bambuddy/backend/app/services/usage_tracker.py

"""Automatic filament consumption tracking.

Captures AMS tray remain% at print start, then computes consumption
deltas at print complete to update spool weight_used and last_used.

Primary tracking uses 3MF slicer estimates (precise per-filament data).
AMS remain% delta is the fallback for trays not covered by 3MF data.
"""

import asyncio
import json
import logging
import re
from dataclasses import dataclass, field
from datetime import datetime, timezone

from sqlalchemy import func, select, update
from sqlalchemy.ext.asyncio import AsyncSession

from backend.app.models.spool import Spool
from backend.app.models.spool_assignment import SpoolAssignment
from backend.app.models.spool_usage_history import SpoolUsageHistory

logger = logging.getLogger(__name__)


def _decode_mqtt_mapping(mapping_raw: list | None) -> list[int] | None:
    """Decode MQTT mapping field (snow-encoded) to bambuddy global tray IDs.

    The printer's MQTT mapping field is an array indexed by slicer filament slot
    (0-based). Each value uses snow encoding: ams_hw_id * 256 + local_slot.
    65535 means unmapped.

    Returns a list of bambuddy global tray IDs (or -1 for unmapped), or None if
    no valid mappings found.
    """
    if not isinstance(mapping_raw, list) or not mapping_raw:
        return None

    result = []
    for value in mapping_raw:
        if not isinstance(value, int) or value >= 65535:
            result.append(-1)
            continue

        ams_hw_id = value >> 8
        slot = value & 0xFF

        if 0 <= ams_hw_id <= 3:
            # Regular AMS: sequential global ID
            result.append(ams_hw_id * 4 + (slot & 0x03))
        elif 128 <= ams_hw_id <= 135:
            # AMS-HT: global ID is the hardware ID (one slot per unit)
            result.append(ams_hw_id)
        elif ams_hw_id in (254, 255):
            # External spool
            result.append(254 if slot != 255 else 255)
        else:
            result.append(-1)

    # Only return if at least one valid mapping exists
    if all(v < 0 for v in result):
        return None

    return result


def _spool_color_to_hex(rgba: str | None) -> str | None:
    """Normalise a ``Spool.rgba`` value (``RRGGBBAA`` hex, no ``#``) to the
    ``#RRGGBB`` form archives store in ``filament_color``.

    Alpha is dropped — the archive colour list and the Color Distribution
    graph treat filament colour as opaque. Returns ``None`` for a missing or
    too-short value so the caller can fall back to the 3MF colour.
    """
    if not rgba:
        return None
    h = rgba.strip().lstrip("#")
    if len(h) < 6:
        return None
    return "#" + h[:6].upper()


def _archive_colors_from_spools(filament_usage: list[dict], results: list[dict]) -> list[str] | None:
    """Slot-ordered, de-duplicated hex colours for an archive's ``filament_color``,
    taken from the inventory spools that actually fed the print (#1494).

    The slicer's 3MF carries its own ``filament_colour`` per slot — a value
    picked independently of the colour the user curates on the matched
    inventory spool. So an archive printed from a ``#000000`` inventory spool
    would otherwise show the slicer's near-black ``#161616``. Once usage
    tracking has resolved the used slots to spools, the spool colours are the
    authoritative source and replace the 3MF values.

    Returns ``None`` — leave the 3MF colour untouched — unless *every* slot
    with non-zero usage was matched to a spool that carries a colour. A
    partial rewrite would silently drop the unmatched slots' colours from the
    archive (and the Color Distribution graph), so it is all-or-nothing.
    """
    used_slots = {u["slot_id"] for u in filament_usage if u.get("used_g", 0) > 0 and u.get("slot_id") is not None}
    if not used_slots:
        return None

    slot_color: dict[int, str] = {}
    for r in results:
        slot_id = r.get("slot_id")
        color = r.get("color")
        if slot_id is not None and color:
            slot_color.setdefault(slot_id, color)

    if not used_slots.issubset(slot_color):
        return None

    ordered: list[str] = []
    for slot_id in sorted(used_slots):
        color = slot_color[slot_id]
        if color not in ordered:
            ordered.append(color)
    return ordered


def _archive_types_from_spools(filament_usage: list[dict], results: list[dict]) -> list[str] | None:
    """Slot-ordered, de-duplicated materials for an archive's ``filament_type``,
    taken from the inventory spools that actually fed the print (#2563).

    The slicer's 3MF records the filament type it was *sliced for*. When the
    user manually maps a slot to a differently-typed loaded spool in the Print
    dialog — a PLA slice routed to the only loaded PETG slot — that sliced type
    misclassifies the run in the archive card, the Print Log and the material
    statistics, even though the deduction correctly hit the PETG spool. Once
    usage tracking has resolved every used slot to an inventory spool, the
    spool's declared material is the authoritative record of what was consumed,
    the same reasoning that already adopts the spool colour (#1494).

    Returns ``None`` — leave the 3MF type untouched — unless *every* slot with
    non-zero usage was matched to a spool that carries a material. All-or-
    nothing, exactly like ``_archive_colors_from_spools``: a partial rewrite
    would silently drop the unmatched slots' types from the archive (and the
    material stats).
    """
    used_slots = {u["slot_id"] for u in filament_usage if u.get("used_g", 0) > 0 and u.get("slot_id") is not None}
    if not used_slots:
        return None

    slot_material: dict[int, str] = {}
    for r in results:
        slot_id = r.get("slot_id")
        material = (r.get("material") or "").strip()
        if slot_id is not None and material:
            slot_material.setdefault(slot_id, material)

    if not used_slots.issubset(slot_material):
        return None

    ordered: list[str] = []
    for slot_id in sorted(used_slots):
        material = slot_material[slot_id]
        if material not in ordered:
            ordered.append(material)
    return ordered


def _match_slots_by_color(
    filament_usage: list[dict],
    ams_raw: dict | list | None,
) -> list[int] | None:
    """Match 3MF filament slots to AMS trays by color.

    Fallback mapping for printers that don't provide the MQTT mapping field
    or request topic subscription (e.g. A1, A1 Mini, P1S, P2S).

    Compares the 3MF slicer filament color (per slot) against each AMS tray's
    color to find a unique match. Only returns a mapping if every used slot
    matches exactly one tray (no ambiguity).

    Args:
        filament_usage: List of 3MF slot dicts with 'slot_id', 'color', 'type'
        ams_raw: raw_data["ams"] dict or list from printer state

    Returns:
        List of global tray IDs indexed by slicer slot (0-based), or None.
    """
    if not filament_usage or not ams_raw:
        return None

    ams_data = ams_raw.get("ams", []) if isinstance(ams_raw, dict) else ams_raw if isinstance(ams_raw, list) else []
    if not ams_data:
        return None

    # Build map of normalized color → list of global tray IDs
    color_to_trays: dict[str, list[int]] = {}
    for ams_unit in ams_data:
        ams_id = int(ams_unit.get("id", 0))
        for tray in ams_unit.get("tray", []):
            tray_id = int(tray.get("id", 0))
            tray_color = tray.get("tray_color", "")
            tray_type = tray.get("tray_type", "")
            if not tray_color or not tray_type:
                continue
            # Normalize AMS color: strip alpha (last 2 chars), lowercase
            norm = tray_color[:6].lower() if len(tray_color) >= 6 else tray_color.lower()
            if ams_id >= 128:
                global_id = ams_id  # AMS-HT
            else:
                global_id = ams_id * 4 + tray_id
            color_to_trays.setdefault(norm, []).append(global_id)

    if not color_to_trays:
        return None

    # Find max slot_id to size the result array
    max_slot = max(u.get("slot_id", 0) for u in filament_usage)
    if max_slot <= 0:
        return None

    result = [-1] * max_slot
    used_trays: set[int] = set()

    for usage in filament_usage:
        slot_id = usage.get("slot_id", 0)
        if slot_id <= 0:
            continue
        slot_color = usage.get("color", "").lstrip("#").lower()
        if len(slot_color) < 6:
            return None  # Can't match without a valid color

        slot_color = slot_color[:6]  # Strip alpha if present
        candidates = color_to_trays.get(slot_color, [])
        # Filter out trays already claimed by another slot
        available = [t for t in candidates if t not in used_trays]

        if len(available) != 1:
            # Ambiguous (multiple trays with same color) or no match
            return None

        result[slot_id - 1] = available[0]
        used_trays.add(available[0])

    # Only return if at least one valid mapping exists
    if all(v < 0 for v in result):
        return None

    logger.info("[UsageTracker] Color-matched slot_to_tray: %s", result)
    return result


@dataclass
class PrintSession:
    printer_id: int
    print_name: str
    started_at: datetime
    tray_remain_start: dict[tuple[int, int], int] = field(default_factory=dict)
    # tray_now at print start (correct value, unlike at completion where it's 255)
    tray_now_at_start: int = -1
    # Snapshot of spool assignments at print start: {(ams_id, tray_id): spool_id}
    # Prevents usage loss when on_ams_change unlinks a spool mid-print
    spool_assignments: dict[tuple[int, int], int] = field(default_factory=dict)
    # AMS mapping from print command (captured at start, needed when auto-archive is off)
    ams_mapping: list[int] | None = None
    # Queue item's plate_id when this print is a multi-plate 3MF dispatched for a
    # single plate (#1697). None for non-queue prints — the file's first/only plate
    # is the default and the 3MF parser already returns the full file in that case.
    plate_id: int | None = None


# Module-level storage, keyed by printer_id. Mirrored to the
# ``active_print_sessions`` table so a restart mid-print doesn't lose the
# context — see ``persist_session`` / ``restore_session``.
_active_sessions: dict[int, PrintSession] = {}

# Printers whose finished print is being closed out. on_print_complete takes the
# session first and charges the usage several awaits later; the printer already
# reports FINISH, so without this mark the AMS remain% weight sync would run in
# between and the print would be charged twice (WU-3).
_completing: set[int] = set()


def mark_completing(printer_id: int) -> None:
    """The completion path's first step: hold the weight sync off until the
    usage is booked (discard_session) or the completion ends."""
    _completing.add(printer_id)


def done_completing(printer_id: int) -> None:
    _completing.discard(printer_id)


def is_completing(printer_id: int) -> bool:
    """The printer's finished print is being closed out (on_print_complete runs)."""
    return printer_id in _completing


def printer_is_charging(printer_id: int) -> bool:
    """A print's usage is still to be charged: it runs, or it ended and its
    completion has not booked it yet. The AMS remain% sync leaves the
    printer's spools alone meanwhile (#880)."""
    return printer_id in _active_sessions or printer_id in _completing


# Serialises the read-modify-write on the persisted tray-change log, per printer.
_tray_change_locks: dict[int, asyncio.Lock] = {}


def _tray_key_to_str(key: tuple[int, int]) -> str:
    return f"{key[0]}-{key[1]}"


def _tray_key_from_str(key: str) -> tuple[int, int] | None:
    ams_str, _, tray_str = key.partition("-")
    try:
        return int(ams_str), int(tray_str)
    except ValueError:
        return None


def _tray_map_to_json(mapping: dict[tuple[int, int], int]) -> dict[str, int]:
    return {_tray_key_to_str(k): v for k, v in mapping.items()}


def _tray_map_from_json(mapping: dict | None) -> dict[tuple[int, int], int]:
    result: dict[tuple[int, int], int] = {}
    for raw_key, value in (mapping or {}).items():
        key = _tray_key_from_str(str(raw_key))
        if key is not None and isinstance(value, int):
            result[key] = value
    return result


async def _charge_spool(db: AsyncSession, spool: Spool, grams: float) -> bool:
    """Add *grams* to the spool's usage in the database itself (WU-4).

    The spool was loaded several awaits earlier; a weight set by hand or
    weighed on the scale since then would be lost to a write of the value
    computed from that copy. The loaded copy is set to the stored result: from
    this statement until the commit, the transaction holds the row (the write
    lock on SQLite), so writing it back on flush changes nothing.

    False when the spool was deleted meanwhile: the caller skips it, since a
    usage row for it would break its foreign key on PostgreSQL and roll back
    the whole completion.
    """
    now = datetime.now(timezone.utc)
    stored = await db.scalar(
        update(Spool)
        .where(Spool.id == spool.id)
        .values(weight_used=func.coalesce(Spool.weight_used, 0) + grams, last_used=now)
        .returning(Spool.weight_used)
        .execution_options(synchronize_session=False)
    )
    if stored is None:
        return False
    spool.weight_used = stored
    spool.last_used = now
    return True


async def persist_session(
    db: AsyncSession,
    session: PrintSession,
    tray_change_log: list | None = None,
) -> None:
    """Mirror ``session`` into ``active_print_sessions`` for restart recovery.

    Overwrites any existing row for the printer: a printer runs one print at a
    time, and a row left behind by a completion we never saw must not outlive
    the next print start.
    """
    from backend.app.models.active_print_session import ActivePrintSession

    row = await db.get(ActivePrintSession, session.printer_id)
    if row is None:
        row = ActivePrintSession(printer_id=session.printer_id)
        db.add(row)

    row.print_name = session.print_name or ""
    row.started_at = session.started_at.replace(tzinfo=None)
    row.tray_now_at_start = session.tray_now_at_start
    row.plate_id = session.plate_id
    row.ams_mapping = list(session.ams_mapping) if session.ams_mapping else None
    row.spool_assignments = _tray_map_to_json(session.spool_assignments) or None
    row.tray_remain_start = _tray_map_to_json(session.tray_remain_start) or None
    row.tray_change_log = [list(entry) for entry in (tray_change_log or [])] or None

    await db.commit()


async def record_tray_change(db: AsyncSession, printer_id: int, tray_global: int, layer_num: int) -> None:
    """Append one tray change to the persisted log.

    No-op when no print-start row exists — a tray change outside a tracked
    print has nothing to attribute.
    """
    from backend.app.models.active_print_session import ActivePrintSession

    # Read-modify-write on a JSON column: two changes close together (a runout
    # parks the extruder and the backup tray loads moments later) would
    # otherwise race and drop a segment boundary.
    async with _tray_change_locks.setdefault(printer_id, asyncio.Lock()):
        row = await db.get(ActivePrintSession, printer_id)
        if row is None:
            return

        log = [list(entry) for entry in (row.tray_change_log or [])]
        entry = [tray_global, layer_num]
        if log and log[-1] == entry:
            # print-start seeds the log from PrinterState, which may already
            # hold a change this callback is also reporting.
            return
        log.append(entry)
        row.tray_change_log = log
        await db.commit()


async def get_persisted_print_name(db: AsyncSession, printer_id: int) -> str | None:
    """Print name on the persisted row, for identity-checking a restored session."""
    from backend.app.models.active_print_session import ActivePrintSession

    row = await db.get(ActivePrintSession, printer_id)
    return row.print_name if row is not None else None


async def restore_session(db: AsyncSession, printer_id: int, register_active: bool = True) -> list[list[int]] | None:
    """Rebuild the in-memory session for ``printer_id`` from the persisted row.

    Returns the persisted tray-change log so the caller can put it back on
    ``PrinterState``, or None when there is nothing to restore.

    ``register_active=False`` returns the log without publishing the session to
    ``_active_sessions`` — for Spoolman users, who need the tray-change log
    restored but whose remain%-sync must not be suppressed by it (see
    ``on_print_start``).
    """
    from backend.app.models.active_print_session import ActivePrintSession

    row = await db.get(ActivePrintSession, printer_id)
    if row is None:
        return None

    started_at = row.started_at
    if started_at.tzinfo is None:
        started_at = started_at.replace(tzinfo=timezone.utc)

    session = PrintSession(
        printer_id=printer_id,
        print_name=row.print_name or "",
        started_at=started_at,
        tray_remain_start=_tray_map_from_json(row.tray_remain_start),
        tray_now_at_start=row.tray_now_at_start,
        spool_assignments=_tray_map_from_json(row.spool_assignments),
        ams_mapping=list(row.ams_mapping) if row.ams_mapping else None,
        plate_id=row.plate_id,
    )
    if register_active:
        _active_sessions[printer_id] = session

    log = [list(entry) for entry in (row.tray_change_log or [])]
    logger.info(
        "[UsageTracker] Restored print session for printer %d: plate_id=%s, ams_mapping=%s, "
        "%d assignments, tray_change_log=%s",
        printer_id,
        row.plate_id,
        row.ams_mapping,
        len(row.spool_assignments or {}),
        log,
    )
    return log


async def clear_persisted_session(db: AsyncSession, printer_id: int) -> None:
    """Drop the persisted print-start row once the print is closed out."""
    from backend.app.models.active_print_session import ActivePrintSession

    row = await db.get(ActivePrintSession, printer_id)
    if row is not None:
        await db.delete(row)
        await db.commit()


def forget_printer(printer_id: int) -> None:
    """A deleted printer's print-start context in memory (the row goes with the printer)."""
    _active_sessions.pop(printer_id, None)
    _completing.discard(printer_id)
    _tray_change_locks.pop(printer_id, None)


async def discard_session(db: AsyncSession, printer_id: int) -> None:
    """Forget a printer's print-start context, in memory and on disk.

    The completion path calls this for every print, including the ones whose
    usage Spoolman owns: the context is captured for both backends, but only
    the internal tracker's ``on_print_complete`` consumes (and pops) it.
    """
    _active_sessions.pop(printer_id, None)
    _completing.discard(printer_id)
    _tray_change_locks.pop(printer_id, None)
    await clear_persisted_session(db, printer_id)


def _to_epoch_seconds(value: datetime | None) -> float | None:
    """Convert datetime to epoch seconds, assuming UTC for naive values."""
    if value is None:
        return None
    dt = value
    if dt.tzinfo is None:
        dt = dt.replace(tzinfo=timezone.utc)
    return dt.timestamp()


async def _resolve_spool_id_for_tray(
    printer_id: int,
    ams_id: int,
    tray_id: int,
    db: AsyncSession,
    spool_assignments_snapshot: dict[tuple[int, int], int] | None = None,
    print_started_at: datetime | None = None,
) -> int | None:
    """Resolve spool ID for a tray with safe support for mid-print reassignment.

    Resolution order:
    1. If snapshot exists and live assignment changed *during this print*, use live spool.
    2. Otherwise use snapshot spool when available.
    3. Fall back to live assignment.
    """
    key = (ams_id, tray_id)
    snapshot_spool_id = spool_assignments_snapshot.get(key) if spool_assignments_snapshot else None

    # Backward-compatible fast path: if we have a snapshot but no print-start
    # timestamp, preserve legacy behavior and avoid extra DB lookups.
    if snapshot_spool_id is not None and print_started_at is None:
        return snapshot_spool_id

    result = await db.execute(
        select(SpoolAssignment).where(
            SpoolAssignment.printer_id == printer_id,
            SpoolAssignment.ams_id == ams_id,
            SpoolAssignment.tray_id == tray_id,
        )
    )
    live_assignment = result.scalar_one_or_none()

    if snapshot_spool_id is not None:
        if live_assignment and live_assignment.spool_id != snapshot_spool_id:
            live_created_ts = _to_epoch_seconds(getattr(live_assignment, "created_at", None))
            started_ts = _to_epoch_seconds(print_started_at)
            if live_created_ts is not None and started_ts is not None and live_created_ts >= started_ts:
                logger.info(
                    "[UsageTracker] Assignment changed during print for printer %d AMS%d-T%d: snapshot spool %d -> live spool %d",
                    printer_id,
                    ams_id,
                    tray_id,
                    snapshot_spool_id,
                    live_assignment.spool_id,
                )
                return live_assignment.spool_id
        return snapshot_spool_id

    if live_assignment:
        return live_assignment.spool_id

    return None


async def on_print_start(
    printer_id: int,
    data: dict,
    printer_manager,
    db: AsyncSession | None = None,
    spoolman_owns_usage: bool = False,
) -> None:
    """Capture AMS tray remain% and spool assignments at print start.

    The capture runs for both inventory backends — the persisted row carries
    the tray-change log, which is the only record of which spool fed which
    layers when AMS Filament Backup swaps trays, and Spoolman's own durable
    row (#1820) does not hold it.

    ``spoolman_owns_usage`` keeps the in-memory session out of
    ``_active_sessions`` when Spoolman is writing the usage. That dict doubles
    as ``on_ams_change``'s "a print is running, so skip the remain%-based
    weight sync because the internal tracker will deduct precisely" flag
    (#880); registering a session the internal tracker will never complete
    would suppress a sync those users still need.
    """
    # A new print: whatever the last completion left marked is over.
    _completing.discard(printer_id)
    state = printer_manager.get_status(printer_id)
    if not state or not state.raw_data:
        logger.debug("[UsageTracker] No state for printer %d, skipping", printer_id)
        return

    ams_raw = state.raw_data.get("ams", [])
    ams_data = ams_raw.get("ams", []) if isinstance(ams_raw, dict) else ams_raw if isinstance(ams_raw, list) else []

    tray_remain_start: dict[tuple[int, int], int] = {}
    skipped_invalid: list[str] = []

    for ams_unit in ams_data:
        ams_id = int(ams_unit.get("id", 0))
        for tray in ams_unit.get("tray", []):
            tray_id = int(tray.get("id", 0))
            remain = tray.get("remain", -1)
            if isinstance(remain, int) and 0 <= remain <= 100:
                tray_remain_start[(ams_id, tray_id)] = remain
            else:
                skipped_invalid.append(f"AMS{ams_id}-T{tray_id}(remain={remain})")

    # Also capture VT (external) tray remain% — these are separate from AMS units
    vt_tray_raw = state.raw_data.get("vt_tray") or []
    if isinstance(vt_tray_raw, dict):
        vt_tray_raw = [vt_tray_raw]
    for vt in vt_tray_raw:
        if not isinstance(vt, dict):
            continue
        vt_id = int(vt.get("id", 254))
        # VT tray id 254 → (ams_id=255, tray_id=0), id 255 → (ams_id=255, tray_id=1)
        vt_tray_id = vt_id - 254
        remain = vt.get("remain", -1)
        if isinstance(remain, int) and 0 <= remain <= 100:
            tray_remain_start[(255, vt_tray_id)] = remain
        else:
            skipped_invalid.append(f"VT{vt_id}(remain={remain})")

    if skipped_invalid:
        logger.info(
            "[UsageTracker] Skipped trays with invalid remain%% for printer %d: %s",
            printer_id,
            ", ".join(skipped_invalid),
        )

    if not ams_data and not vt_tray_raw:
        logger.debug("[UsageTracker] No AMS or VT tray data for printer %d, skipping", printer_id)
        return

    print_name = data.get("subtask_name", "") or data.get("filename", "unknown")

    # Capture tray_now at print start (reliable, unlike at completion where it's 255)
    tray_now_at_start = state.tray_now if state else -1

    # --- Diagnostic logging: dump mapping-related MQTT fields at print start ---
    # This helps us understand what each printer model reports for slot-to-tray mapping.
    mapping_field = state.raw_data.get("mapping")
    logger.info(
        "[UsageTracker] PRINT START printer %d: mapping=%s, tray_now=%d, last_loaded_tray=%s",
        printer_id,
        mapping_field,
        tray_now_at_start,
        getattr(state, "last_loaded_tray", "N/A"),
    )
    # Log all raw_data keys containing "map" or "ams" for discovery
    map_keys = {k: state.raw_data[k] for k in state.raw_data if "map" in k.lower()}
    if map_keys:
        logger.info("[UsageTracker] PRINT START printer %d: mapping-related keys: %s", printer_id, map_keys)
    # Log per-tray summary: tray_now, tray_tar, tray_type, tray_color for each slot
    for ams_unit in ams_data:
        ams_id = int(ams_unit.get("id", 0))
        tray_summary = []
        for tray in ams_unit.get("tray", []):
            tray_summary.append(
                f"T{tray.get('id', '?')}(type={tray.get('tray_type', '')}, "
                f"color={tray.get('tray_color', '')}, "
                f"now={ams_raw.get('tray_now', '?') if isinstance(ams_raw, dict) else '?'}, "
                f"tar={ams_raw.get('tray_tar', '?') if isinstance(ams_raw, dict) else '?'})"
            )
        logger.info("[UsageTracker] PRINT START printer %d AMS %d: %s", printer_id, ams_id, ", ".join(tray_summary))

    # Snapshot spool assignments so usage isn't lost if on_ams_change unlinks mid-print
    spool_assignments: dict[tuple[int, int], int] = {}
    if db:
        assign_result = await db.execute(select(SpoolAssignment).where(SpoolAssignment.printer_id == printer_id))
        for assignment in assign_result.scalars().all():
            spool_assignments[(assignment.ams_id, assignment.tray_id)] = assignment.spool_id
        if spool_assignments:
            logger.info(
                "[UsageTracker] Snapshotted %d spool assignments for printer %d: %s",
                len(spool_assignments),
                printer_id,
                {f"{k[0]}-{k[1]}": v for k, v in spool_assignments.items()},
            )

    # Capture the queue item's plate_id so 3MF parsing at completion is scoped to
    # the plate that actually ran, not the whole multi-plate file (#1697).
    plate_id: int | None = None
    if db:
        from backend.app.models.print_queue import PrintQueueItem

        queue_result = await db.execute(
            select(PrintQueueItem)
            .where(PrintQueueItem.printer_id == printer_id)
            .where(PrintQueueItem.status == "printing")
        )
        queue_item = queue_result.scalars().first()
        if queue_item is not None:
            plate_id = queue_item.plate_id

    # Always create session (even without valid remain data) so print_name
    # is available at completion for 3MF-based tracking
    session = PrintSession(
        printer_id=printer_id,
        print_name=print_name,
        started_at=datetime.now(timezone.utc),
        tray_remain_start=tray_remain_start,
        tray_now_at_start=tray_now_at_start,
        spool_assignments=spool_assignments,
        ams_mapping=data.get("ams_mapping"),
        plate_id=plate_id,
    )
    if spoolman_owns_usage:
        _active_sessions.pop(printer_id, None)
    else:
        _active_sessions[printer_id] = session

    # Mirror to the DB so a restart mid-print doesn't lose the context. The
    # tray-change log has already been cleared and seeded with the starting
    # tray by bambu_mqtt before this callback fires.
    if db:
        try:
            await persist_session(db, session, getattr(state, "tray_change_log", None))
        except Exception:
            logger.exception("[UsageTracker] Failed to persist print session for printer %d", printer_id)

    if tray_remain_start:
        logger.info(
            "[UsageTracker] Captured start remain%% for printer %d (%d trays): %s",
            printer_id,
            len(tray_remain_start),
            {f"{k[0]}-{k[1]}": v for k, v in tray_remain_start.items()},
        )
    else:
        logger.debug("[UsageTracker] No valid remain%% for printer %d, 3MF fallback available", printer_id)


async def on_print_complete(
    printer_id: int,
    data: dict,
    printer_manager,
    db: AsyncSession,
    archive_id: int | None = None,
    ams_mapping: list[int] | None = None,
) -> list[dict]:
    """Compute consumption deltas and update spool weight_used/last_used.

    Uses two tracking strategies in priority order:
    1. 3MF per-filament estimates (primary) — precise slicer data for all spools
    2. AMS remain% delta (fallback) — only for trays not already handled by 3MF

    Returns a list of dicts describing what was logged (for WebSocket broadcast).
    """
    from sqlalchemy import select

    from backend.app.models.spool_usage_history import SpoolUsageHistory

    session = _active_sessions.pop(printer_id, None)
    if session is None:
        # Restart mid-print: the in-memory session is gone but the print-start
        # row survived. Without this the completion path loses the plate, the
        # dispatched mapping and the assignment snapshot, and attributes the
        # whole print to whichever tray happened to finish it.
        try:
            await restore_session(db, printer_id)
        except Exception:
            logger.exception("[UsageTracker] Failed to restore print session for printer %d", printer_id)
        session = _active_sessions.pop(printer_id, None)
    status = data.get("status", "completed")
    results = []
    handled_trays: set[tuple[int, int]] = set()

    # Fetch default filament cost from settings for fallback
    from backend.app.services.print_cost_estimate import default_cost_per_kg

    default_filament_cost = await default_cost_per_kg(db)

    # Fall back to ams_mapping captured at print start (needed when auto-archive is off
    # and the caller can't retrieve the mapping from _print_ams_mappings without archive_id)
    if not ams_mapping and session and session.ams_mapping:
        ams_mapping = session.ams_mapping

    logger.info(
        "[UsageTracker] on_print_complete: printer=%d, archive=%s, session=%s, ams_mapping=%s",
        printer_id,
        archive_id,
        "yes" if session else "no",
        ams_mapping,
    )

    # --- Diagnostic logging: dump mapping-related MQTT fields at print completion ---
    state = printer_manager.get_status(printer_id)
    if state and state.raw_data:
        logger.info(
            "[UsageTracker] PRINT COMPLETE printer %d: mapping=%s, tray_now=%s, last_loaded_tray=%s",
            printer_id,
            state.raw_data.get("mapping"),
            state.tray_now,
            getattr(state, "last_loaded_tray", "N/A"),
        )

    # --- Path 1 (PRIMARY): 3MF per-filament estimates ---
    print_name = (
        (session.print_name if session else None) or data.get("subtask_name", "") or data.get("filename", "unknown")
    )

    # When auto-archive is disabled (archive_id=None), try to find a 3MF by filename
    # from the library or previous archives so we can still track filament usage.
    threemf_path = None
    if not archive_id:
        from backend.app.core.config import settings as app_settings

        search_filename = data.get("filename") or data.get("subtask_name") or (session.print_name if session else "")
        if search_filename:
            threemf_path = await _find_3mf_by_filename(
                printer_id,
                search_filename,
                db,
                app_settings.base_dir,
                print_name=data.get("subtask_name") or (session.print_name if session else None),
            )

    if archive_id or threemf_path:
        threemf_results = await _track_from_3mf(
            printer_id,
            archive_id,
            status,
            print_name,
            handled_trays,
            printer_manager,
            db,
            ams_mapping=ams_mapping,
            tray_now_at_start=session.tray_now_at_start if session else -1,
            last_progress=data.get("last_progress", 0.0),
            last_layer_num=data.get("last_layer_num", 0),
            default_filament_cost=default_filament_cost,
            spool_assignments=session.spool_assignments if session else None,
            print_started_at=session.started_at if session else None,
            threemf_path=threemf_path,
            plate_id=session.plate_id if session else None,
        )
        results.extend(threemf_results)

    # --- Path 2 (FALLBACK): AMS remain% delta (only for trays not handled by 3MF) ---
    if session and session.tray_remain_start:
        state = printer_manager.get_status(printer_id)
        if state and state.raw_data:
            ams_raw = state.raw_data.get("ams", [])
            ams_data = (
                ams_raw.get("ams", []) if isinstance(ams_raw, dict) else ams_raw if isinstance(ams_raw, list) else []
            )

            # Build set of trays actually involved in this print (#1269).
            # Without this guard, swapping a spool in an UNUSED slot mid-print
            # makes that slot's remain% drop to 0, which the fallback below
            # would otherwise charge to the originally-assigned spool.
            def _global_to_ams_key(global_tray_id: int) -> tuple[int, int]:
                if global_tray_id >= 254:
                    return (255, global_tray_id - 254)
                if global_tray_id >= 128:
                    return (global_tray_id, 0)
                return (global_tray_id // 4, global_tray_id % 4)

            print_used_keys: set[tuple[int, int]] = set()
            if ams_mapping:
                for gid in ams_mapping:
                    if isinstance(gid, int) and gid >= 0:
                        print_used_keys.add(_global_to_ams_key(gid))
            for change in getattr(state, "tray_change_log", None) or []:
                if isinstance(change, (tuple, list)) and len(change) >= 1:
                    gid = change[0]
                    if isinstance(gid, int) and gid >= 0:
                        print_used_keys.add(_global_to_ams_key(gid))
            # 255 is not a slot: it is what ``tray_now`` reads at rest, before
            # the printer has reported one and while nothing is loaded, and an
            # unparseable reading falls back to it too. Mapped as a tray id it
            # becomes (255, 1), and if it were the only evidence every real
            # slot would be excluded and the fallback would charge nothing at
            # all (#1820). The external spool reports 254 when in use.
            if session.tray_now_at_start is not None and 0 <= session.tray_now_at_start <= 254:
                print_used_keys.add(_global_to_ams_key(session.tray_now_at_start))

            # Collect all trays to check: AMS trays + VT (external) trays
            # Each entry: (ams_id_for_assignment, tray_id_for_assignment, current_remain, label)
            trays_to_check: list[tuple[int, int, int, str]] = []

            for ams_unit in ams_data:
                ams_id = int(ams_unit.get("id", 0))
                for tray in ams_unit.get("tray", []):
                    tray_id = int(tray.get("id", 0))
                    remain = tray.get("remain", -1)
                    trays_to_check.append((ams_id, tray_id, remain, f"AMS{ams_id}-T{tray_id}"))

            # VT (external) trays — same remain% delta logic
            vt_tray_raw = state.raw_data.get("vt_tray") or []
            if isinstance(vt_tray_raw, dict):
                vt_tray_raw = [vt_tray_raw]
            for vt in vt_tray_raw:
                if not isinstance(vt, dict):
                    continue
                vt_id = int(vt.get("id", 254))
                vt_tray_id = vt_id - 254  # 254→0, 255→1
                remain = vt.get("remain", -1)
                trays_to_check.append((255, vt_tray_id, remain, f"VT{vt_id}"))

            for assign_ams_id, assign_tray_id, current_remain, tray_label in trays_to_check:
                key = (assign_ams_id, assign_tray_id)

                if key in handled_trays:
                    continue  # Already tracked via 3MF

                if key not in session.tray_remain_start:
                    # No usable remain% when the print began, so there is no delta
                    # to charge. Said out loud for the same reason as the branches
                    # below: a slot the print used, holding a spool the operator
                    # assigned, otherwise vanished from the accounting without a
                    # word. Common on non-RFID spools, which report remain = -1
                    # until a remaining amount is set by hand.
                    if not print_used_keys or key in print_used_keys:
                        logger.info(
                            "[UsageTracker] %s: no valid remain%% at print start, nothing to charge for printer %d",
                            tray_label,
                            printer_id,
                        )
                    continue

                # Skip trays the print never touched. Only enforce when we have
                # evidence of which trays the print used; if print_used_keys is
                # empty (no mapping, no change log, no tray_now_at_start) keep
                # the legacy behavior of scanning every tray.
                if print_used_keys and key not in print_used_keys:
                    logger.info(
                        "[UsageTracker] %s: not in print mapping/tray_change_log — skipping fallback for printer %d",
                        tray_label,
                        printer_id,
                    )
                    continue

                if not isinstance(current_remain, int) or current_remain < 0 or current_remain > 100:
                    logger.info(
                        "[UsageTracker] %s: invalid remain%% at completion (%s), skipping fallback for printer %d",
                        tray_label,
                        current_remain,
                        printer_id,
                    )
                    continue

                start_remain = session.tray_remain_start[key]
                delta_pct = start_remain - current_remain

                if delta_pct <= 0:
                    # Not necessarily "nothing was printed". A fresh spool sits
                    # at 100% for the first tens of grams, and the AMS estimate
                    # drifts upward on its own, so a real print can end with the
                    # same or a higher reading than it started with. Said out
                    # loud because the alternative -- charging nothing, silently
                    # -- is indistinguishable from having nothing to charge, and
                    # the operator has no other way to find the prints that went
                    # uncounted (#1820).
                    logger.info(
                        "[UsageTracker] %s: remain%% did not fall over the print (%d%% -> %d%%), "
                        "nothing charged for printer %d",
                        tray_label,
                        start_remain,
                        current_remain,
                        printer_id,
                    )
                    continue

                spool_id = await _resolve_spool_id_for_tray(
                    printer_id=printer_id,
                    ams_id=assign_ams_id,
                    tray_id=assign_tray_id,
                    db=db,
                    spool_assignments_snapshot=session.spool_assignments,
                    print_started_at=session.started_at,
                )
                if spool_id is None:
                    logger.info(
                        "[UsageTracker] %s: no spool assigned, skipping fallback for printer %d",
                        tray_label,
                        printer_id,
                    )
                    continue

                # Load spool
                spool_result = await db.execute(select(Spool).where(Spool.id == spool_id))
                spool = spool_result.scalar_one_or_none()
                if not spool:
                    continue

                # Compute weight consumed
                weight_grams = (delta_pct / 100.0) * spool.label_weight

                # Update spool
                if not await _charge_spool(db, spool, weight_grams):
                    continue

                # Calculate cost for this usage
                cost = None
                cost_per_kg = spool.cost_per_kg if spool.cost_per_kg is not None else default_filament_cost
                if cost_per_kg > 0:
                    cost = round((weight_grams / 1000.0) * cost_per_kg, 2)

                # Insert usage history record
                history = SpoolUsageHistory(
                    spool_id=spool.id,
                    printer_id=printer_id,
                    print_name=session.print_name,
                    weight_used=round(weight_grams, 1),
                    percent_used=delta_pct,
                    status=status,
                    cost=cost,
                    archive_id=archive_id,
                )
                db.add(history)

                handled_trays.add(key)
                results.append(
                    {
                        "spool_id": spool.id,
                        "weight_used": round(weight_grams, 1),
                        "percent_used": delta_pct,
                        "ams_id": assign_ams_id,
                        "tray_id": assign_tray_id,
                        "material": spool.material,
                        "cost": cost,
                        # AMS remain%-delta fallback has no 3MF slot — slot_id
                        # stays None so it is excluded from the colour rewrite.
                        "slot_id": None,
                        "color": _spool_color_to_hex(spool.rgba),
                    }
                )

                logger.info(
                    "[UsageTracker] Spool %d consumed %.1fg (%d%%) on printer %d %s (AMS fallback, %s)",
                    spool.id,
                    weight_grams,
                    delta_pct,
                    printer_id,
                    tray_label,
                    status,
                )

    if results:
        await db.commit()

    # --- Update PrintArchive.cost from THIS print session only ---
    #
    # Cover any filament weight that wasn't tracked by an inventory spool with
    # the global default rate (#1344). Without this, a multi-color print where
    # only some AMS trays are mapped to inventory spools would record only the
    # mapped slots' share — e.g. $0.01 for a 110g print when 3 of 4 trays had
    # no spool record. The initial cost set by archive.py (total grams *
    # primary cost_per_kg) is fine on its own, but this block overwrites it,
    # so the overwrite must reconstruct the whole-print cost.

    if archive_id and results:
        from sqlalchemy import select

        from backend.app.models.archive import PrintArchive

        archive_result = await db.execute(select(PrintArchive).where(PrintArchive.id == archive_id))
        archive = archive_result.scalar_one_or_none()
        if archive:
            total_cost = sum(r.get("cost", 0) or 0 for r in results)
            tracked_grams = sum(r.get("weight_used", 0) or 0 for r in results)
            archive_grams = archive.filament_used_grams or 0
            untracked_grams = max(0.0, archive_grams - tracked_grams)
            if untracked_grams > 0 and default_filament_cost > 0:
                total_cost += (untracked_grams / 1000.0) * default_filament_cost
            if total_cost > 0:
                # Only overwrite archive.cost on the first run. Reprint actuals
                # live in PrintLogEntry; the archive card keeps the first run's
                # cost so a failed reprint doesn't visually clobber a successful
                # 100 g/$X print with a 10 g/$X/10 partial (#1378).
                from backend.app.services.print_log import other_runs_of

                if not await other_runs_of(db, archive):
                    archive.cost = round(total_cost, 2)
                    await db.commit()

    return results


# A running print's ``filename`` is the path the printer is executing, and on a
# sliced job that is always ``…/Metadata/plate_<N>.gcode``. Its stem names the
# *plate*, not the model, and every Bambu print in existence has one — so it
# identifies nothing and must never be used to match a 3MF. It reached the
# matcher for real on H2-series and P2S prints, where the file goes to internal
# eMMC, no 3MF can be fetched, and the archive keeps the gcode path as its
# filename: `plate_1` then matched an unrelated `lid_plate_1.gcode.3mf` and that
# print's filament figures were read off a different model entirely.
_GENERIC_PLATE_STEM = re.compile(r"^plate_?\d+$", re.IGNORECASE)


def _like_escape(value: str) -> str:
    """Escape LIKE metacharacters so a stem matches literally.

    ``_`` is a single-character wildcard, and model names are full of them.
    """
    return value.replace("\\", "\\\\").replace("%", "\\%").replace("_", "\\_")


def _threemf_search_stem(*candidates: str | None) -> str | None:
    """First candidate that names a model, or None if none of them do.

    Candidates are tried in order and the generic plate name is skipped rather
    than accepted, so a print that only has one falls through to "no match"
    instead of matching everything.
    """
    for raw in candidates:
        if not raw:
            continue
        stem = raw.split("/")[-1].strip()
        for suffix in (".gcode.3mf", ".gcode", ".3mf"):
            if stem.lower().endswith(suffix):
                stem = stem[: -len(suffix)]
                break
        # Stripped only to judge the stem, never to change it: a real archive
        # here is named "…Face Down .gcode.3mf", and a stem trimmed to
        # "…Face Down" no longer matches the file it came from.
        probe = stem.strip()
        if probe and not _GENERIC_PLATE_STEM.match(probe):
            return stem
    return None


def _stem_matches(column, stem: str):
    """Filter matching *stem* at a filename boundary rather than anywhere.

    ``ilike("%<stem>.%")`` also matched a *suffix* of a longer name, which is how
    `plate_1` reached `lid_plate_1.gcode.3mf`. A name is either the whole
    basename or the basename after a directory separator.
    """
    escaped = _like_escape(stem)
    return column.ilike(f"{escaped}.%", escape="\\") | column.ilike(f"%/{escaped}.%", escape="\\")


def _expected_plate_for_print(plate_id: int | None, gcode_file: str | None) -> int | None:
    """The plate a running print is on, from whatever was recorded about it.

    ``plate_id`` is the reliable source, and the archives that need a donor 3MF
    have none: the no-3MF fallback row is created before any 3MF is read, so
    the column is never filled. The gcode path the printer echoed is the other
    source, exact on the firmwares that echo ``Metadata/plate_N.gcode``. Some
    P1S builds echo only the 3MF filename, and then the plate is simply not
    knowable at print start (#2957).
    """
    from backend.app.services.printer_manager import parse_plate_id

    if plate_id is not None:
        return plate_id
    return parse_plate_id(gcode_file)


def _donor_3mf_conflicts(candidate, expected_plate: int | None) -> str | None:
    """Why *candidate* cannot be this print's 3MF, or None if nothing rules it out.

    A same-name 3MF is not the same print. Bambu Studio writes the printer-side
    filename from the project's ``Title`` metadata, so every plate of a project
    arrives under one name however the user renamed the file on disk, and a
    donor chosen on the name alone hands one plate's slicer estimates to another
    plate's print. A reporter's single-filament job was charged against three
    spools that way, and nothing about the deduction said it was a guess
    (#2957).

    The plate is the one thing that can settle this. It is the same comparison
    #1204 already makes against a freshly downloaded 3MF, so a single-plate
    export is known to carry its original index rather than a renumbered 1.

    Filament *count* deliberately is not checked, however tempting: the slicer's
    ``ams_mapping`` is indexed by the project's filament slot -- see
    ``slot_to_tray[slot_id - 1]`` below -- not by the plate's, so a real
    single-filament print reports ``[0, -1, -1, -1]`` and its length says
    nothing about how many filaments the plate uses.
    """
    from backend.app.services.archive import plate_indexes_in_3mf

    if expected_plate is None:
        return None

    plates = plate_indexes_in_3mf(candidate)
    if not plates or any(plate is None for plate in plates):
        # Nothing was read, or not all of it was, and neither is evidence about
        # the plate. Refusing here would drop the fallback for every 3MF variant
        # this parser does not understand; downstream reports that honestly as
        # "no filament usage data".
        return None
    if len(plates) == 1 and plates[0] != expected_plate:
        return f"it holds plate {plates[0]}, this print is plate {expected_plate}"
    if expected_plate not in plates:
        # An all-plates export is a good donor precisely when it carries the
        # plate that is running. Without this the plate is looked for
        # downstream, found missing, and the whole file's filaments are summed
        # onto one plate's print.
        return f"it has no plate {expected_plate}"
    return None


async def _resolve_3mf_fallback(archive, db: AsyncSession, base_dir):
    """Try to find a 3MF file from library or a previous archive when the current archive has none.

    This handles fallback archives (FTP download failed) where the 3MF may already exist
    locally from a library upload or a previous successful print of the same file.

    A name match alone does not make a candidate this print's file, so every
    candidate is put through :func:`_donor_3mf_conflicts` before it is handed
    back (#2957).
    """
    from pathlib import Path

    from backend.app.models.archive import PrintArchive
    from backend.app.models.library import LibraryFile

    # Derive search name from archive filename (e.g. "benchy.3mf" or "benchy.gcode.3mf"),
    # falling back to the print name when the filename is only a plate path.
    search_base = _threemf_search_stem(archive.filename, archive.print_name)
    if not search_base:
        return None

    print_data = (getattr(archive, "extra_data", None) or {}).get("_print_data") or {}
    expected_plate = _expected_plate_for_print(
        getattr(archive, "plate_id", None),
        archive.filename or print_data.get("filename"),
    )
    if expected_plate is None:
        # Worth saying out loud. On the firmwares that echo only the 3MF
        # filename there is nothing to check a donor against, so whatever is
        # accepted below is accepted on its name alone -- which is how the
        # reporter's spools were debited for another plate's filament. The
        # deduction being silent was half the bug (#2957).
        logger.warning(
            "[UsageTracker] 3MF fallback: archive %s does not know its plate (%r), so a same-named "
            "3MF can only be matched on its name",
            archive.id,
            archive.filename,
        )

    # 1. Try library files matching the name (match base name at file boundary)
    try:
        lib_result = await db.execute(
            LibraryFile.active()
            .where(_stem_matches(LibraryFile.file_path, search_base))
            .where(LibraryFile.file_path.ilike("%.3mf"))
            .order_by(LibraryFile.created_at.desc())
            .limit(3)
        )
        for lib_file in lib_result.scalars().all():
            lib_path = Path(lib_file.file_path)
            candidate = lib_path if lib_path.is_absolute() else base_dir / lib_file.file_path
            if candidate.exists() and candidate.suffix == ".3mf":
                conflict = _donor_3mf_conflicts(candidate, expected_plate)
                if conflict:
                    logger.warning(
                        "[UsageTracker] 3MF fallback: not using library file %s for archive %s — %s",
                        candidate,
                        archive.id,
                        conflict,
                    )
                    continue
                logger.info(
                    "[UsageTracker] 3MF fallback: found library file %s for archive %s (expected plate=%s)",
                    candidate,
                    archive.id,
                    expected_plate,
                )
                return candidate
    except Exception as e:
        logger.debug("[UsageTracker] 3MF fallback: library lookup failed: %s", e)

    # 2. Try previous archives with the same filename that have a valid file_path
    try:
        prev_result = await db.execute(
            select(PrintArchive)
            .where(PrintArchive.id != archive.id)
            .where(PrintArchive.printer_id == archive.printer_id)
            .where(PrintArchive.file_path != "")
            .where(PrintArchive.file_path.isnot(None))
            .where(_stem_matches(PrintArchive.filename, search_base))
            .order_by(PrintArchive.created_at.desc())
            .limit(3)
        )
        for prev_archive in prev_result.scalars().all():
            candidate = base_dir / prev_archive.file_path
            if candidate.exists() and candidate.suffix == ".3mf":
                conflict = _donor_3mf_conflicts(candidate, expected_plate)
                if conflict:
                    logger.warning(
                        "[UsageTracker] 3MF fallback: not using archive %s's file for archive %s — %s",
                        prev_archive.id,
                        archive.id,
                        conflict,
                    )
                    continue
                logger.info(
                    "[UsageTracker] 3MF fallback: found previous archive %s file for archive %s (expected plate=%s)",
                    prev_archive.id,
                    archive.id,
                    expected_plate,
                )
                return candidate
    except Exception as e:
        logger.debug("[UsageTracker] 3MF fallback: previous archive lookup failed: %s", e)

    return None


async def _find_3mf_by_filename(
    printer_id: int,
    filename: str,
    db: AsyncSession,
    base_dir,
    print_name: str | None = None,
):
    """Find a 3MF file by filename from library or previous archives.

    Used when auto-archive is disabled and there's no archive_id, but we still
    need the 3MF slicer data for filament usage tracking.

    ``print_name`` is the model name to fall back to when ``filename`` is the
    printer's plate path, which names no model at all -- and when it is that
    plate path, it is also what keeps a same-named file for a different plate
    from being adopted (#2957); see :func:`_donor_3mf_conflicts`.
    """
    from pathlib import Path

    from backend.app.models.archive import PrintArchive
    from backend.app.models.library import LibraryFile

    search_base = _threemf_search_stem(filename, print_name)
    if not search_base:
        return None

    expected_plate = _expected_plate_for_print(None, filename)

    # 1. Try library files matching the name
    try:
        lib_result = await db.execute(
            LibraryFile.active()
            .where(_stem_matches(LibraryFile.file_path, search_base))
            .where(LibraryFile.file_path.ilike("%.3mf"))
            .order_by(LibraryFile.created_at.desc())
            .limit(3)
        )
        for lib_file in lib_result.scalars().all():
            lib_path = Path(lib_file.file_path)
            candidate = lib_path if lib_path.is_absolute() else base_dir / lib_file.file_path
            if candidate.exists() and candidate.suffix == ".3mf":
                conflict = _donor_3mf_conflicts(candidate, expected_plate)
                if conflict:
                    logger.warning(
                        "[UsageTracker] 3MF (no-archive): not using library file %s for '%s' — %s",
                        candidate,
                        filename,
                        conflict,
                    )
                    continue
                logger.info("[UsageTracker] 3MF (no-archive): found library file %s for '%s'", candidate, filename)
                return candidate
    except Exception as e:
        logger.debug("[UsageTracker] 3MF (no-archive): library lookup failed: %s", e)

    # 2. Try previous archives with a valid 3MF file_path
    try:
        prev_result = await db.execute(
            select(PrintArchive)
            .where(PrintArchive.printer_id == printer_id)
            .where(PrintArchive.file_path != "")
            .where(PrintArchive.file_path.isnot(None))
            .where(_stem_matches(PrintArchive.filename, search_base))
            .order_by(PrintArchive.created_at.desc())
            .limit(3)
        )
        for prev_archive in prev_result.scalars().all():
            candidate = base_dir / prev_archive.file_path
            if candidate.exists() and candidate.suffix == ".3mf":
                conflict = _donor_3mf_conflicts(candidate, expected_plate)
                if conflict:
                    logger.warning(
                        "[UsageTracker] 3MF (no-archive): not using archive %s's file for '%s' — %s",
                        prev_archive.id,
                        filename,
                        conflict,
                    )
                    continue
                logger.info(
                    "[UsageTracker] 3MF (no-archive): found previous archive %s file for '%s'",
                    prev_archive.id,
                    filename,
                )
                return candidate
    except Exception as e:
        logger.debug("[UsageTracker] 3MF (no-archive): previous archive lookup failed: %s", e)

    return None


async def _track_from_3mf(
    printer_id: int,
    archive_id: int | None,
    status: str,
    print_name: str,
    handled_trays: set[tuple[int, int]],
    printer_manager,
    db: AsyncSession,
    ams_mapping: list[int] | None = None,
    tray_now_at_start: int = -1,
    last_progress: float = 0.0,
    last_layer_num: int = 0,
    default_filament_cost: float = 0.0,
    spool_assignments: dict[tuple[int, int], int] | None = None,
    print_started_at: datetime | None = None,
    threemf_path=None,
    plate_id: int | None = None,
) -> list[dict]:
    """Track usage from 3MF per-filament slicer data (primary path).

    Uses slicer-estimated filament weight for all spools (BL and non-BL).
    For partial prints (failed/aborted), tries per-layer gcode data first,
    then falls back to linear scaling by progress.

    When archive_id is None (auto-archive disabled), a pre-resolved threemf_path
    can be provided to still track filament usage from slicer data.

    When ``plate_id`` is set (queue prints of a single plate from a multi-plate
    3MF), only that plate's filaments contribute. Without it the 3MF parser sums
    every plate, which is correct for direct/library Print flows that always
    target the first or only plate (#1697).

    Slot-to-tray mapping priority:
    1. Stored ams_mapping from print command (reprints/direct prints)
    2. MQTT mapping field from printer state (universal, all print sources)
    3. Queue item ams_mapping (for queue-initiated prints)
    4. tray_now from printer state (for single-filament non-queue prints)
    5. Position-based default using sorted available tray IDs (handles external spools)
    6. Default mapping: slot_id - 1 = global_tray_id (last resort)
    """
    from pathlib import Path

    from backend.app.core.config import settings as app_settings
    from backend.app.models.archive import PrintArchive
    from backend.app.models.print_queue import PrintQueueItem
    from backend.app.utils.threemf_tools import extract_filament_usage_from_3mf

    file_path: Path | None = threemf_path
    archive: PrintArchive | None = None

    if file_path is None and archive_id:
        result = await db.execute(select(PrintArchive).where(PrintArchive.id == archive_id))
        archive = result.scalar_one_or_none()
        if not archive:
            logger.info("[UsageTracker] 3MF: archive %s not found, skipping", archive_id)
            return []

        # Try archive's own file_path first
        if archive.file_path:
            candidate = app_settings.base_dir / archive.file_path
            if candidate.exists():
                file_path = candidate

        # Fallback: find 3MF from library or a previous archive with the same filename
        if file_path is None:
            file_path = await _resolve_3mf_fallback(archive, db, app_settings.base_dir)

    if file_path is None:
        logger.info("[UsageTracker] 3MF: no file available for archive %s, skipping", archive_id)
        return []

    # The queue item carries both the plate and the dispatched mapping; look it
    # up at most once. A batch dispatches one archive as several queue items,
    # on several printers at once: only this printer's newest is this run.
    # Completion has already closed it, as cancelled for an aborted print.
    _queue_item_lookup: list = []

    async def _dispatch_queue_item():
        if not _queue_item_lookup:
            if not archive_id:
                _queue_item_lookup.append(None)
            else:
                queue_result = await db.execute(
                    select(PrintQueueItem)
                    .where(PrintQueueItem.archive_id == archive_id)
                    .where(PrintQueueItem.printer_id == printer_id)
                    .where(PrintQueueItem.status.in_(["printing", "completed", "failed", "cancelled"]))
                    .order_by(PrintQueueItem.id.desc())
                )
                _queue_item_lookup.append(queue_result.scalars().first())
        return _queue_item_lookup[0]

    # The caller's plate_id comes from the in-memory session, which a restart
    # mid-print destroys. Both the archive and the queue item recorded the
    # plate at dispatch — without falling back to them the parser sums every
    # plate of a multi-plate file and charges the lot to one spool. The
    # newest queue item goes first: the archive keeps the plate of its first
    # print, so a reprint of another plate is only on the queue item.
    if plate_id is None:
        plate_queue_item = await _dispatch_queue_item()
        if plate_queue_item is not None and plate_queue_item.plate_id is not None:
            plate_id = plate_queue_item.plate_id
            logger.info(
                "[UsageTracker] 3MF: plate_id=%s recovered from queue item %s",
                plate_id,
                plate_queue_item.id,
            )
        elif archive is not None and archive.plate_id is not None:
            plate_id = archive.plate_id
            logger.info("[UsageTracker] 3MF: plate_id=%s recovered from archive %s", plate_id, archive_id)

    filament_usage = extract_filament_usage_from_3mf(file_path, plate_id)
    if not filament_usage and plate_id is not None:
        # The plate isn't in this file. That happens when the archive's own 3MF
        # is gone and `_resolve_3mf_fallback` substituted a same-named file from
        # the library that was sliced with different plates. Summing the whole
        # file is wrong for a single-plate run, but it is closer than recording
        # nothing at all — and unlike the silent whole-file sum this replaces,
        # it says so.
        filament_usage = extract_filament_usage_from_3mf(file_path, None)
        if filament_usage:
            logger.warning(
                "[UsageTracker] 3MF: plate %s not present in %s — falling back to the whole-file total",
                plate_id,
                file_path,
            )
            plate_id = None
    if not filament_usage:
        logger.info("[UsageTracker] 3MF: no filament usage data in %s", file_path)
        return []

    logger.info("[UsageTracker] 3MF: archive %s, plate_id=%s, filament_usage=%s", archive_id, plate_id, filament_usage)

    # --- Resolve slot-to-tray mapping ---
    mapping_source = None

    # 1. Use stored ams_mapping from the print command (reprints/direct prints)
    slot_to_tray = ams_mapping
    if slot_to_tray:
        mapping_source = "print_cmd"

    # 2. Try queue item ams_mapping (queue-initiated prints store the exact mapping)
    #
    # Ranked above the live MQTT field on purpose: `mapping` reports the tray
    # the printer is feeding from *now*, and AMS filament backup rewrites it to
    # the substitute tray when a spool runs dry. Read at completion it names
    # the tray that finished the print, not the one the slicer assigned — the
    # queue item's copy is the mapping the print was actually dispatched with.
    if not slot_to_tray and archive_id:
        queue_item = await _dispatch_queue_item()
        if queue_item and queue_item.ams_mapping:
            try:
                slot_to_tray = json.loads(queue_item.ams_mapping)
                mapping_source = "queue"
            except (json.JSONDecodeError, TypeError):
                pass

    # 3. Try MQTT mapping field from printer state (universal, all print sources)
    if not slot_to_tray:
        state = printer_manager.get_status(printer_id)
        raw_data = getattr(state, "raw_data", None) if state else None
        if raw_data:
            mqtt_mapping = raw_data.get("mapping")
            decoded = _decode_mqtt_mapping(mqtt_mapping)
            if decoded:
                slot_to_tray = decoded
                mapping_source = "mqtt"

    # 4. Color-match 3MF filament slots to AMS trays (for printers without mapping field)
    if not slot_to_tray:
        state = printer_manager.get_status(printer_id)
        raw_data = getattr(state, "raw_data", None) if state else None
        if raw_data:
            matched = _match_slots_by_color(filament_usage, raw_data.get("ams"))
            if matched:
                slot_to_tray = matched
                mapping_source = "color_match"

    logger.info(
        "[UsageTracker] 3MF: slot_to_tray=%s (source: %s)",
        slot_to_tray,
        mapping_source or "none",
    )

    # A mapping that names no tray for any slot the print used carries no
    # evidence at all -- typically a flat ams_mapping whose external spool is
    # -1 and came without an ams_mapping2 to resolve it (#3166). Drop it so the
    # tray_now evidence below decides, rather than leaving every slot unfed.
    if slot_to_tray:
        used_slots = [u.get("slot_id", 0) for u in filament_usage if u.get("used_g", 0) > 0]
        if used_slots and all(
            not (0 < s <= len(slot_to_tray) and isinstance(slot_to_tray[s - 1], int) and slot_to_tray[s - 1] >= 0)
            for s in used_slots
        ):
            logger.info(
                "[UsageTracker] 3MF: mapping %s names no tray for used slots %s — ignoring it",
                slot_to_tray,
                used_slots,
            )
            slot_to_tray = None
            mapping_source = None

    # 5. For single-filament non-queue prints, use tray_now from printer state
    #    Priority: tray_change_log (multi-tray split) > tray_now_at_start > current tray_now
    #              > last_loaded_tray > vt_tray check
    #
    # tray_change_log evidence wins over slot_to_tray when present: if the
    # printer fed from multiple trays mid-print (AMS auto-fallback when one
    # spool runs out, #957), the slicer's mapping captured at print start
    # is stale and needs to be replaced with per-layer split attribution.
    nonzero_slots = [u for u in filament_usage if u.get("used_g", 0) > 0]
    tray_now_override: int | None = None
    tray_changes: list[tuple[int, int]] = []  # [(global_tray_id, layer_num), ...]
    state = printer_manager.get_status(printer_id) if len(nonzero_slots) == 1 else None
    if state is not None:
        tray_changes = getattr(state, "tray_change_log", []) or []
    elif len(nonzero_slots) > 1:
        # Multi-material print: every filament change moves tray_now, so the
        # log can't be read as "this slot moved to that tray" and splitting
        # would attribute worse than the mapping does. Say so rather than
        # silently dropping the evidence — a runout mid-print on a
        # multi-material job still lands entirely on the mapped tray.
        _multi_state = printer_manager.get_status(printer_id)
        if len(getattr(_multi_state, "tray_change_log", []) or []) > 1:
            logger.warning(
                "[UsageTracker] 3MF: %d tray changes observed but %d filament slots used — "
                "splitting needs a single slot, attributing by mapping alone (printer %d, archive %s)",
                len(_multi_state.tray_change_log),
                len(nonzero_slots),
                printer_id,
                archive_id,
            )

    if len(tray_changes) > 1:
        # Multi-tray usage detected — splitting takes over regardless of slot_to_tray.
        logger.info("[UsageTracker] 3MF: tray change log: %s (will split weight)", tray_changes)
    elif not slot_to_tray and len(nonzero_slots) == 1:
        if 0 <= tray_now_at_start <= 254:
            tray_now_override = tray_now_at_start
            logger.info("[UsageTracker] 3MF: using tray_now_at_start=%d (single-filament fallback)", tray_now_at_start)
        elif state and 0 <= state.tray_now <= 254:
            tray_now_override = state.tray_now
            logger.info("[UsageTracker] 3MF: using current tray_now=%d", state.tray_now)
        elif state and 0 <= state.last_loaded_tray <= 253:
            tray_now_override = state.last_loaded_tray
            logger.info("[UsageTracker] 3MF: using last_loaded_tray=%d (post-retract fallback)", state.last_loaded_tray)
        elif state and state.tray_now == 255:
            # 255 = "no filament" on legacy printers, but valid 2nd external spool on H2-series
            vt_tray = state.raw_data.get("vt_tray") or []
            if any(int(vt.get("id", 0)) == 255 for vt in vt_tray if isinstance(vt, dict)):
                tray_now_override = state.tray_now
                logger.info("[UsageTracker] 3MF: using tray_now=255 (H2-series external spool)")
        if tray_now_override is None:
            logger.info(
                "[UsageTracker] 3MF: no valid tray_now (at_start=%d, current=%s, last_loaded=%s)",
                tray_now_at_start,
                state.tray_now if state else "N/A",
                state.last_loaded_tray if state else "N/A",
            )

    # Scale factor for partial prints (failed/aborted)
    if status == "completed":
        scale = 1.0
    else:
        state = printer_manager.get_status(printer_id)
        progress = state.progress if state else 0
        # Firmware resets progress to 0 on cancel — use last valid progress captured during print
        if progress <= 0 and last_progress > 0:
            progress = last_progress
            logger.info("[UsageTracker] 3MF: using last_progress=%.1f (firmware reset current to 0)", last_progress)
        scale = max(0.0, min(progress / 100.0, 1.0))

    # Per-layer gcode accuracy for partial prints
    layer_grams: dict[int, float] | None = None
    if status != "completed":
        state = printer_manager.get_status(printer_id)
        current_layer = state.layer_num if state else 0
        # Firmware resets layer_num to 0 on cancel — use last valid layer captured during print
        if current_layer <= 0 and last_layer_num > 0:
            current_layer = last_layer_num
            logger.info("[UsageTracker] 3MF: using last_layer_num=%d (firmware reset current to 0)", last_layer_num)
        if current_layer > 0:
            try:
                from backend.app.utils.threemf_tools import (
                    extract_filament_properties_from_3mf,
                    extract_layer_filament_usage_from_3mf,
                    get_cumulative_usage_at_layer,
                    mm_to_grams,
                )

                layer_usage = extract_layer_filament_usage_from_3mf(file_path, plate_id)
                if layer_usage:
                    cumulative_mm = get_cumulative_usage_at_layer(layer_usage, current_layer)
                    filament_props = extract_filament_properties_from_3mf(file_path)
                    layer_grams = {}
                    for filament_id, mm_used in cumulative_mm.items():
                        slot_id = filament_id + 1  # 0-based to 1-based
                        props = filament_props.get(slot_id, {})
                        density = props.get("density", 1.24)
                        diameter = props.get("diameter", 1.75)
                        layer_grams[slot_id] = mm_to_grams(mm_used, diameter, density)
            except Exception:
                pass  # Fall back to linear scaling

    results = []
    # Trays this print drew from that no longer have an assignment to charge.
    # Collected rather than acted on inline so one notification covers the whole
    # print instead of one per slot (#2812).
    unassigned_global_trays: list[int] = []
    # Deduplicated by slicer slot, not by tray (#3230). Several slots mapped to
    # one tray, or a single-slot print that returns to an earlier tray, each
    # consume filament of their own. A slot only repeats when the plate is
    # unknown and every plate of the file is listed, and that must not charge
    # the same slot once per plate. Only a tray the caller had already covered
    # before this pass is skipped.
    charged_slots: set[int] = set()
    covered_before = frozenset(handled_trays)

    for usage in filament_usage:
        slot_id = usage.get("slot_id", 0)
        used_g = usage.get("used_g", 0)
        if used_g <= 0:
            continue
        if slot_id in charged_slots:
            continue
        charged_slots.add(slot_id)

        # --- Mid-print tray switch: split weight across trays ---
        # Split math is shared with the Spoolman writer via
        # ``utils.tray_split.compute_tray_split_grams`` (#1793) — both
        # inventory backends must attribute segments identically or a
        # user running dual-mode sees divergent totals.
        if len(tray_changes) > 1:
            # Compute total weight for this slot (same logic as normal path)
            if layer_grams and slot_id in layer_grams:
                total_weight = layer_grams[slot_id]
            else:
                total_weight = used_g * scale

            if total_weight <= 0:
                continue

            # Extract per-layer gcode for segment splitting
            split_layer_usage = None
            split_props: dict = {}
            try:
                from backend.app.utils.threemf_tools import (
                    extract_filament_properties_from_3mf,
                    extract_layer_filament_usage_from_3mf,
                )

                split_layer_usage = extract_layer_filament_usage_from_3mf(file_path, plate_id)
                filament_props = extract_filament_properties_from_3mf(file_path)
                split_props = filament_props.get(slot_id, {})
            except Exception:
                pass  # Fall back to linear splitting

            from backend.app.utils.tray_split import compute_tray_split_grams

            segments = compute_tray_split_grams(
                tray_changes=tray_changes,
                total_weight=total_weight,
                slot_id=slot_id,
                layer_usage=split_layer_usage,
                density=split_props.get("density", 1.24),
                diameter=split_props.get("diameter", 1.75),
                total_layers=(state.total_layers if state else 0) or 0,
                last_layer_num=last_layer_num,
            )

            for seg_idx, tray_global, segment_grams in segments:
                if segment_grams <= 0:
                    continue

                # Convert global tray ID to (ams_id, tray_id)
                if tray_global >= 254:
                    seg_ams_id = 255
                    seg_tray_id = tray_global - 254
                elif tray_global >= 128:
                    seg_ams_id = tray_global
                    seg_tray_id = 0
                else:
                    seg_ams_id = tray_global // 4
                    seg_tray_id = tray_global % 4

                seg_key = (seg_ams_id, seg_tray_id)
                if seg_key in covered_before:
                    continue

                seg_start_layer = tray_changes[seg_idx][1]
                is_last = seg_idx + 1 >= len(tray_changes)
                logger.info(
                    "[UsageTracker] 3MF split: segment %d tray=%d (AMS%d-T%d) layers %d-%s -> %.1fg",
                    seg_idx,
                    tray_global,
                    seg_ams_id,
                    seg_tray_id,
                    seg_start_layer,
                    tray_changes[seg_idx + 1][1] if not is_last else "end",
                    segment_grams,
                )

                seg_spool_id = await _resolve_spool_id_for_tray(
                    printer_id=printer_id,
                    ams_id=seg_ams_id,
                    tray_id=seg_tray_id,
                    db=db,
                    spool_assignments_snapshot=spool_assignments,
                    print_started_at=print_started_at,
                )
                if seg_spool_id is None:
                    logger.info(
                        "[UsageTracker] 3MF split: no spool at printer %d AMS%d-T%d, skipping segment",
                        printer_id,
                        seg_ams_id,
                        seg_tray_id,
                    )
                    continue

                spool_result = await db.execute(select(Spool).where(Spool.id == seg_spool_id))
                spool = spool_result.scalar_one_or_none()
                if not spool:
                    continue

                if not await _charge_spool(db, spool, segment_grams):
                    continue

                percent = round(segment_grams / (spool.label_weight or 1000) * 100)

                cost = None
                cost_per_kg = spool.cost_per_kg if spool.cost_per_kg is not None else default_filament_cost
                if cost_per_kg > 0:
                    cost = round((segment_grams / 1000.0) * cost_per_kg, 2)

                history = SpoolUsageHistory(
                    spool_id=spool.id,
                    printer_id=printer_id,
                    print_name=print_name,
                    weight_used=round(segment_grams, 1),
                    percent_used=percent,
                    status=status,
                    cost=cost,
                    archive_id=archive_id,
                )
                db.add(history)

                handled_trays.add(seg_key)
                results.append(
                    {
                        "spool_id": spool.id,
                        "weight_used": round(segment_grams, 1),
                        "percent_used": percent,
                        "ams_id": seg_ams_id,
                        "tray_id": seg_tray_id,
                        "material": spool.material,
                        "cost": cost,
                        "slot_id": slot_id,
                        "color": _spool_color_to_hex(spool.rgba),
                    }
                )

                logger.info(
                    "[UsageTracker] Spool %d consumed %.1fg (3MF split seg%d) on printer %d AMS%d-T%d (%s)",
                    spool.id,
                    segment_grams,
                    seg_idx,
                    printer_id,
                    seg_ams_id,
                    seg_tray_id,
                    status,
                )

            continue  # Skip normal single-tray processing for this slot

        # Map 3MF slot_id to physical (ams_id, tray_id) using resolved mapping
        tray_is_guessed = False
        if tray_now_override is not None:
            # Single-filament non-queue print: use actual tray from printer state
            global_tray_id = tray_now_override
        else:
            # Explicit mapping (print command, MQTT, queue, color match)
            global_tray_id = None
            if slot_to_tray and slot_id <= len(slot_to_tray):
                mapped = slot_to_tray[slot_id - 1]
                if isinstance(mapped, int) and mapped >= 0:
                    global_tray_id = mapped
                elif mapped == -1:
                    # The mapping says this slot isn't fed from any tray. The
                    # position-based guess below would hand it the Nth loaded
                    # tray anyway -- an AMS spool that never moved (#3166), or
                    # the tray another slot really used, which that slot then
                    # finds already handled and drops (#2880).
                    logger.info(
                        "[UsageTracker] 3MF: slot_id=%d is unmapped (-1) — nothing charged (used_g=%.1f)",
                        slot_id,
                        used_g,
                    )
                    continue
            # Position-based default: sort available tray IDs so external spools (254/255)
            # naturally follow standard AMS trays, matching slicer slot numbering.
            #
            # Filter out AMS slots that have no spool loaded (empty `tray_type`) —
            # BambuStudio/OrcaSlicer compact the slot list when assigning filaments
            # and don't expose empty AMS slots to the user, so the slicer's 3MF
            # slot N maps to the Nth *loaded* tray, not the Nth physical position.
            # Without this filter a "3 AMS slots loaded + 1 empty + external"
            # layout routes the slicer's 4th filament to the empty AMS slot
            # instead of the external (#1607), and the external's spool usage
            # never gets recorded. vt_tray entries are already filtered the
            # same way inside `build_ams_tray_lookup` (line 174 checks
            # `tray_type`), so this just mirrors that for the AMS side.
            tray_is_guessed = global_tray_id is None
            if global_tray_id is None:
                _state = printer_manager.get_status(printer_id)
                _raw = getattr(_state, "raw_data", None) if _state else None
                if _raw:
                    from backend.app.services.spoolman_tracking import build_ams_tray_lookup

                    _lookup = build_ams_tray_lookup(_raw)
                    available_trays = sorted(gid for gid, info in _lookup.items() if info.get("tray_type"))
                    if slot_id <= len(available_trays):
                        global_tray_id = available_trays[slot_id - 1]
            # Final fallback: slot_id - 1 (legacy, works for pure AMS without external spools)
            if global_tray_id is None:
                global_tray_id = slot_id - 1

        if global_tray_id >= 254:
            # External spool: ams_id=255 (sentinel), tray_id=slot index (0 or 1)
            ams_id = 255
            tray_id = global_tray_id - 254
        elif global_tray_id >= 128:
            ams_id = global_tray_id
            tray_id = 0
        else:
            ams_id = global_tray_id // 4
            tray_id = global_tray_id % 4

        logger.info(
            "[UsageTracker] 3MF: slot_id=%d -> global_tray=%d -> AMS%d-T%d (used_g=%.1f, tray_now_override=%s)",
            slot_id,
            global_tray_id,
            ams_id,
            tray_id,
            used_g,
            tray_now_override,
        )

        key = (ams_id, tray_id)
        if key in covered_before:
            continue
        if tray_is_guessed and key in handled_trays:
            # A guess by position can land a second slot on a tray another slot
            # was charged for. That says nothing about which spool fed it, so
            # it is not charged to that tray's spool as well.
            continue

        spool_id = await _resolve_spool_id_for_tray(
            printer_id=printer_id,
            ams_id=ams_id,
            tray_id=tray_id,
            db=db,
            spool_assignments_snapshot=spool_assignments,
            print_started_at=print_started_at,
        )
        if spool_id is None:
            # WARNING, not INFO: everything upstream of this line succeeded --
            # the 3MF was found, the grams were read, the tray resolved -- and
            # the print will still report success while this filament is never
            # deducted. At INFO it was invisible under the default log level and
            # absent from the reasoning in support bundles (#2812).
            logger.warning(
                "[UsageTracker] 3MF: no spool assignment at printer %d AMS%d-T%d — %.1fg not deducted",
                printer_id,
                ams_id,
                tray_id,
                used_g,
            )
            unassigned_global_trays.append(global_tray_id)
            continue

        # Load spool
        spool_result = await db.execute(select(Spool).where(Spool.id == spool_id))
        spool = spool_result.scalar_one_or_none()
        if not spool:
            continue

        # Use per-layer grams if available, otherwise linear scale
        if layer_grams and slot_id in layer_grams:
            weight_grams = layer_grams[slot_id]
        else:
            weight_grams = used_g * scale

        if weight_grams <= 0:
            continue

        # Update spool
        if not await _charge_spool(db, spool, weight_grams):
            continue

        percent = round(weight_grams / (spool.label_weight or 1000) * 100)

        # Calculate cost for this usage
        cost = None
        cost_per_kg = spool.cost_per_kg if spool.cost_per_kg is not None else default_filament_cost
        if cost_per_kg > 0:
            cost = round((weight_grams / 1000.0) * cost_per_kg, 2)

        # Insert usage history record
        history = SpoolUsageHistory(
            spool_id=spool.id,
            printer_id=printer_id,
            print_name=print_name,
            weight_used=round(weight_grams, 1),
            percent_used=percent,
            status=status,
            cost=cost,
            archive_id=archive_id,
        )
        db.add(history)

        handled_trays.add(key)
        results.append(
            {
                "spool_id": spool.id,
                "weight_used": round(weight_grams, 1),
                "percent_used": percent,
                "ams_id": ams_id,
                "tray_id": tray_id,
                "material": spool.material,
                "cost": cost,
                "slot_id": slot_id,
                "color": _spool_color_to_hex(spool.rgba),
            }
        )

        # Determine mapping source for debug logging
        if tray_now_override is not None:
            map_src = ", tray_now"
        elif mapping_source:
            map_src = f", {mapping_source}_map"
        else:
            map_src = ""
        logger.info(
            "[UsageTracker] Spool %d consumed %.1fg (3MF%s%s) on printer %d AMS%d-T%d (%s)",
            spool.id,
            weight_grams,
            " per-layer" if (layer_grams and slot_id in layer_grams) else (f" scaled {scale:.0%}" if scale < 1 else ""),
            map_src,
            printer_id,
            ams_id,
            tray_id,
            status,
        )

    # --- Adopt the matched inventory spools' colours for the archive (#1494) ---
    # The archive's filament_color was set from the slicer's 3MF at creation
    # time; now that every used slot has been resolved to an inventory spool,
    # the curated spool colour is authoritative. Committed by the caller's
    # `if results: await db.commit()`.
    if archive is not None:
        spool_colors = _archive_colors_from_spools(filament_usage, results)
        if spool_colors:
            joined = ",".join(spool_colors)
            if joined != archive.filament_color:
                logger.info(
                    "[UsageTracker] 3MF: archive %s filament_color %r -> %r (from inventory spools)",
                    archive_id,
                    archive.filament_color,
                    joined,
                )
                archive.filament_color = joined

        # Adopt the matched spools' materials too (#2563) — a slot mapped to a
        # differently-typed spool than it was sliced for otherwise records the
        # sliced type in the archive, Print Log and material stats.
        spool_types = _archive_types_from_spools(filament_usage, results)
        if spool_types:
            joined_types = ",".join(spool_types)
            if joined_types != archive.filament_type:
                logger.info(
                    "[UsageTracker] 3MF: archive %s filament_type %r -> %r (from inventory spools)",
                    archive_id,
                    archive.filament_type,
                    joined_types,
                )
                archive.filament_type = joined_types

    if unassigned_global_trays:
        from backend.app.services.spool_assignment_notifications import (
            notify_missing_spool_assignments_on_print_complete,
        )

        await notify_missing_spool_assignments_on_print_complete(printer_id, unassigned_global_trays, db, logger)

    return results