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* Multicolor abacus → ONE print-ready `.3mf` object (Gitea #5).
*
* WHY THIS EXISTS. The shared `meshesToThreeMf` emits one *separate* top-level
* `<object>` per filament — perfect for the receipt path (QR pads nested in cover
* wells), fatal for the abacus. The abacus prints IN PLACE: the beads are free
* shells trapped in the frame's channels at 0.25 mm clearance. As four separate
* objects, OrcaSlicer's auto-arrange pulls them apart (beads scatter out of the
* frame) and its auto-placed prime tower lands in an invalid spot → the
* multi-extruder gcode check rejects the plate (`exit 154`, "unprintable area").
* Reproduced and root-caused on THH's sidecar 2026-07-23.
*
* WHAT THIS DOES INSTEAD. It welds the co-registered per-filament bodies into ONE
* printable object — a `<components>` assembly that references each colored mesh
* as a `<part>` carrying its `extruder` index — so the whole abacus translates as
* a unit and the beads stay threaded. Then it OWNS the layout the way THH's slicer
* won't do safely on its own:
* 1. the object is centered on the target bed (build-item transform), and
* 2. the prime tower is pinned (`wipe_tower_x/y` in `project_settings.config`)
* into a gap that clears the model.
* Both survive THH's slice for the same reason: a 3MF that carries
* `Metadata/project_settings.config` is a *project* file, and Orca skips arrange
* entirely for one (`need_arrange=0` in the log). So our transform and our pin are
* honoured as written — verified exit 0 with all filaments used, no THH-side change
* required. Centering is for bed margin, not for surviving arrange; it's the
* pre-fix files, which shipped no `Metadata/`, that got arranged and scattered.
*
* That last sentence holds only while the gap is wide enough. With supports on the
* first layer reaches past the model outline while the tower's own brim reaches back
* toward it; in a 6 mm gap the two extrusions meet and Orca's post-slice conflict
* check fails the plate (exit 155). That is why `placeWipeTower` takes the options
* — see SUPPORT_SKIRT.
*
* This is the multicolor path only. The single-filament export still rides
* `meshesToThreeMf` unchanged (one object already slices clean).
*/
import type { BedSize } from '@eink/frames-engine/print-bundle'
import { strToU8, zipSync } from 'fflate'
/**
* The zip timestamp every 3MF we emit carries. fflate stamps `Date.now()` into
* each entry's DOS date when `mtime` is unset, so two builds of the same design
* differed by wall-clock bytes — and THH admits a chained Stage B print
* (things-haunt-house#456, abaci #38) only when its model bytes equal Stage A's.
* abaci rebuilds the 3MF on every submit, so the bytes must be a pure function of
* the design. 1980-01-01 is the DOS-date epoch (fflate rejects anything earlier —
* `mtime: 0` throws "invalid date"), built with the local-time constructor because
* fflate reads it back through local getters: identical bytes in every timezone.
*/
export const THREE_MF_ZIP_MTIME = new Date(1980, 0, 1)
/** A co-registered, single-filament body: its triangle soup (9 floats/tri, in the
* shared render pose) plus the filament it prints on. */
export interface AssemblyBody {
/** Triangle soup — every triangle three consecutive (x,y,z) vertices, mm. */
readonly positions: Float32Array
/** Display/filament color: `#RGB`, `#RRGGBB`, or `#RRGGBBAA`. */
readonly colorHex: string
/** Object/part name shown in the slicer. */
readonly label: string
/** 1-based filament index (extruder / AMS slot) this body prints on. */
readonly extruder: number
/** Orca process keys this part owns, written beside `extruder` in its
* `model_settings.config` entry. Per-part config is the one channel that
* reaches a submitted print untouched: THH's `--load-settings` replaces the
* project's global settings, not a part's own (the support-transition
* modifier rides the same channel). Values in Orca's own serialization —
* a percent is `"100%"`. */
readonly process?: Readonly<Record<string, string>>
}
export interface Assembled3mf {
readonly bytes: Uint8Array
/** Orca's wipe_tower_x/y pin (mm, bed frame) — surfaced for the THH job contract. */
readonly wipeTower: { readonly xMm: number; readonly yMm: number }
}
export interface WipeTowerEnvelopeMm {
readonly minX: number
readonly minY: number
readonly maxX: number
readonly maxY: number
}
export interface WipeTowerProfileGeometry {
readonly profile: string
/** The count-unaware bound — the max-filament row. */
readonly envelopeMm: WipeTowerEnvelopeMm
/** The bound per filament count, keyed by the count as a string. See
* {@link envelopeForFilaments}: reserving the bound on a two-filament plate
* throws away bed depth the tower will never occupy. */
readonly envelopeByFilamentsMm?: Readonly<Record<string, WipeTowerEnvelopeMm>>
readonly process: {
readonly prime_tower_width: number
readonly prime_tower_brim_width: number
readonly wipe_tower_wall_type: string
}
}
/** Download/back-compat twin of THH's v1 bounded profile. The print path replaces this
* with the selected printer's advertised copy, so a deploy can update geometry without
* an Abaci release.
*
* The rows mirror THH's measured table (things-haunt-house#433, re-measured for #457):
* width is count-independent, depth grows ~10.5 mm per purge in the worst layer, and an
* N-filament layer can purge N times (Orca may enter a layer on a toolchange), so the
* N row is the (N+1)-swatch depth. The bound was 56 here until #34 — the pre-#433
* number, which THH's own source records as escaped by the six-filament fine-layer
* tower it claimed to hold — and 59 until #457, escaped by a two-filament coupon. */
export const DEFAULT_WIPE_TOWER_PROFILE: WipeTowerProfileGeometry = {
profile: 'orca-rectangle-60-v1',
envelopeMm: { minX: -4, minY: -4, maxX: 66, maxY: 69.5 },
envelopeByFilamentsMm: {
'2': { minX: -4, minY: -4, maxX: 66, maxY: 27.5 },
'3': { minX: -4, minY: -4, maxX: 66, maxY: 38 },
'4': { minX: -4, minY: -4, maxX: 66, maxY: 48.5 },
'5': { minX: -4, minY: -4, maxX: 66, maxY: 59 },
'6': { minX: -4, minY: -4, maxX: 66, maxY: 69.5 },
},
process: {
prime_tower_width: 60,
prime_tower_brim_width: 3,
wipe_tower_wall_type: 'rectangle',
},
}
/**
* The envelope to reserve for a plate that loads `filaments` filaments.
*
* The service measures the tower per filament count and publishes the table
* alongside the count-unaware bound. Two filaments purge into a 70×21 band; six
* need 70×63. Reserving the bound for everything costs 42 mm of bed depth that
* nothing will ever print on — on a 256 bed that is the difference between a
* 13-column kit fitting one plate and being refused.
*
* The floor of 2 is deliberate and is the same reason the reserve is unconditional
* at all: a one-filament plate grows a tower the moment ticket routing attaches a
* support-interface spool, and the plate is packed before that routing resolves. At
* row-2 cost that hedge is nearly free.
*
* Falls back to the bound whenever the table is absent (a pre-#433 service), has no
* row for this count (more filaments than the profile is bounded for), or the row is
* malformed — a bad optional field must never shrink a reservation.
*/
export function envelopeForFilaments(
profile: WipeTowerProfileGeometry,
filaments?: number
): WipeTowerEnvelopeMm {
const table = profile.envelopeByFilamentsMm
if (!table || filaments === undefined || !Number.isFinite(filaments)) return profile.envelopeMm
const row = table[String(Math.max(2, Math.floor(filaments)))]
const usable =
!!row &&
[row.minX, row.minY, row.maxX, row.maxY].every(Number.isFinite) &&
row.maxX > row.minX &&
row.maxY > row.minY
return usable ? row : profile.envelopeMm
}
export interface Assemble3mfOpts {
/** Bounded profile advertised by the selected THH printer. */
readonly wipeTower?: WipeTowerProfileGeometry
/** Bake support-enabling keys into `project_settings.config` (printed TPU feet,
* Gitea #23: the whole bottom face prints on plate-grown supports + interface).
* Also relaxes the >= 2 bodies guard: a printed-feet export must ride the
* assembly path even single-bodied (the no-TPU fallback merges feet into the
* frame slot), because a `meshesToThreeMf` file carries no project settings and
* a directly-sliced download would print the raised bottom face unsupported. */
readonly support?: boolean
/** Supports will be ON when the SUBMITTED print is sliced, for a reason other
* than printed feet — the operator's ticket style turned `enable_support` on,
* which any design can do. Placement only: nothing is baked into
* `project_settings.config` (a downloaded file must not inherit a print-panel
* setting), but the tower needs a wider gap, because supports push the first
* layer past the model outline and Orca's post-slice conflict check rejects a
* plate whose tower extrusion touches the model's — "gcode path conflicts found
* between WipeTower and abacus" (exit 155). That is what prod hit on 2026-07-29.
* See SUPPORT_SKIRT. `support` implies this. */
readonly supportsAtSlice?: boolean
/** The bodies ALREADY sit where they print on THIS bed — the packed module-kit
* plate (Gitea #32), whose x/y came out of a packer that ran against this bed's
* keep-outs and a purge-tower rect reserved BEFORE packing.
*
* Two things change, and both are the same point: on a packed plate the layout
* is a decision, not a pose.
* 1. No bed-centering. Recentering preserves the arrangement but slides it off
* the coordinates the packer cleared, which can walk a module into the
* filament-cutter zone it was packed around.
* 2. The tower pin is taken, not derived. `placeWipeTower` reasons about the
* model's bounding BOX, and a plate's box swallows the hole reserved inside
* it — so re-deriving would either waste the reservation or fail outright on
* a full plate. The reserve is what makes the tower fit; honour it.
*
* Also relaxes the >= 2 bodies guard: a plate is a multi-object layout even when
* every object rides one filament, and the `meshesToThreeMf` path would re-origin
* it into the bed corner. Z is NOT affected: `tz` still drops the plate to the
* bed exactly as it drops a mono abacus, which is what keeps the support-transition
* modifier on the frame's z=0 plane rather than under the feet. */
readonly placedOnBed?: {
/** Orca's `wipe_tower_x/y`, from the reservation the packer left room for. */
readonly towerPinMm: { readonly x: number; readonly y: number }
}
/** How many filaments this plate will load once the ticket resolves — the
* emitted bodies plus anything routing adds (a support-interface spool). Picks
* the profile's envelope row; see {@link envelopeForFilaments}. Omitted, the
* count-unaware bound is reserved, which is safe and wasteful. */
readonly filaments?: number
/** The feet-only two-stage variant (Gitea #45): one `support_blocker` volume per
* foot, keeping Stage B's PLA support out of the nozzle's way around feet that
* are already standing. See {@link supportBlockerRadius}. Never printed, never
* moves the footprint. */
readonly supportBlockers?: readonly SupportBlocker[]
}
/** The printed-feet frame starts at source Z=0, above feet that dip below zero.
* This modifier follows that frame/support boundary through Orca's slice: the
* contact layer plus the next two 0.20 mm layers print slowly enough to settle
* onto a low-adhesion support interface before normal process speeds resume. */
export const SUPPORT_TRANSITION_HEIGHT_MM = 0.6
export const SUPPORT_TRANSITION_SPEED_MM_S = 25
export const SUPPORT_TRANSITION_NAME = 'abaci-support-transition-v1'
/**
* Per-foot support blockers for the feet-only two-stage variant (Gitea #45).
*
* Stage B prints its support body from layer 1 around feet that are already
* standing `heightMm` tall on the plate, so every support line has to clear the
* NOZZLE, not just the foot: a flat tip Ø3 with 45° sides out to Ø12 (the X1C
* hotend, user-measured 2026-09-09). With the tip at layer top z the foot top is
* `heightMm − z` above it, so the void about each foot centre is
*
* R(z) = r_foot + slop + min(tip_r + (H − z), cone_r)
*
* 7.9 mm at layer 1 → 6.5 mm at the seam for the stock 1.6 mm feet. Graduated on
* purpose: a flat `support_object_xy_distance` would need the layer-1 value all
* the way up and double the unsupported ring at the seam. One volume per foot,
* revolved from that profile (a frustum while H is under the cone's height, a
* cylinder under a frustum beyond it), source z −H..0 = bed z 0..H. Orca sizes an
* object by its model parts, so blockers never move the footprint or the tower.
* `raft_first_layer_expansion` must be 0 alongside: Orca grows support layer 0
* AFTER blockers apply.
*/
export const NOZZLE_TIP_RADIUS_MM = 1.5
export const NOZZLE_CONE_RADIUS_MM = 6
/** Half a 0.42 mm support line, plus XY slop. */
export const SUPPORT_BLOCKER_SLOP_MM = 0.5
export const SUPPORT_BLOCKER_NAME = 'abaci-support-blocker-v1'
const SUPPORT_BLOCKER_SEGMENTS = 32
export interface SupportBlocker {
/** Foot centre, source XY — the frame the bodies are in. */
readonly cx: number
readonly cy: number
/** The feet stand-off = the seam height (`feet_proud`). */
readonly heightMm: number
/** The stand-off's radius about its centre (a square foot's circumradius). */
readonly rFootMm: number
}
/** The support void's radius about a foot centre with the nozzle tip at layer top `zMm` (bed z). */
export function supportBlockerRadius(zMm: number, heightMm: number, rFootMm: number): number {
return (
rFootMm +
SUPPORT_BLOCKER_SLOP_MM +
Math.min(NOZZLE_TIP_RADIUS_MM + (heightMm - zMm), NOZZLE_CONE_RADIUS_MM)
)
}
/** The revolved profile, bottom to top in bed z: the knots where R(z) bends. */
export function supportBlockerProfile(
heightMm: number,
rFootMm: number
): readonly { readonly z: number; readonly r: number }[] {
// Above this height the cone's full radius is already reached at the plate, so
// R is flat from the plate up to the knee and slopes only above it.
const knee = heightMm - (NOZZLE_CONE_RADIUS_MM - NOZZLE_TIP_RADIUS_MM)
const zs = knee > 0 && knee < heightMm ? [0, knee, heightMm] : [0, heightMm]
return zs.map((z) => ({ z, r: supportBlockerRadius(z, heightMm, rFootMm) }))
}
/**
* The printed feet's own process keys: the feet print solid, always.
*
* Two reasons, both the feet's alone. A soft TPU foot over sparse infill squashes
* unevenly under the frame, so the feet were settled as 100 % from the start. And
* in a two-stage print the feet ARE Stage A: their top layers are the seam, with
* no top shell of their own (the foot's top is interior to the feet+frame union),
* so Stage B's first layer lands on whatever infill the feet have. Solid feet make
* that a solid bed. Carried per part rather than as a plate-wide style key so the
* operator's infill density stays on the frame and beads — the style-wide 100 %
* the two-stage mode shipped at first printed every bead solid.
*
* Only a body that is the feet and nothing else gets these (see
* `emitThreeMfBodies`): merged into another role's body, the keys would take the
* frame with them.
*/
export const FEET_PART_PROCESS: Readonly<Record<string, string>> = {
sparse_infill_density: '100%',
sparse_infill_pattern: 'rectilinear',
}
/** Download fallback. Print submission uses the selected printer's live bed geometry. */
export const BAMBU_256_BED: BedSize = {
wMm: 256,
dMm: 256,
exclude: [{ xMm: 0, yMm: 0, wMm: 18, dMm: 28 }],
}
/** Clear space kept between the tower and the model. Exported because the packed
* kit plate (abacus-kit-plate.ts) reserves its tower rect BEFORE packing rather
* than placing it beside a finished model — same clearance law, applied at the
* other end of the pipeline, so the number must not be restated there. */
export const TOWER_GAP = 6
// Extra reserve once supports are on: the first layer stops being the model's own
// footprint. Support material grows outward from the overhangs it holds, so extrusion
// reaches past the model outline. Measured 2026-07-29 from THH's supports-on slice
// (the `Support` feature's extents vs the declared object box): 1.47 mm on the sides,
// 5.32 mm at the front, 1.32 mm at the back. SUPPORT_SKIRT reserves the worst case
// with headroom.
//
// WHY 1.5 mm MATTERS MORE THAN IT LOOKS — the exit-155 chain. The gap has to hold two
// growths, not one: the model's, and the tower's own brim (`prime_tower_brim_width` 3,
// which extends back toward the model). TOWER_GAP alone is 6 mm, so with supports on
// prod was left ~1.5 mm of real clearance, and a model brim (`brim_width` 5, auto_brim)
// closes even that. Orca's post-slice `gcode path conflicts check` then fails the
// plate: "gcode path conflicts found between WipeTower and abacus" (exit 155).
// Widening the gap is what Orca's own error text prescribes — "try moving the wipe
// tower further from other models".
//
// NOT A ROTATION. An earlier version of this comment claimed supports make Orca
// re-arrange and rotate the plate; that was a measurement error on our side (the
// `Outer wall` extents include the prime tower, so moving the pin changed the bounding
// box and looked like a transposed model). Two direct observations from our own slice
// disprove it: the log says `before arrange, need_arrange=0` — arrange never runs on a
// 3MF project — and the model printed at its declared min corner (declared 90.25,77.75
// vs printed 90.46,75.96), in its declared orientation. Distance is the only lever.
//
// Exported alongside TOWER_GAP for the packed kit plate's pre-pack reserve.
export const SUPPORT_SKIRT = 8
// How far a cornered tower keeps off the bed edge. The reserve above covers the
// tower's own extrusion, but a tower pushed flush into the corner still trips the
// multi-extruder printable-area check (exit 154, "gcode in unprintable area") —
// measured on the sidecar. 16 mm back from both edges slices clean.
const TOWER_EDGE = 16
const ASSEMBLY_ID = 1000 // printable object id; child meshes take 2..N+1
const SUPPORT_TRANSITION_ID = ASSEMBLY_ID + 1
/** Per-foot support blockers take 1002, 1003, … in `FEET_POS` order. */
export const SUPPORT_BLOCKER_ID_BASE = ASSEMBLY_ID + 2
// A parameter modifier has to cap every feature Orca may assign to the frame's
// first few layers. In particular, the contact layer is Bridge/Overhang wall,
// while the very next layer becomes ordinary walls + internal solid infill.
const SUPPORT_TRANSITION_SPEED_KEYS = [
'outer_wall_speed',
'inner_wall_speed',
'sparse_infill_speed',
'internal_solid_infill_speed',
'top_surface_speed',
'gap_infill_speed',
'bridge_speed',
'overhang_1_4_speed',
'overhang_2_4_speed',
'overhang_3_4_speed',
'overhang_4_4_speed',
'overhang_totally_speed',
] as const
/** Compact mm formatter: fixed 3-decimals (µm), trailing zeros trimmed. */
function fmt(v: number): string {
let s = v.toFixed(3)
if (s.includes('.')) s = s.replace(/0+$/, '').replace(/\.$/, '')
return s === '-0' ? '0' : s
}
function escapeXml(s: string): string {
return s
.replace(/&/g, '&')
.replace(/</g, '<')
.replace(/>/g, '>')
.replace(/"/g, '"')
}
/** Normalize any accepted hex to a full 8-digit `#RRGGBBAA` (3MF displaycolor). */
function displayColor(hex: string): string {
let h = hex.replace('#', '')
if (h.length === 3)
h = h
.split('')
.map((c) => c + c)
.join('')
if (h.length === 6) h += 'FF'
return `#${h.toUpperCase()}`
}
/** Normalize to `#RRGGBB` for the slicer's `filament_colour` list. */
function filamentColor(hex: string): string {
let h = hex.replace('#', '')
if (h.length === 3)
h = h
.split('')
.map((c) => c + c)
.join('')
return `#${h.slice(0, 6).toUpperCase()}`
}
/** Weld a body's triangle soup to indexed geometry (µm quantization) and emit the
* 3MF `<vertices>`/`<triangles>` XML. Welding is per-body — bodies never merge. */
/** A part's own process keys, as Orca writes them beside `extruder`. */
function partProcessXml(b: AssemblyBody): string {
return Object.entries(b.process ?? {})
.map(([key, value]) => `<metadata key="${key}" value="${escapeXml(value)}"/>`)
.join('')
}
function emitBodyMesh(positions: Float32Array): { verts: string; tris: string } {
const index = new Map<string, number>()
const coords: number[] = []
const tri: number[] = []
const n = (positions.length / 9) | 0
for (let t = 0; t < n; t++) {
for (let k = 0; k < 3; k++) {
const o = t * 9 + k * 3
const x = positions[o]
const y = positions[o + 1]
const z = positions[o + 2]
const key = `${Math.round(x * 1000)},${Math.round(y * 1000)},${Math.round(z * 1000)}`
let id = index.get(key)
if (id === undefined) {
id = coords.length / 3
index.set(key, id)
coords.push(x, y, z)
}
tri.push(id)
}
}
let verts = ''
for (let i = 0; i < coords.length; i += 3) {
verts += `<vertex x="${fmt(coords[i])}" y="${fmt(coords[i + 1])}" z="${fmt(coords[i + 2])}"/>`
}
let tris = ''
for (let i = 0; i < tri.length; i += 3) {
tris += `<triangle v1="${tri[i]}" v2="${tri[i + 1]}" v3="${tri[i + 2]}"/>`
}
return { verts, tris }
}
/** Closed box used as an Orca parameter-modifier volume (it is never printed). */
function emitModifierBox(
x0: number,
y0: number,
x1: number,
y1: number,
z0: number,
z1: number
): { verts: string; tris: string } {
const vertices = [
[x0, y0, z0],
[x1, y0, z0],
[x1, y1, z0],
[x0, y1, z0],
[x0, y0, z1],
[x1, y0, z1],
[x1, y1, z1],
[x0, y1, z1],
] as const
const faces = [
[0, 2, 1],
[0, 3, 2],
[4, 5, 6],
[4, 6, 7],
[0, 1, 5],
[0, 5, 4],
[1, 2, 6],
[1, 6, 5],
[2, 3, 7],
[2, 7, 6],
[3, 0, 4],
[3, 4, 7],
] as const
return {
verts: vertices
.map(([x, y, z]) => `<vertex x="${fmt(x)}" y="${fmt(y)}" z="${fmt(z)}"/>`)
.join(''),
tris: faces.map(([a, b, c]) => `<triangle v1="${a}" v2="${b}" v3="${c}"/>`).join(''),
}
}
/** A solid of revolution about (cx, cy) from a bottom-to-top profile of (z, r)
* rings — a blocker volume, never printed. Wound outward. */
function emitRevolvedSolid(
cx: number,
cy: number,
zOffset: number,
profile: readonly { readonly z: number; readonly r: number }[],
segments: number
): { verts: string; tris: string } {
const n = segments
const pts: [number, number, number][] = []
for (const ring of profile) {
for (let i = 0; i < n; i++) {
const a = (2 * Math.PI * i) / n
pts.push([cx + ring.r * Math.cos(a), cy + ring.r * Math.sin(a), zOffset + ring.z])
}
}
const bottomCentre = pts.length
pts.push([cx, cy, zOffset + profile[0].z])
const topCentre = pts.length
pts.push([cx, cy, zOffset + profile[profile.length - 1].z])
const top = (profile.length - 1) * n
const faces: [number, number, number][] = []
for (let i = 0; i < n; i++) {
const j = (i + 1) % n
faces.push([bottomCentre, j, i])
faces.push([topCentre, top + i, top + j])
for (let k = 0; k + 1 < profile.length; k++) {
const lo = k * n
const hi = (k + 1) * n
faces.push([lo + i, lo + j, hi + j])
faces.push([lo + i, hi + j, hi + i])
}
}
return {
verts: pts.map(([x, y, z]) => `<vertex x="${fmt(x)}" y="${fmt(y)}" z="${fmt(z)}"/>`).join(''),
tris: faces.map(([a, b, c]) => `<triangle v1="${a}" v2="${b}" v3="${c}"/>`).join(''),
}
}
interface Box {
x0: number
y0: number
x1: number
y1: number
}
const intersects = (a: Box, b: Box): boolean =>
a.x0 < b.x1 && a.x1 > b.x0 && a.y0 < b.y1 && a.y1 > b.y0
const clamp = (v: number, lo: number, hi: number): number => Math.max(lo, Math.min(hi, v))
/** Grow a box outwards by `d` on every side. */
function inflate(b: Box, d: number): Box {
return { x0: b.x0 - d, y0: b.y0 - d, x1: b.x1 + d, y1: b.y1 + d }
}
/**
* Pin the prime tower into a gap that stays clear of the model.
*
* The tower goes beside the model: the sides are tried in descending free-room
* order (right / front / back / left) and the first that fits on the bed and clears
* every keep-out zone wins. With supports on, the keep-out is the model grown by
* SUPPORT_SKIRT, so the gap widens far enough that the tower's brim can never reach
* the model's support extrusion (see SUPPORT_SKIRT).
*
* The rectangle being packed is THH's pin-relative reservation — not
* `prime_tower_width`, and not a guessed min corner. That distinction is the whole
* contract: Orca's real bbox extends on both sides of its x/y pin and changes with
* purge inputs. THH verifies the output remains within this reservation.
*/
function placeWipeTower(
bed: BedSize,
obj: Box,
opts: Assemble3mfOpts = {}
): { xMm: number; yMm: number } {
const margin = bed.marginMm ?? 0
const excludes: Box[] = (bed.exclude ?? []).map((e) => ({
x0: e.xMm,
y0: e.yMm,
x1: e.xMm + e.wMm,
y1: e.yMm + e.dMm,
}))
const cx = (obj.x0 + obj.x1) / 2
const cy = (obj.y0 + obj.y1) / 2
const profile = opts.wipeTower ?? DEFAULT_WIPE_TOWER_PROFILE
const envelope = envelopeForFilaments(profile, opts.filaments)
const pinMidX = (envelope.minX + envelope.maxX) / 2
const pinMidY = (envelope.minY + envelope.maxY) / 2
// What the tower must stay off. Supports push the first layer outward, so the
// keep-out is the model plus SUPPORT_SKIRT — and the side candidates below hug
// THAT box, which is the whole fix: supports simply widen the gap, so the tower's
// brim and the model's support extrusion can never meet.
const supportSkirt = opts.support === true || opts.supportsAtSlice === true ? SUPPORT_SKIRT : 0
const grown = supportSkirt > 0 ? inflate(obj, supportSkirt) : obj
const keepOut: Box[] = [grown]
// Candidate PINS on each side, ordered by free room. Convert the desired reservation
// edge back through its pin-relative offset; wipe_tower_x/y is not the bbox min corner.
const sides = [
{
room: bed.wMm - margin - grown.x1,
x: grown.x1 + TOWER_GAP - envelope.minX,
y: cy - pinMidY,
}, // right
{
room: grown.y0 - margin,
x: cx - pinMidX,
y: grown.y0 - TOWER_GAP - envelope.maxY,
}, // front
{
room: bed.dMm - margin - grown.y1,
x: cx - pinMidX,
y: grown.y1 + TOWER_GAP - envelope.minY,
}, // back
{
room: grown.x0 - margin,
x: grown.x0 - TOWER_GAP - envelope.maxX,
y: cy - pinMidY,
}, // left
].sort((a, b) => b.room - a.room)
const fits = (pinX: number, pinY: number): Box | null => {
const rect: Box = {
x0: pinX + envelope.minX,
y0: pinY + envelope.minY,
x1: pinX + envelope.maxX,
y1: pinY + envelope.maxY,
}
const onBed =
rect.x0 >= margin &&
rect.y0 >= margin &&
rect.x1 <= bed.wMm - margin &&
rect.y1 <= bed.dMm - margin
const clear = ![...keepOut, ...excludes].some((k) => intersects(rect, k))
return onBed && clear ? rect : null
}
for (const s of sides) {
const x = clamp(s.x, margin - envelope.minX, bed.wMm - margin - envelope.maxX)
const y = clamp(s.y, margin - envelope.minY, bed.dMm - margin - envelope.maxY)
if (fits(x, y)) return { xMm: x, yMm: y }
}
// No side works: push the reservation into each bed corner and keep whichever sits
// furthest from hot extrusion. This is a last resort for unusually full plates.
const nearX = margin + TOWER_EDGE - envelope.minX
const farX = bed.wMm - margin - TOWER_EDGE - envelope.maxX
const nearY = margin + TOWER_EDGE - envelope.minY
const farY = bed.dMm - margin - TOWER_EDGE - envelope.maxY
const corners = [
{ x: farX, y: farY },
{ x: nearX, y: farY },
{ x: farX, y: nearY },
{ x: nearX, y: nearY },
]
let best: { xMm: number; yMm: number; room: number } | null = null
for (const c of corners) {
const rect = fits(c.x, c.y)
if (!rect) continue
const room = Math.min(
...[...keepOut, ...excludes].map((k) =>
Math.max(k.x0 - rect.x1, rect.x0 - k.x1, k.y0 - rect.y1, rect.y0 - k.y1)
)
)
if (!best || room > best.room) best = { xMm: c.x, yMm: c.y, room }
}
if (best) return { xMm: best.xMm, yMm: best.yMm }
throw new Error(
'abacus is too large to fit a prime tower on the print bed — reduce the size or filament count'
)
}
/**
* Assemble co-registered per-filament bodies into one bed-centered printable
* object with an owned prime tower. Multicolor only (`bodies.length >= 2`).
*/
export function assembleAbacus3mf(
bodies: readonly AssemblyBody[],
bed: BedSize,
opts: Assemble3mfOpts = {}
): Assembled3mf {
if (bodies.length === 0) {
throw new Error('assembleAbacus3mf needs at least one filament body')
}
if (bodies.length < 2 && !opts.support && !opts.placedOnBed) {
throw new Error(
'assembleAbacus3mf needs >= 2 filament bodies (single color rides meshesToThreeMf)'
)
}
// Merged bounding box across every body (shared render pose).
let minX = Infinity
let minY = Infinity
let minZ = Infinity
let maxX = -Infinity
let maxY = -Infinity
for (const b of bodies) {
const p = b.positions
for (let i = 0; i < p.length; i += 3) {
if (p[i] < minX) minX = p[i]
if (p[i] > maxX) maxX = p[i]
if (p[i + 1] < minY) minY = p[i + 1]
if (p[i + 1] > maxY) maxY = p[i + 1]
if (p[i + 2] < minZ) minZ = p[i + 2]
}
}
// Center the footprint on the bed and drop it to z=0 — unless the bodies were
// PLACED on this bed already (see Assemble3mfOpts.placedOnBed), in which case
// their x/y are the layout and only the z-drop applies.
const bedCx = bed.wMm / 2
const bedCy = bed.dMm / 2
const placed = opts.placedOnBed
const tx = placed ? 0 : bedCx - (minX + maxX) / 2
const ty = placed ? 0 : bedCy - (minY + maxY) / 2
const tz = -minZ
const objBox: Box = {
x0: bedCx - (maxX - minX) / 2,
y0: bedCy - (maxY - minY) / 2,
x1: bedCx + (maxX - minX) / 2,
y1: bedCy + (maxY - minY) / 2,
}
const tower = placed
? { xMm: placed.towerPinMm.x, yMm: placed.towerPinMm.y }
: placeWipeTower(bed, objBox, opts)
// ---- 3D/3dmodel.model ----
const childIds = bodies.map((_, i) => i + 2)
const baseEntries = bodies
.map(
(b, i) => `<base name="${escapeXml(b.label)}" displaycolor="${displayColor(b.colorHex)}"/>`
)
.join('')
const objectsXml = bodies
.map((b, i) => {
const { verts, tris } = emitBodyMesh(b.positions)
// object-level pid/pindex paints the whole body for core-3MF slicers
// (PrusaSlicer/Cura); Bambu/Orca color comes from the part `extruder` below.
return `<object id="${childIds[i]}" type="model" pid="1" pindex="${i}"><mesh><vertices>${verts}</vertices><triangles>${tris}</triangles></mesh></object>`
})
.join('')
// A generic core 3MF cannot carry Orca's height-range file reliably: Orca
// ignores that file unless the package is a fully native Bambu project. A
// modifier part in model_settings.config works on both generic and native
// projects, moves with this one assembly, and survives THH's --arrange 0 path.
const transitionMesh = opts.support
? emitModifierBox(minX, minY, maxX, maxY, 0, SUPPORT_TRANSITION_HEIGHT_MM)
: null
const transitionObjectXml = transitionMesh
? `<object id="${SUPPORT_TRANSITION_ID}" type="model"><mesh><vertices>${transitionMesh.verts}</vertices><triangles>${transitionMesh.tris}</triangles></mesh></object>`
: ''
// The feet-only variant's blockers (Gitea #45): one revolved volume per foot in
// source space, so they ride the same build transform as the bodies — source
// −H..0 lands on bed 0..H exactly where the foot stand-off does.
const blockers = (opts.supportBlockers ?? []).map((b, k) => ({
id: SUPPORT_BLOCKER_ID_BASE + k,
mesh: emitRevolvedSolid(
b.cx,
b.cy,
-b.heightMm,
supportBlockerProfile(b.heightMm, b.rFootMm),
SUPPORT_BLOCKER_SEGMENTS
),
}))
const blockerObjectsXml = blockers
.map(
({ id, mesh }) =>
`<object id="${id}" type="model"><mesh><vertices>${mesh.verts}</vertices><triangles>${mesh.tris}</triangles></mesh></object>`
)
.join('')
const componentsXml = childIds
.map((id) => `<component objectid="${id}" transform="1 0 0 0 1 0 0 0 1 0 0 0"/>`)
.concat(
transitionMesh
? [`<component objectid="${SUPPORT_TRANSITION_ID}" transform="1 0 0 0 1 0 0 0 1 0 0 0"/>`]
: [],
blockers.map(({ id }) => `<component objectid="${id}" transform="1 0 0 0 1 0 0 0 1 0 0 0"/>`)
)
.join('')
const assemblyXml = `<object id="${ASSEMBLY_ID}" type="model"><components>${componentsXml}</components></object>`
const model =
`<?xml version="1.0" encoding="UTF-8"?>\n` +
`<model unit="millimeter" xml:lang="en-US" xmlns="http://schemas.microsoft.com/3dmanufacturing/core/2015/02">` +
`<resources><basematerials id="1">${baseEntries}</basematerials>${objectsXml}${transitionObjectXml}${blockerObjectsXml}${assemblyXml}</resources>` +
`<build><item objectid="${ASSEMBLY_ID}" transform="1 0 0 0 1 0 0 0 1 ${fmt(tx)} ${fmt(ty)} ${fmt(tz)}"/></build>` +
`</model>`
// ---- Metadata/model_settings.config (Bambu/Orca per-part extruder) ----
const partsXml = bodies
.map(
(b, i) =>
`<part id="${childIds[i]}" subtype="normal_part"><metadata key="name" value="${escapeXml(b.label)}"/><metadata key="extruder" value="${b.extruder}"/>${partProcessXml(b)}</part>`
)
.join('')
const transitionPartXml = transitionMesh
? `<part id="${SUPPORT_TRANSITION_ID}" subtype="modifier_part">` +
`<metadata key="name" value="${SUPPORT_TRANSITION_NAME}"/>` +
SUPPORT_TRANSITION_SPEED_KEYS.map(
(key) => `<metadata key="${key}" value="${fmt(SUPPORT_TRANSITION_SPEED_MM_S)}"/>`
).join('') +
`</part>`
: ''
const blockerPartsXml = blockers
.map(
({ id }, k) =>
`<part id="${id}" subtype="support_blocker"><metadata key="name" value="${SUPPORT_BLOCKER_NAME}-foot-${k + 1}"/></part>`
)
.join('')
const modelSettings =
`<?xml version="1.0" encoding="UTF-8"?>\n<config>` +
`<object id="${ASSEMBLY_ID}"><metadata key="name" value="abacus"/>${partsXml}${transitionPartXml}${blockerPartsXml}</object>` +
`</config>`
// ---- Metadata/project_settings.config (owned tower + filament pin) ----
// `filament_map` pins every filament to AMS group 1 (single-extruder X1C/A1) —
// defeats Orca's filament-grouping rejection (exit 156). THH re-sets these on its
// side; we include them so a directly-sliced download is correct too.
//
// The support block (printed feet, Gitea #23) is the same belt: THH re-derives
// support policy from the ticket style, but a direct download must slice with
// the bottom face supported on its own. `support_on_build_plate_only` is load-
// bearing — nothing may grow inside the bead channels or on the beads; the only
// support this print wants rises plate→bottom-face. `support_interface_filament`
// is deliberately absent: the interface spool isn't a 3MF body, THH owns that
// key (computed from ticket filament order).
const projectSettings = JSON.stringify({
filament_colour: bodies.map((b) => filamentColor(b.colorHex)),
filament_map_mode: 'Manual',
filament_map: bodies.map(() => '1'),
wipe_tower_x: fmt(tower.xMm),
wipe_tower_y: fmt(tower.yMm),
// Direct-download slices use the same bounded shape as API prints. THH owns and
// re-applies these on submit; embedding them here keeps the standalone 3MF honest.
prime_tower_width: fmt(
(opts.wipeTower ?? DEFAULT_WIPE_TOWER_PROFILE).process.prime_tower_width
),
prime_tower_brim_width: fmt(
(opts.wipeTower ?? DEFAULT_WIPE_TOWER_PROFILE).process.prime_tower_brim_width
),
wipe_tower_wall_type: (opts.wipeTower ?? DEFAULT_WIPE_TOWER_PROFILE).process
.wipe_tower_wall_type,
...(opts.support
? {
enable_support: '1',
support_type: 'normal(auto)',
support_on_build_plate_only: '1',
support_interface_top_layers: '2',
support_top_z_distance: '0.2',
}
: {}),
})
const contentTypes =
`<?xml version="1.0" encoding="UTF-8"?>\n` +
`<Types xmlns="http://schemas.openxmlformats.org/package/2006/content-types">` +
`<Default Extension="rels" ContentType="application/vnd.openxmlformats-package.relationships+xml"/>` +
`<Default Extension="model" ContentType="application/vnd.ms-package.3dmanufacturing-3dmodel+xml"/>` +
`</Types>`
const rels =
`<?xml version="1.0" encoding="UTF-8"?>\n` +
`<Relationships xmlns="http://schemas.openxmlformats.org/package/2006/relationships">` +
`<Relationship Target="/3D/3dmodel.model" Id="rel-1" Type="http://schemas.microsoft.com/3dmanufacturing/2013/01/3dmodel"/>` +
`</Relationships>`
const entries = {
'[Content_Types].xml': strToU8(contentTypes),
'_rels/.rels': strToU8(rels),
'3D/3dmodel.model': strToU8(model),
'Metadata/model_settings.config': strToU8(modelSettings),
'Metadata/project_settings.config': strToU8(projectSettings),
}
const bytes = zipSync(entries, { mtime: THREE_MF_ZIP_MTIME })
return { bytes, wipeTower: tower }
}
|