(
-      sanitized.layer_change_gcode
+    normalized.layer_gcode = this.stripAbsoluteExtruderResets(normalized.layer_gcode);
+    normalized.layer_change_gcode = this.stripAbsoluteExtruderResets(
+      normalized.layer_change_gcode
     );
 
-    return sanitized;
+    return normalized;
   }
 
   private writeTempJson(outputBase: string, suffix: string, value: any): string {
@@ -584,6 +596,36 @@ export class STLManipulator extends EventEmitter {
     };
   }
 
+  /**
+   * The CLI applies every key in every --load-settings/--load-filaments file,
+   * so machine settings carried by a process or filament file (for example a
+   * template 3MF's project_settings from another printer) would replace the
+   * selected preset's start G-code, model, and bed geometry. The machine
+   * preset owns those keys; drop them from the other profiles.
+   */
+  private isolateMachineSettings(bundle: BambuSettingsBundle): BambuSettingsBundle {
+    const [machinePath, processPath] = bundle.settingsArg?.split(';') ?? [];
+    if (!machinePath || !processPath) return bundle;
+    const machineKeys = Object.keys(this.readJsonFile(machinePath)).filter(key => !PROFILE_METADATA_KEYS.has(key));
+    const isolate = (filePath: string, label: string): string => {
+      const profile = this.readJsonFile(filePath);
+      const foreign = machineKeys.filter(key => Object.prototype.hasOwnProperty.call(profile, key));
+      if (foreign.length === 0) return filePath;
+      const isolated = { ...profile };
+      for (const key of foreign) delete isolated[key];
+      console.error(
+        `Ignoring ${foreign.length} machine setting(s) in ${label} profile ${filePath} ` +
+        `(the selected machine preset owns them): ${foreign.slice(0, 8).join(', ')}${foreign.length > 8 ? ', ...' : ''}`
+      );
+      return this.writeTempJson(path.basename(filePath, '.json'), `${label}_without_machine`, isolated);
+    };
+    return {
+      ...bundle,
+      settingsArg: [machinePath, isolate(processPath, 'process')].join(';'),
+      filamentPaths: bundle.filamentPaths.map(filePath => isolate(filePath, 'filament')),
+    };
+  }
+
   /** --load-filaments is positional; a single override must cover every project slot. */
   private async expandProjectFilaments(
     inputPath: string,
@@ -1621,20 +1663,25 @@ export class STLManipulator extends EventEmitter {
               await this.expandProjectFilaments(stlFilePath, rawBundle), bambuOptions, profilesRoot);
             // Inherited process G-code is now present; apply Orca's existing
             // absolute-extrusion normalization after resolving those ancestors.
+            // The machine owns the extrusion mode and layer G-code once process
+            // files lose machine keys, so normalize it there as well.
             if (slicerType === 'orcaslicer' && settingsBundle.settingsArg) {
               const [machinePath, processPath] = settingsBundle.settingsArg.split(';');
-              settingsBundle.settingsArg = [machinePath, this.writeTempJson(
-                outputBase, 'process_orca_resolved',
-                this.sanitizeProcessForOrca(this.readJsonFile(processPath), printerPreset)
-              )].join(';');
+              settingsBundle.settingsArg = [
+                this.writeTempJson(outputBase, 'machine_orca_resolved',
+                  this.useAbsoluteExtrusionForOrca(this.readJsonFile(machinePath))),
+                this.writeTempJson(outputBase, 'process_orca_resolved',
+                  this.sanitizeProcessForOrca(this.readJsonFile(processPath), printerPreset)),
+              ].join(';');
             }
+            const cliBundle = this.isolateMachineSettings(settingsBundle);
             args = [
               '--slice', String(bambuOptions?.slicePlate ?? 0),
               '--outputdir', outputDir,
               '--export-3mf', path.basename(bambuOutputPath),
             ];
-            if (settingsBundle.settingsArg) {
-              args.push('--load-settings', settingsBundle.settingsArg);
+            if (cliBundle.settingsArg) {
+              args.push('--load-settings', cliBundle.settingsArg);
             }
             // Always allow newer-version 3MF files (the CLI rejects them by default)
             args.push('--allow-newer-file');
@@ -1655,8 +1702,8 @@ export class STLManipulator extends EventEmitter {
             if (bambuOptions?.rotateY !== undefined) args.push('--rotate-y', String(bambuOptions.rotateY));
             if (bambuOptions?.cloneObjects) args.push('--clone-objects', bambuOptions.cloneObjects);
             if (bambuOptions?.skipObjects) args.push('--skip-objects', bambuOptions.skipObjects);
-            if (settingsBundle.filamentPaths.length > 0) {
-              args.push('--load-filaments', settingsBundle.filamentPaths.join(';'));
+            if (cliBundle.filamentPaths.length > 0) {
+              args.push('--load-filaments', cliBundle.filamentPaths.join(';'));
               args.push('--load-defaultfila');
             }
             if (bambuOptions?.loadFilamentIds) args.push('--load-filament-ids', bambuOptions.loadFilamentIds);