WIP: Parallelize macOS CI builds by splitting arm64 and x86_64 into separate jobs (#12562)

* Parallelize macOS CI builds by splitting arm64 and x86_64 into separate jobs

* fix shell errors

* Delete intermediate per-arch artifacts

.github/workflows/build_all.yml

@@ -58,23 +58,41 @@ jobs:
       os: ubuntu-24.04
       build-deps-only: ${{ inputs.build-deps-only || false }}
     secrets: inherit
-  build_all:
-    strategy:
-      fail-fast: false
-      matrix:
-        include:
-          - os: windows-latest
-          - os: ${{ vars.SELF_HOSTED && 'orca-macos-arm64' || 'macos-14' }}
-            arch: arm64
+  build_windows:
     # Don't run scheduled builds on forks:
     if: ${{ !cancelled() && (github.event_name != 'schedule' || github.repository == 'OrcaSlicer/OrcaSlicer') }}
     uses: ./.github/workflows/build_check_cache.yml
     with:
-      os: ${{ matrix.os }}
+      os: windows-latest
+      build-deps-only: ${{ inputs.build-deps-only || false }}
+      force-build: ${{ github.event_name == 'schedule' }}
+    secrets: inherit
+  build_macos_arch:
+    strategy:
+      fail-fast: false
+      matrix:
+        arch:
+          - arm64
+          - x86_64
+    # Don't run scheduled builds on forks:
+    if: ${{ !cancelled() && (github.event_name != 'schedule' || github.repository == 'OrcaSlicer/OrcaSlicer') }}
+    uses: ./.github/workflows/build_check_cache.yml
+    with:
+      os: ${{ vars.SELF_HOSTED && 'orca-macos-arm64' || 'macos-14' }}
       arch: ${{ matrix.arch }}
       build-deps-only: ${{ inputs.build-deps-only || false }}
       force-build: ${{ github.event_name == 'schedule' }}
     secrets: inherit
+  build_macos_universal:
+    name: Build macOS Universal
+    needs: build_macos_arch
+    if: ${{ !cancelled() && needs.build_macos_arch.result == 'success' && !inputs.build-deps-only && (github.event_name != 'schedule' || github.repository == 'OrcaSlicer/OrcaSlicer') }}
+    uses: ./.github/workflows/build_orca.yml
+    with:
+      os: ${{ vars.SELF_HOSTED && 'orca-macos-arm64' || 'macos-14' }}
+      arch: universal
+      macos-combine-only: true
+    secrets: inherit
   unit_tests:
     name: Unit Tests
     runs-on: ubuntu-24.04

.github/workflows/build_check_cache.yml

@@ -30,16 +30,16 @@ jobs:
         with:
           lfs: 'true'
         
-      - name: set outputs
-        id: set_outputs
-        env:
-          # Normalize macOS runner names so self-hosted and GitHub-hosted produce the same cache key
-          cache-os: ${{ contains(inputs.os, 'macos') && 'macos-arm64' || inputs.os }}
-          dep-folder-name: ${{ !contains(inputs.os, 'macos') && '/OrcaSlicer_dep' || '' }}
-          output-cmd: ${{ inputs.os == 'windows-latest' && '$env:GITHUB_OUTPUT' || '"$GITHUB_OUTPUT"'}}
-        run: |
-          echo cache-key=${{ env.cache-os }}-cache-orcaslicer_deps-build-${{ hashFiles('deps/**') }} >> ${{ env.output-cmd }}
-          echo cache-path=${{ github.workspace }}/deps/build${{ env.dep-folder-name }} >> ${{ env.output-cmd }}
+      - name: set outputs
+        id: set_outputs
+        env:
+          # Keep macOS cache keys and paths architecture-specific.
+          cache-os: ${{ contains(inputs.os, 'macos') && format('macos-{0}', inputs.arch) || inputs.os }}
+          dep-folder-name: ${{ contains(inputs.os, 'macos') && format('/{0}', inputs.arch) || '/OrcaSlicer_dep' }}
+          output-cmd: ${{ inputs.os == 'windows-latest' && '$env:GITHUB_OUTPUT' || '"$GITHUB_OUTPUT"'}}
+        run: |
+          echo cache-key=${{ env.cache-os }}-cache-orcaslicer_deps-build-${{ hashFiles('deps/**') }} >> ${{ env.output-cmd }}
+          echo cache-path=${{ github.workspace }}/deps/build${{ env.dep-folder-name }} >> ${{ env.output-cmd }}
             
       - name: load cache
         id: cache_deps

.github/workflows/build_deps.yml

@@ -80,11 +80,9 @@ jobs:
             if [ -z "${{ vars.SELF_HOSTED }}" ]; then
               brew install automake texinfo libtool
             fi
-            ./build_release_macos.sh -dx ${{ !vars.SELF_HOSTED && '-1' || '' }} -a universal -t 10.15
-            for arch in arm64 x86_64; do
-                (cd "${{ github.workspace }}/deps/build/${arch}" && \
-                find . -mindepth 1 -maxdepth 1 ! -name 'OrcaSlicer_dep' -exec rm -rf {} +)
-            done
+            ./build_release_macos.sh -dx ${{ !vars.SELF_HOSTED && '-1' || '' }} -a ${{ inputs.arch }} -t 10.15
+            (cd "${{ github.workspace }}/deps/build/${{ inputs.arch }}" && \
+            find . -mindepth 1 -maxdepth 1 ! -name 'OrcaSlicer_dep' -exec rm -rf {} +)
 
 
       - name: Apt-Install Dependencies

.github/workflows/build_orca.yml

@@ -2,10 +2,10 @@ on:
     workflow_call:
       inputs:
         cache-key:
-          required: true
+          required: false
           type: string
         cache-path:
-          required: true
+          required: false
           type: string
         os:
           required: true
@@ -13,6 +13,10 @@ on:
         arch:
           required: false
           type: string
+        macos-combine-only:
+          required: false
+          type: boolean
+          default: false
 
 jobs:
   build_orca:
@@ -31,6 +35,7 @@ jobs:
           lfs: 'true'
 
       - name: load cached deps
+        if: ${{ !(contains(inputs.os, 'macos') && inputs.macos-combine-only) }}
         uses: actions/cache@v5
         with:
           path: ${{ inputs.cache-path }}
@@ -86,16 +91,16 @@ jobs:
 
 #   Mac
       - name: Install tools mac
-        if: contains(inputs.os, 'macos')
+        if: contains(inputs.os, 'macos') && !inputs.macos-combine-only
         run: |
           if [ -z "${{ vars.SELF_HOSTED }}" ]; then
             brew install libtool
             brew list
           fi
-          mkdir -p ${{ github.workspace }}/deps/build
+          mkdir -p ${{ github.workspace }}/deps/build/${{ inputs.arch }}
 
       - name: Free disk space
-        if: contains(inputs.os, 'macos') && !vars.SELF_HOSTED
+        if: contains(inputs.os, 'macos') && !inputs.macos-combine-only && !vars.SELF_HOSTED
         run: |
           df -hI /dev/disk3s1s1
           sudo find /Applications -maxdepth 1 -type d -name "Xcode_*.app" ! -name "Xcode_15.4.app" -exec rm -rf {} +
@@ -103,14 +108,65 @@ jobs:
           df -hI /dev/disk3s1s1
 
       - name: Build slicer mac
-        if: contains(inputs.os, 'macos')
+        if: contains(inputs.os, 'macos') && !inputs.macos-combine-only
         working-directory: ${{ github.workspace }}
         run: |
-          ./build_release_macos.sh -s -n -x ${{ !vars.SELF_HOSTED && '-1' || '' }} -a universal -t 10.15
+          ./build_release_macos.sh -s -n -x ${{ !vars.SELF_HOSTED && '-1' || '' }} -a ${{ inputs.arch }} -t 10.15
+
+      - name: Pack macOS app bundle ${{ inputs.arch }}
+        if: contains(inputs.os, 'macos') && !inputs.macos-combine-only
+        working-directory: ${{ github.workspace }}
+        run: |
+          tar -czvf OrcaSlicer_Mac_bundle_${{ inputs.arch }}_${{ github.sha }}.tar.gz -C build/${{ inputs.arch }} OrcaSlicer
+
+      - name: Upload macOS app bundle ${{ inputs.arch }}
+        if: contains(inputs.os, 'macos') && !inputs.macos-combine-only
+        uses: actions/upload-artifact@v6
+        with:
+          name: OrcaSlicer_Mac_bundle_${{ inputs.arch }}_${{ github.sha }}
+          path: ${{ github.workspace }}/OrcaSlicer_Mac_bundle_${{ inputs.arch }}_${{ github.sha }}.tar.gz
+
+      - name: Download macOS arm64 app bundle
+        if: contains(inputs.os, 'macos') && inputs.macos-combine-only
+        uses: actions/download-artifact@v7
+        with:
+          name: OrcaSlicer_Mac_bundle_arm64_${{ github.sha }}
+          path: ${{ github.workspace }}/mac_bundles/arm64
+
+      - name: Download macOS x86_64 app bundle
+        if: contains(inputs.os, 'macos') && inputs.macos-combine-only
+        uses: actions/download-artifact@v7
+        with:
+          name: OrcaSlicer_Mac_bundle_x86_64_${{ github.sha }}
+          path: ${{ github.workspace }}/mac_bundles/x86_64
+
+      - name: Extract macOS app bundles
+        if: contains(inputs.os, 'macos') && inputs.macos-combine-only
+        working-directory: ${{ github.workspace }}
+        run: |
+          mkdir -p build/arm64 build/x86_64
+          arm_bundle=$(find "${{ github.workspace }}/mac_bundles/arm64" -name '*.tar.gz' -print -quit)
+          x86_bundle=$(find "${{ github.workspace }}/mac_bundles/x86_64" -name '*.tar.gz' -print -quit)
+          tar -xzvf "$arm_bundle" -C "${{ github.workspace }}/build/arm64"
+          tar -xzvf "$x86_bundle" -C "${{ github.workspace }}/build/x86_64"
+
+      - name: Build universal mac app bundle
+        if: contains(inputs.os, 'macos') && inputs.macos-combine-only
+        working-directory: ${{ github.workspace }}
+        run: |
+          ./build_release_macos.sh -u -x ${{ !vars.SELF_HOSTED && '-1' || '' }} -a universal -t 10.15
+
+      - name: Delete intermediate per-arch artifacts
+        if: contains(inputs.os, 'macos') && inputs.macos-combine-only
+        uses: geekyeggo/delete-artifact@v5
+        with:
+          name: |
+            OrcaSlicer_Mac_bundle_arm64_${{ github.sha }}
+            OrcaSlicer_Mac_bundle_x86_64_${{ github.sha }}
 
  # Thanks to RaySajuuk, it's working now
       - name: Sign app and notary
-        if: github.repository == 'OrcaSlicer/OrcaSlicer' && (github.ref == 'refs/heads/main' || startsWith(github.ref, 'refs/heads/release/')) && contains(inputs.os, 'macos')
+        if: github.repository == 'OrcaSlicer/OrcaSlicer' && (github.ref == 'refs/heads/main' || startsWith(github.ref, 'refs/heads/release/')) && contains(inputs.os, 'macos') && inputs.macos-combine-only
         working-directory: ${{ github.workspace }}
         env:
           BUILD_CERTIFICATE_BASE64: ${{ secrets.BUILD_CERTIFICATE_BASE64 }}
@@ -164,7 +220,7 @@ jobs:
           fi
 
       - name: Create DMG without notary
-        if: github.ref != 'refs/heads/main' && contains(inputs.os, 'macos')
+        if: github.ref != 'refs/heads/main' && contains(inputs.os, 'macos') && inputs.macos-combine-only
         working-directory: ${{ github.workspace }}
         run: |
           mkdir -p ${{ github.workspace }}/build/universal/OrcaSlicer_dmg
@@ -183,14 +239,14 @@ jobs:
           fi
 
       - name: Upload artifacts mac
-        if: contains(inputs.os, 'macos')
+        if: contains(inputs.os, 'macos') && inputs.macos-combine-only
         uses: actions/upload-artifact@v6
         with:
           name: OrcaSlicer_Mac_universal_${{ env.ver }}
           path: ${{ github.workspace }}/OrcaSlicer_Mac_universal_${{ env.ver }}.dmg
 
       - name: Upload OrcaSlicer_profile_validator DMG mac
-        if: contains(inputs.os, 'macos')
+        if: contains(inputs.os, 'macos') && inputs.macos-combine-only
         uses: actions/upload-artifact@v6
         with:
           name: OrcaSlicer_profile_validator_Mac_universal_DMG_${{ env.ver }}
@@ -198,7 +254,7 @@ jobs:
           if-no-files-found: ignore
 
       - name: Deploy Mac release
-        if: github.repository == 'OrcaSlicer/OrcaSlicer' && github.ref == 'refs/heads/main' && contains(inputs.os, 'macos')
+        if: github.repository == 'OrcaSlicer/OrcaSlicer' && github.ref == 'refs/heads/main' && contains(inputs.os, 'macos') && inputs.macos-combine-only
         uses: WebFreak001/deploy-nightly@v3.2.0
         with:
           upload_url: https://uploads.github.com/repos/OrcaSlicer/OrcaSlicer/releases/137995723/assets{?name,label}
@@ -209,7 +265,7 @@ jobs:
           max_releases: 1 # optional, if there are more releases than this matching the asset_name, the oldest ones are going to be deleted
 
       - name: Deploy Mac OrcaSlicer_profile_validator DMG release
-        if: github.repository == 'OrcaSlicer/OrcaSlicer' && github.ref == 'refs/heads/main' && contains(inputs.os, 'macos')
+        if: github.repository == 'OrcaSlicer/OrcaSlicer' && github.ref == 'refs/heads/main' && contains(inputs.os, 'macos') && inputs.macos-combine-only
         uses: WebFreak001/deploy-nightly@v3.2.0
         with:
           upload_url: https://uploads.github.com/repos/OrcaSlicer/OrcaSlicer/releases/137995723/assets{?name,label}

build_release_macos.sh

@@ -3,7 +3,7 @@
 set -e
 set -o pipefail
 
-while getopts ":dpa:snt:xbc:1Th" opt; do
+while getopts ":dpa:snt:xbc:1Tuh" opt; do
   case "${opt}" in
     d )
         export BUILD_TARGET="deps"
@@ -40,10 +40,14 @@ while getopts ":dpa:snt:xbc:1Th" opt; do
     T )
         export BUILD_TESTS="1"
         ;;
+    u )
+        export BUILD_TARGET="universal"
+        ;;
     h ) echo "Usage: ./build_release_macos.sh [-d]"
         echo "   -d: Build deps only"
         echo "   -a: Set ARCHITECTURE (arm64 or x86_64 or universal)"
         echo "   -s: Build slicer only"
+        echo "   -u: Build universal app only (requires existing arm64 and x86_64 app bundles)"
         echo "   -n: Nightly build"
         echo "   -t: Specify minimum version of the target platform, default is 11.3"
         echo "   -x: Use Ninja Multi-Config CMake generator, default is Xcode"
@@ -249,48 +253,54 @@ function build_slicer() {
     done
 }
 
+function lipo_dir() {
+    local universal_dir="$1"
+    local x86_64_dir="$2"
+
+    # Find all Mach-O files in the universal (arm64-based) copy and lipo them
+    while IFS= read -r -d '' f; do
+        local rel="${f#"$universal_dir"/}"
+        local x86="$x86_64_dir/$rel"
+        if [ -f "$x86" ]; then
+            echo "  lipo: $rel"
+            lipo -create "$f" "$x86" -output "$f.tmp"
+            mv "$f.tmp" "$f"
+        else
+            echo "  warning: no x86_64 counterpart for $rel, keeping arm64 only"
+        fi
+    done < <(find "$universal_dir" -type f -print0 | while IFS= read -r -d '' candidate; do
+        if file "$candidate" | grep -q "Mach-O"; then
+            printf '%s\0' "$candidate"
+        fi
+    done)
+}
+
 function build_universal() {
     echo "Building universal binary..."
 
     PROJECT_BUILD_DIR="$PROJECT_DIR/build/$ARCH"
-    
-    # Create universal binary
-    echo "Creating universal binary..."
-    # PROJECT_BUILD_DIR="$PROJECT_DIR/build_Universal"
+    ARM64_APP="$PROJECT_DIR/build/arm64/OrcaSlicer/OrcaSlicer.app"
+    X86_64_APP="$PROJECT_DIR/build/x86_64/OrcaSlicer/OrcaSlicer.app"
+
     mkdir -p "$PROJECT_BUILD_DIR/OrcaSlicer"
     UNIVERSAL_APP="$PROJECT_BUILD_DIR/OrcaSlicer/OrcaSlicer.app"
     rm -rf "$UNIVERSAL_APP"
-    cp -R "$PROJECT_DIR/build/arm64/OrcaSlicer/OrcaSlicer.app" "$UNIVERSAL_APP"
-    
-    # Get the binary path inside the .app bundle
-    BINARY_PATH="Contents/MacOS/OrcaSlicer"
-    
-    # Create universal binary using lipo
-    lipo -create \
-        "$PROJECT_DIR/build/x86_64/OrcaSlicer/OrcaSlicer.app/$BINARY_PATH" \
-        "$PROJECT_DIR/build/arm64/OrcaSlicer/OrcaSlicer.app/$BINARY_PATH" \
-        -output "$UNIVERSAL_APP/$BINARY_PATH"
-        
-    echo "Universal binary created at $UNIVERSAL_APP"
-    
+    cp -R "$ARM64_APP" "$UNIVERSAL_APP"
+
+    echo "Creating universal binaries for OrcaSlicer.app..."
+    lipo_dir "$UNIVERSAL_APP" "$X86_64_APP"
+    echo "Universal OrcaSlicer.app created at $UNIVERSAL_APP"
+
     # Create universal binary for profile validator if it exists
-    if [ -f "$PROJECT_DIR/build/arm64/OrcaSlicer/OrcaSlicer_profile_validator.app/Contents/MacOS/OrcaSlicer_profile_validator" ] && \
-       [ -f "$PROJECT_DIR/build/x86_64/OrcaSlicer/OrcaSlicer_profile_validator.app/Contents/MacOS/OrcaSlicer_profile_validator" ]; then
-        echo "Creating universal binary for OrcaSlicer_profile_validator..."
+    ARM64_VALIDATOR="$PROJECT_DIR/build/arm64/OrcaSlicer/OrcaSlicer_profile_validator.app"
+    X86_64_VALIDATOR="$PROJECT_DIR/build/x86_64/OrcaSlicer/OrcaSlicer_profile_validator.app"
+    if [ -d "$ARM64_VALIDATOR" ] && [ -d "$X86_64_VALIDATOR" ]; then
+        echo "Creating universal binaries for OrcaSlicer_profile_validator.app..."
         UNIVERSAL_VALIDATOR_APP="$PROJECT_BUILD_DIR/OrcaSlicer/OrcaSlicer_profile_validator.app"
         rm -rf "$UNIVERSAL_VALIDATOR_APP"
-        cp -R "$PROJECT_DIR/build/arm64/OrcaSlicer/OrcaSlicer_profile_validator.app" "$UNIVERSAL_VALIDATOR_APP"
-        
-        # Get the binary path inside the profile validator .app bundle
-        VALIDATOR_BINARY_PATH="Contents/MacOS/OrcaSlicer_profile_validator"
-        
-        # Create universal binary using lipo
-        lipo -create \
-            "$PROJECT_DIR/build/x86_64/OrcaSlicer/OrcaSlicer_profile_validator.app/$VALIDATOR_BINARY_PATH" \
-            "$PROJECT_DIR/build/arm64/OrcaSlicer/OrcaSlicer_profile_validator.app/$VALIDATOR_BINARY_PATH" \
-            -output "$UNIVERSAL_VALIDATOR_APP/$VALIDATOR_BINARY_PATH"
-            
-        echo "Universal binary for OrcaSlicer_profile_validator created at $UNIVERSAL_VALIDATOR_APP"
+        cp -R "$ARM64_VALIDATOR" "$UNIVERSAL_VALIDATOR_APP"
+        lipo_dir "$UNIVERSAL_VALIDATOR_APP" "$X86_64_VALIDATOR"
+        echo "Universal OrcaSlicer_profile_validator.app created at $UNIVERSAL_VALIDATOR_APP"
     fi
 }
 
@@ -305,13 +315,16 @@ case "${BUILD_TARGET}" in
     slicer)
         build_slicer
         ;;
+    universal)
+        build_universal
+        ;;
     *)
-        echo "Unknown target: $BUILD_TARGET. Available targets: deps, slicer, all."
+        echo "Unknown target: $BUILD_TARGET. Available targets: deps, slicer, universal, all."
         exit 1
         ;;
 esac
 
-if [ "$ARCH" = "universal" ] && [ "$BUILD_TARGET" != "deps" ]; then
+if [ "$ARCH" = "universal" ] && { [ "$BUILD_TARGET" = "all" ] || [ "$BUILD_TARGET" = "slicer" ]; }; then
     build_universal
 fi