fix(slice): reject slicer warnings in strict mode

CHANGELOG.md

@@ -26,6 +26,7 @@ JSON field names and exit codes are part of the public API.
 - `preflight` `single_filament` now fails only when the number of `--slot`s differs from the number of filaments in the plate. Single-filament jobs send the same payload as before.
 
 ### Fixed
+- `slice --strict` rejects slicer warnings, including floating regions, with exit 11 before publishing new output files. JSON errors include the warnings and slicer log path; slicing without `--strict` still reports warnings in the summary.
 - `slice --set` now preserves JSON list values, including commas inside quoted entries; comma-separated batches and repeated overrides remain supported.
 - `print pause` and `print stop` now verify PAUSE or an idle state before exiting 0; `--wait` defaults to 30s and must be positive.
 - A failed retry cannot reuse a prior successful slice. Every slice verifies its requested filament changes, including an empty change list.

SPEC.md

@@ -230,7 +230,9 @@ All recipes use `brim_type = no_brim`. **Brims are opt-in** (`--set brim_type=ou
 `preflight` and `print send` accept `--strict`, retaining the Python operator's gates while keeping the existing Go
 default: material variants must match exactly, temperature bounds must both be finite and valid, and unknown nozzle
 material produces a WARN rather than an assumed match. `preflight.strict` records the selected mode. `slice --strict`
-requires an extracted plate preview before publishing the new 3MF. All slices reject unexpected tool changes and stale
+requires an extracted plate preview and rejects slicer warnings (including floating regions) with exit 11 before
+publishing any new slice outputs. The JSON error includes the warning text and slicer log path. Without `--strict`,
+warnings remain in the successful slice summary. All slices reject unexpected tool changes and stale
 output from a previous invocation.
 
 | gate | FAIL when | WARN when |

docs/operator-migration.md

@@ -31,7 +31,8 @@ remain in place. A multi-filament `slice --slot` records one suggested slot; act
 
 Use `--strict` for operator slice/preflight/send. Default Go gate behavior stays compatible, including same-family
 material warnings and omitted temperature bounds. Strict mode fails unequal material types and unknown or malformed
-temperature bounds. A different product/profile remains a WARN in both tools. The strict slice requires a preview.
+temperature bounds. A different product/profile remains a WARN in both tools. The strict slice requires a preview
+and rejects slicer warnings with exit 11 before publishing new outputs.
 
 Go's slice JSON is the summary directly, without Python's `slice` wrapper. It includes
 `objects[].footprint_incl_brim_mm`, the first plate's dimensions, and `suggested_slot`. `status` keeps a `status` wrapper

internal/cmd/slice.go

@@ -27,7 +27,7 @@ type SliceCmd struct {
 	Out        string    `short:"o" help:"Output directory (default: config output_dir, else current dir)." type:"path"`
 	AutoOrient bool      `name:"auto-orient" help:"Let the slicer re-orient the model (default: keep the model's orientation)."`
 	Slot       string    `help:"Record the intended AMS slot in the summary; send still requires --slot."`
-	Strict     bool      `help:"Require a plate preview as part of the slice evidence."`
+	Strict     bool      `help:"Require a plate preview and reject slicer warnings before publishing outputs."`
 }
 
 // Run executes the command.
@@ -82,7 +82,7 @@ func (c *SliceCmd) Run(g *Globals) error {
 		Model: c.Model, Recipe: r, MachinePreset: m.MachinePreset(p.NozzleString()), Plate: p.Plate,
 		Filaments: c.Filament, Colors: c.Color, ChangeZs: c.ChangeZ, Sets: c.Set, Name: name, OutDir: out,
 		WorkDir: filepath.Join(cache, "bambu", "slice", name), AutoOrient: c.AutoOrient,
-		StepPython: expand(cfg.Slicer.StepPython), SuggestedSlot: c.Slot, RequirePreview: c.Strict,
+		StepPython: expand(cfg.Slicer.StepPython), SuggestedSlot: c.Slot, Strict: c.Strict,
 	})
 	if err != nil {
 		return err

internal/slicer/parity_test.go

@@ -9,9 +9,11 @@ import (
 	"path/filepath"
 	"reflect"
 	"runtime"
+	"strings"
 	"testing"
 
 	"github.com/voska/bambu/internal/errfmt"
+	"github.com/voska/bambu/internal/testutil"
 )
 
 func TestRunDoesNotReuseStaleSlice(t *testing.T) {
@@ -84,7 +86,7 @@ func TestStrictSliceNeedsPreview(t *testing.T) {
 		t.Skip("shell fake")
 	}
 	_, rq, err := twoFilamentRun(t, func(r *Request) {
-		r.RequirePreview = true
+		r.Strict = true
 		zr, err := zip.OpenReader(os.Getenv("FAKE_3MF"))
 		if err != nil {
 			t.Fatal(err)
@@ -126,6 +128,77 @@ func TestStrictSliceNeedsPreview(t *testing.T) {
 	}
 }
 
+func TestStrictSliceWarnings(t *testing.T) {
+	if runtime.GOOS == "windows" {
+		t.Skip("shell fake")
+	}
+	const floating = "It seems object CadQuery Component has floating regions. Please re-orient the object or enable support generation."
+	for _, tc := range []struct {
+		name    string
+		strict  bool
+		warning string
+	}{
+		{"strict floating regions", true, floating},
+		{"strict other warning", true, "Unsupported regions detected."},
+		{"strict clean slice", true, ""},
+		{"default floating regions", false, floating},
+	} {
+		t.Run(tc.name, func(t *testing.T) {
+			sum, rq, err := twoFilamentRun(t, func(r *Request) {
+				r.Strict = tc.strict
+				r.Filaments, r.Colors, r.ChangeZs = nil, nil, nil
+				t.Setenv("FAKE_3MF", testutil.Write(t, t.TempDir(), "prepared", testutil.Opts{}))
+				b, err := os.ReadFile(os.Getenv("FAKE_RESULT"))
+				if err != nil {
+					t.Fatal(err)
+				}
+				var res map[string]any
+				if err := json.Unmarshal(b, &res); err != nil {
+					t.Fatal(err)
+				}
+				res["sliced_plates"].([]any)[0].(map[string]any)["warning_message"] = tc.warning
+				b, err = json.Marshal(res)
+				if err != nil {
+					t.Fatal(err)
+				}
+				path := filepath.Join(t.TempDir(), "warning-result.json")
+				if err := os.WriteFile(path, b, 0o600); err != nil {
+					t.Fatal(err)
+				}
+				t.Setenv("FAKE_RESULT", path)
+			})
+			if tc.strict && tc.warning != "" {
+				if err == nil {
+					t.Fatal("strict slice accepted a slicer warning")
+				}
+				e := errfmt.As(err)
+				if e.Code != errfmt.ExitSliceFailed || !strings.Contains(e.Message, tc.warning) ||
+					!reflect.DeepEqual(e.Data["warnings"], []string{tc.warning}) || e.Data["log"] == "" {
+					t.Fatalf("warning must be reported as a structured slice failure: %+v", e)
+				}
+				if sum != nil {
+					t.Fatal("rejected slice returned a success summary")
+				}
+				entries, err := os.ReadDir(rq.OutDir)
+				if err != nil || len(entries) != 0 {
+					t.Fatalf("rejected slice must not publish any output: %v %v", entries, err)
+				}
+				return
+			}
+			if err != nil {
+				t.Fatal(err)
+			}
+			want := []string{}
+			if tc.warning != "" {
+				want = append(want, tc.warning)
+			}
+			if !reflect.DeepEqual(sum.Warnings, want) || !exists(sum.Gcode3MF) || !exists(sum.SummaryJSON) {
+				t.Fatalf("successful slice must preserve warnings and publish outputs: %+v", sum)
+			}
+		})
+	}
+}
+
 func TestSTEPConversion(t *testing.T) {
 	if runtime.GOOS == "windows" {
 		t.Skip("shell fake")

internal/slicer/slice.go

@@ -42,21 +42,21 @@ var CLIErrors = map[int]string{
 
 // Request is one slice job.
 type Request struct {
-	Model          string
-	Recipe         recipe.Recipe
-	MachinePreset  string    // e.g. "Bambu Lab X1 Carbon 0.4 nozzle"
-	Plate          string    // installed plate id, e.g. "textured_plate"
-	Filaments      []string  // filament presets in print order (default: the recipe's)
-	Colors         []string  // spool colour per filament (RRGGBB); Studio sizes the purge between filaments from them
-	ChangeZs       []float64 // filament n+1 starts on the first layer above ChangeZs[n-1]
-	Sets           []string  // key=value overrides
-	Name           string    // output base name
-	OutDir         string    // where the .gcode.3mf/.png/.summary.json go
-	WorkDir        string    // scratch dir for configs and slicer output
-	AutoOrient     bool
-	StepPython     string // interpreter with CadQuery for STEP input (default python3)
-	SuggestedSlot  string
-	RequirePreview bool
+	Model         string
+	Recipe        recipe.Recipe
+	MachinePreset string    // e.g. "Bambu Lab X1 Carbon 0.4 nozzle"
+	Plate         string    // installed plate id, e.g. "textured_plate"
+	Filaments     []string  // filament presets in print order (default: the recipe's)
+	Colors        []string  // spool colour per filament (RRGGBB); Studio sizes the purge between filaments from them
+	ChangeZs      []float64 // filament n+1 starts on the first layer above ChangeZs[n-1]
+	Sets          []string  // key=value overrides
+	Name          string    // output base name
+	OutDir        string    // where the .gcode.3mf/.png/.summary.json go
+	WorkDir       string    // scratch dir for configs and slicer output
+	AutoOrient    bool
+	StepPython    string // interpreter with CadQuery for STEP input (default python3)
+	SuggestedSlot string
+	Strict        bool // require a preview and reject slicer warnings before publishing outputs
 }
 
 // Summary is the slice result (the --json contract).
@@ -498,12 +498,23 @@ func Run(ctx context.Context, st *Studio, ix *Index, req Request) (*Summary, err
 			WithHint("%s; fix the recipe/--set values; log: %s", or(CLIErrors[res.ReturnCode], "see log"), logPath).
 			WithData("return_code", res.ReturnCode).WithData("details", details).WithData("log", logPath)
 	}
+	warnings := []string{}
+	for _, p := range res.SlicedPlates {
+		if p.WarningMessage != "" {
+			warnings = append(warnings, p.WarningMessage)
+		}
+	}
+	if req.Strict && len(warnings) > 0 {
+		return nil, errfmt.New(errfmt.ExitSliceFailed, "strict slice rejected slicer warnings: %s", strings.Join(warnings, "; ")).
+			WithHint("no new slice outputs were published; resolve the warnings and inspect the G-code before printing; log: %s", logPath).
+			WithData("warnings", warnings).WithData("log", logPath)
+	}
 	if err := checkChanges(filepath.Join(work, threemf), tops, logPath); err != nil {
 		return nil, err
 	}
 	png := filepath.Join(out, name+".png")
 	if err := extract(filepath.Join(work, threemf), "Metadata/plate_1.png", png); err != nil {
-		if req.RequirePreview {
+		if req.Strict {
 			return nil, errfmt.Wrap(errfmt.ExitSliceFailed, err, "slicer did not produce a plate preview")
 		}
 		png = ""
@@ -522,7 +533,7 @@ func Run(ctx context.Context, st *Studio, ix *Index, req Request) (*Summary, err
 		TimeS: j.PredictionS, Time: j.TotalTime, WeightG: j.WeightG, Layers: j.Layers, Filaments: j.Filaments,
 		FilamentChanges: j.FilamentChanges, FilamentPresets: cfgs.FilamentPresets,
 		BedType: j.BedType, BedTemp: j.BedTemp, NozzleTemp: j.NozzleTemp, NozzleFirst: j.NozzleTempFirst,
-		Presets: cfgs.Presets, Overrides: cfgs.Applied, Notes: cfgs.Notes, Warnings: []string{}, Settings: j.Settings,
+		Presets: cfgs.Presets, Overrides: cfgs.Applied, Notes: cfgs.Notes, Warnings: warnings, Settings: j.Settings,
 		AutoOrient: req.AutoOrient, SlicerLog: logPath, StudioVersion: st.Version,
 		SuggestedSlot: req.SuggestedSlot, Objects: []Object{},
 	}
@@ -538,9 +549,6 @@ func Run(ctx context.Context, st *Studio, ix *Index, req Request) (*Summary, err
 				}
 			}
 		}
-		if p.WarningMessage != "" {
-			sum.Warnings = append(sum.Warnings, p.WarningMessage)
-		}
 		sum.PrimeTower = sum.PrimeTower || p.FeatureTypeTimes["Prime tower"] > 0
 		for _, u := range p.Filaments {
 			for i := range sum.Filaments {