Former/session.go

package main

import (
	"fmt"
	"image"
	"image/color"
	"image/draw"
	"image/png"
	"io"
	"log"
	"os"
	"path/filepath"
	"strings"
)

// EnclosureSession holds all state for an active enclosure editing session
type EnclosureSession struct {
	Exports       []string
	OutlineGf     *GerberFile
	OutlineImg    image.Image
	CourtyardImg  image.Image
	SoldermaskImg image.Image
	DrillHoles    []DrillHole
	Config        EnclosureConfig
	OutlineBounds Bounds
	BoardW        float64
	BoardH        float64
	TotalH        float64
	MinBX         float64
	MaxBX         float64
	BoardCenterY  float64
	Sides         []BoardSide
	FabImg           image.Image
	EnclosureWallImg image.Image            // 2D top-down view of enclosure walls
	AllLayerImages   map[string]image.Image  // all rendered gerber layers keyed by original filename
	AllLayerGerbers  map[string]*GerberFile // parsed gerber files keyed by original filename
	SourceDir        string                 // original directory of the gerber files

	// Persistence metadata
	GerberFiles    map[string]string
	DrillPath      string
	NPTHPath       string
	ProjectName    string
	EdgeCutsFile   string
	CourtyardFile  string
	SoldermaskFile string
	FabFile        string
}


// BuildEnclosureSession creates a session from uploaded files and configuration.
// This is used by both the initial upload and by instance restore.
func BuildEnclosureSession(
	gbrjobPath string,
	gerberPaths map[string]string, // original filename -> saved path
	drillPath, npthPath string,
	ecfg EnclosureConfig,
	exports []string,
) (string, *EnclosureSession, error) {

	// Parse gbrjob
	jobResult, err := ParseGerberJob(gbrjobPath)
	if err != nil {
		return "", nil, fmt.Errorf("parse gbrjob: %v", err)
	}

	pcbThickness := jobResult.BoardThickness
	if pcbThickness == 0 {
		pcbThickness = DefaultPCBThickness
	}
	ecfg.PCBThickness = pcbThickness

	// Find outline
	outlinePath, ok := gerberPaths[jobResult.EdgeCutsFile]
	if !ok {
		return "", nil, fmt.Errorf("Edge.Cuts file '%s' not found in uploaded gerbers", jobResult.EdgeCutsFile)
	}

	// Parse outline
	outlineGf, err := ParseGerber(outlinePath)
	if err != nil {
		return "", nil, fmt.Errorf("parse outline: %v", err)
	}

	outlineBounds := outlineGf.CalculateBounds()
	actualBoardW := outlineBounds.MaxX - outlineBounds.MinX
	actualBoardH := outlineBounds.MaxY - outlineBounds.MinY

	margin := ecfg.WallThickness + ecfg.Clearance + 5.0
	outlineBounds.MinX -= margin
	outlineBounds.MinY -= margin
	outlineBounds.MaxX += margin
	outlineBounds.MaxY += margin
	ecfg.OutlineBounds = &outlineBounds

	outlineImg := outlineGf.Render(ecfg.DPI, &outlineBounds)

	// Compute board mask
	minBX, _, maxBX, _ := outlineImg.Bounds().Max.X, outlineImg.Bounds().Max.Y, -1, -1
	var boardCenterY float64
	var boardCount int

	_, boardMask := ComputeWallMask(outlineImg, ecfg.WallThickness+ecfg.Clearance, ecfg.DPI/25.4)
	imgW, imgH := outlineImg.Bounds().Max.X, outlineImg.Bounds().Max.Y
	for y := 0; y < imgH; y++ {
		for x := 0; x < imgW; x++ {
			if boardMask[y*imgW+x] {
				if x < minBX {
					minBX = x
				}
				if x > maxBX {
					maxBX = x
				}
				boardCenterY += float64(y)
				boardCount++
			}
		}
	}
	if boardCount > 0 {
		boardCenterY /= float64(boardCount)
	}

	// Parse drill files
	var drillHoles []DrillHole
	if drillPath != "" {
		if holes, err := ParseDrill(drillPath); err == nil {
			drillHoles = append(drillHoles, holes...)
		}
	}
	if npthPath != "" {
		if holes, err := ParseDrill(npthPath); err == nil {
			drillHoles = append(drillHoles, holes...)
		}
	}

	var filteredHoles []DrillHole
	for _, h := range drillHoles {
		if h.Type != DrillTypeVia {
			filteredHoles = append(filteredHoles, h)
		}
	}

	// Render layer images
	var courtyardImg image.Image
	if courtPath, ok := gerberPaths[jobResult.CourtyardFile]; ok && jobResult.CourtyardFile != "" {
		if courtGf, err := ParseGerber(courtPath); err == nil {
			courtyardImg = courtGf.Render(ecfg.DPI, &outlineBounds)
		}
	}

	var soldermaskImg image.Image
	if maskPath, ok := gerberPaths[jobResult.SoldermaskFile]; ok && jobResult.SoldermaskFile != "" {
		if maskGf, err := ParseGerber(maskPath); err == nil {
			soldermaskImg = maskGf.Render(ecfg.DPI, &outlineBounds)
		}
	}

	// Fab fallback for courtyard
	if courtyardImg == nil && jobResult.FabFile != "" {
		if fabPath, ok := gerberPaths[jobResult.FabFile]; ok {
			if fabGf, err := ParseGerber(fabPath); err == nil {
				courtyardImg = fabGf.Render(ecfg.DPI, &outlineBounds)
			}
		}
	}

	pixelToMM := 25.4 / ecfg.DPI

	// Render ALL uploaded gerber layers
	allLayers := make(map[string]image.Image)
	allGerbers := make(map[string]*GerberFile)
	for origName, fullPath := range gerberPaths {
		if strings.HasSuffix(strings.ToLower(origName), ".gbrjob") {
			continue
		}
		// Skip edge cuts — already rendered as outlineImg
		if origName == jobResult.EdgeCutsFile {
			allLayers[origName] = outlineImg
			allGerbers[origName] = outlineGf
			continue
		}
		gf, err := ParseGerber(fullPath)
		if err != nil {
			log.Printf("Warning: could not parse %s: %v", origName, err)
			continue
		}
		allLayers[origName] = gf.Render(ecfg.DPI, &outlineBounds)
		allGerbers[origName] = gf
	}

	// Build basenames map for persistence
	gerberBasenames := make(map[string]string)
	for origName, fullPath := range gerberPaths {
		gerberBasenames[origName] = filepath.Base(fullPath)
	}

	sessionID := randomID()
	session := &EnclosureSession{
		Exports:       exports,
		OutlineGf:     outlineGf,
		OutlineImg:    outlineImg,
		CourtyardImg:  courtyardImg,
		SoldermaskImg: soldermaskImg,
		DrillHoles:    filteredHoles,
		Config:        ecfg,
		OutlineBounds: outlineBounds,
		BoardW:        actualBoardW,
		BoardH:        actualBoardH,
		TotalH:        ecfg.WallHeight + ecfg.PCBThickness + 1.0,
		MinBX:         float64(minBX)*pixelToMM + outlineBounds.MinX,
		MaxBX:         float64(maxBX)*pixelToMM + outlineBounds.MinX,
		BoardCenterY:  outlineBounds.MaxY - boardCenterY*pixelToMM,
		Sides:         ExtractBoardSidesFromMask(boardMask, imgW, imgH, pixelToMM, &outlineBounds),
		GerberFiles:   gerberBasenames,
		DrillPath:     filepath.Base(drillPath),
		NPTHPath:      filepath.Base(npthPath),
		ProjectName:   jobResult.ProjectName,
		EdgeCutsFile:  jobResult.EdgeCutsFile,
		CourtyardFile: jobResult.CourtyardFile,
		SoldermaskFile: jobResult.SoldermaskFile,
		FabFile:          jobResult.FabFile,
		EnclosureWallImg: renderEnclosureWallImage(outlineImg, ecfg),
		AllLayerImages:   allLayers,
		AllLayerGerbers:  allGerbers,
	}

	log.Printf("Created session %s for project %s (%.1f x %.1f mm)", sessionID, jobResult.ProjectName, actualBoardW, actualBoardH)
	return sessionID, session, nil
}

// UploadFabAndExtractFootprints processes fab gerber files and returns footprint data
func UploadFabAndExtractFootprints(session *EnclosureSession, fabPaths []string) ([]Footprint, image.Image) {
	var allFootprints []Footprint
	var fabGfList []*GerberFile

	for _, path := range fabPaths {
		gf, err := ParseGerber(path)
		if err == nil {
			allFootprints = append(allFootprints, ExtractFootprints(gf)...)
			fabGfList = append(fabGfList, gf)
		}
	}

	// Composite fab images
	var fabImg image.Image
	if len(fabGfList) > 0 {
		bounds := session.OutlineBounds
		imgW := int((bounds.MaxX - bounds.MinX) * session.Config.DPI / 25.4)
		imgH := int((bounds.MaxY - bounds.MinY) * session.Config.DPI / 25.4)
		if imgW > 0 && imgH > 0 {
			composite := image.NewRGBA(image.Rect(0, 0, imgW, imgH))
			draw.Draw(composite, composite.Bounds(), &image.Uniform{color.Transparent}, image.Point{}, draw.Src)

			for _, gf := range fabGfList {
				layerImg := gf.Render(session.Config.DPI, &bounds)
				if rgba, ok := layerImg.(*image.RGBA); ok {
					for y := 0; y < imgH; y++ {
						for x := 0; x < imgW; x++ {
							if r, _, _, _ := rgba.At(x, y).RGBA(); r > 0x7FFF {
								composite.Set(x, y, color.RGBA{0, 255, 255, 180})
							}
						}
					}
				}
			}
			fabImg = composite
		}
	}

	return allFootprints, fabImg
}

// GenerateEnclosureOutputs produces all requested output files for the enclosure
func GenerateEnclosureOutputs(session *EnclosureSession, cutouts []Cutout, outputDir string) ([]string, error) {
	os.MkdirAll(outputDir, 0755)

	// Split unified cutouts into legacy types for STL/SCAD generation
	sideCutouts, lidCutouts := SplitCutouts(cutouts, session.AllLayerGerbers)

	id := randomID()
	var generatedFiles []string

	wantsType := func(t string) bool {
		for _, e := range session.Exports {
			if e == t {
				return true
			}
		}
		return false
	}

	if len(session.Exports) == 0 {
		session.Exports = []string{"stl"}
	}

	// STL
	if wantsType("stl") {
		result := GenerateEnclosure(session.OutlineImg, session.DrillHoles, session.Config, session.CourtyardImg, session.SoldermaskImg, sideCutouts, session.Sides)
		encPath := filepath.Join(outputDir, id+"_enclosure.stl")
		trayPath := filepath.Join(outputDir, id+"_tray.stl")
		WriteSTL(encPath, result.EnclosureTriangles)
		WriteSTL(trayPath, result.TrayTriangles)
		generatedFiles = append(generatedFiles, encPath, trayPath)
	}

	// SCAD
	if wantsType("scad") {
		scadPathEnc := filepath.Join(outputDir, id+"_enclosure.scad")
		scadPathTray := filepath.Join(outputDir, id+"_tray.scad")
		outlinePoly := ExtractPolygonFromGerber(session.OutlineGf)
		WriteNativeSCAD(scadPathEnc, false, outlinePoly, session.Config, session.DrillHoles, sideCutouts, lidCutouts, session.Sides, session.MinBX, session.MaxBX, session.BoardCenterY)
		WriteNativeSCAD(scadPathTray, true, outlinePoly, session.Config, session.DrillHoles, sideCutouts, lidCutouts, session.Sides, session.MinBX, session.MaxBX, session.BoardCenterY)
		generatedFiles = append(generatedFiles, scadPathEnc, scadPathTray)
	}

	// SVG
	if wantsType("svg") && session.OutlineGf != nil {
		svgPath := filepath.Join(outputDir, id+"_outline.svg")
		WriteSVG(svgPath, session.OutlineGf, &session.OutlineBounds)
		generatedFiles = append(generatedFiles, svgPath)
	}

	// PNG
	if wantsType("png") && session.OutlineImg != nil {
		pngPath := filepath.Join(outputDir, id+"_outline.png")
		if f, err := os.Create(pngPath); err == nil {
			png.Encode(f, session.OutlineImg)
			f.Close()
			generatedFiles = append(generatedFiles, pngPath)
		}
	}

	return generatedFiles, nil
}

// SaveOutlineImage saves the outline image as PNG to a file
func SaveOutlineImage(session *EnclosureSession, path string) error {
	f, err := os.Create(path)
	if err != nil {
		return err
	}
	defer f.Close()
	return png.Encode(f, session.OutlineImg)
}

// CopyFile copies a file from src to dst
func CopyFile(src, dst string) error {
	s, err := os.Open(src)
	if err != nil {
		return err
	}
	defer s.Close()

	d, err := os.Create(dst)
	if err != nil {
		return err
	}
	defer d.Close()

	_, err = io.Copy(d, s)
	return err
}