web-cad/frontend/src/services/pdfExport.ts

/**
 * PDF Export – renders CAD elements to PDF using pdf-lib
 */
import { PDFDocument, rgb, StandardFonts } from 'pdf-lib';
import type { CADElement, CADLayer, ProjectData } from '../types/cad.types';

/**
 * Export project data to a PDF byte array.
 */
export async function exportPDF(data: ProjectData): Promise<Uint8Array> {
  const pdfDoc = await PDFDocument.create();
  const font = await pdfDoc.embedFont(StandardFonts.Helvetica);

  // Calculate bounding box of all elements
  const bbox = calculateBoundingBox(data.elements);
  const padding = 20;
  const contentW = bbox.maxX - bbox.minX + padding * 2;
  const contentH = bbox.maxY - bbox.minY + padding * 2;

  // Use A4 landscape or fit to content (whichever is larger)
  const a4W = 842; // A4 landscape in points
  const a4H = 595;
  const pageW = Math.max(a4W, contentW);
  const pageH = Math.max(a4H, contentH);

  const page = pdfDoc.addPage([pageW, pageH]);
  const { width: pw, height: ph } = page.getSize();

  // Flip Y axis: PDF origin is bottom-left, CAD origin is top-left
  const flipY = (y: number) => ph - y + bbox.minY - padding;
  const offsetX = -bbox.minX + padding;
  const offsetY = bbox.minY - padding;

  // Draw elements
  for (const el of data.elements) {
    const layer = data.layers.find(l => l.id === el.layerId);
    if (layer && !layer.visible) continue;
    drawElement(page, el, font, offsetX, offsetY, flipY, layer?.color);
  }

  return pdfDoc.save();
}

function drawElement(
  page: any,
  el: CADElement,
  font: any,
  offX: number,
  offY: number,
  flipY: (y: number) => number,
  layerColor?: string,
): void {
  const p = el.properties;
  const color = hexToRgb(p.stroke as string) ?? hexToRgb(layerColor ?? '#000000') ?? rgb(0, 0, 0);
  const lineWidth = p.strokeWidth ?? 1;

  switch (el.type) {
    case 'line': {
      const x1 = (p.x1 ?? el.x) + offX;
      const y1 = flipY((p.y1 ?? el.y) - offY);
      const x2 = (p.x2 ?? el.x + el.width) + offX;
      const y2 = flipY((p.y2 ?? el.y + el.height) - offY);
      page.drawLine({ start: { x: x1, y: y1 }, end: { x: x2, y: y2 }, thickness: lineWidth, color });
      break;
    }
    case 'circle': {
      const cx = el.x + el.width / 2 + offX;
      const cy = flipY(el.y + el.height / 2 - offY);
      const r = p.radius ?? el.width / 2;
      page.drawCircle({ x: cx, y: cy, radius: r, borderColor: color, borderWidth: lineWidth });
      break;
    }
    case 'arc': {
      // Approximate arc with line segments
      const cx = el.x + el.width / 2 + offX;
      const cy = flipY(el.y + el.height / 2 - offY);
      const r = p.radius ?? el.width / 2;
      const start = p.startAngle ?? 0;
      const end = p.endAngle ?? Math.PI * 2;
      const segments = 32;
      for (let i = 0; i < segments; i++) {
        const a1 = start + (end - start) * (i / segments);
        const a2 = start + (end - start) * ((i + 1) / segments);
        page.drawLine({
          start: { x: cx + Math.cos(a1) * r, y: cy + Math.sin(a1) * r },
          end: { x: cx + Math.cos(a2) * r, y: cy + Math.sin(a2) * r },
          thickness: lineWidth, color,
        });
      }
      break;
    }
    case 'rect': {
      page.drawRectangle({
        x: el.x + offX, y: flipY(el.y + el.height - offY),
        width: el.width, height: el.height,
        borderColor: color, borderWidth: lineWidth,
      });
      break;
    }
    case 'polygon':
    case 'polyline': {
      const pts = p.points ?? [];
      for (let i = 0; i < pts.length - 1; i++) {
        page.drawLine({
          start: { x: pts[i].x + offX, y: flipY(pts[i].y - offY) },
          end: { x: pts[i + 1].x + offX, y: flipY(pts[i + 1].y - offY) },
          thickness: lineWidth, color,
        });
      }
      if (el.type === 'polygon' && pts.length > 2) {
        page.drawLine({
          start: { x: pts[pts.length - 1].x + offX, y: flipY(pts[pts.length - 1].y - offY) },
          end: { x: pts[0].x + offX, y: flipY(pts[0].y - offY) },
          thickness: lineWidth, color,
        });
      }
      break;
    }
    case 'text': {
      const size = p.fontSize ?? 12;
      page.drawText(p.text ?? '', {
        x: el.x + offX, y: flipY(el.y - offY) - size,
        size, font, color,
      });
      break;
    }
    case 'dimension': {
      const pts = p.points ?? [];
      if (pts.length >= 2) {
        page.drawLine({
          start: { x: pts[0].x + offX, y: flipY(pts[0].y - offY) },
          end: { x: pts[1].x + offX, y: flipY(pts[1].y - offY) },
          thickness: lineWidth, color,
        });
        const midX = (pts[0].x + pts[1].x) / 2 + offX;
        const midY = flipY((pts[0].y + pts[1].y) / 2 - offY);
        const dist = Math.hypot(pts[1].x - pts[0].x, pts[1].y - pts[0].y);
        page.drawText(dist.toFixed(2), { x: midX, y: midY, size: 10, font, color });
      }
      break;
    }
    default: {
      // Bounding box for other element types
      page.drawRectangle({
        x: el.x + offX, y: flipY(el.y + el.height - offY),
        width: el.width, height: el.height,
        borderColor: color, borderWidth: lineWidth,
      });
      break;
    }
  }
}

function calculateBoundingBox(elements: CADElement[]) {
  if (elements.length === 0) return { minX: 0, minY: 0, maxX: 1000, maxY: 1000 };
  let minX = Infinity, minY = Infinity, maxX = -Infinity, maxY = -Infinity;
  for (const el of elements) {
    minX = Math.min(minX, el.x);
    minY = Math.min(minY, el.y);
    maxX = Math.max(maxX, el.x + el.width);
    maxY = Math.max(maxY, el.y + el.height);
  }
  return { minX, minY, maxX, maxY };
}

function hexToRgb(hex: string | undefined): ReturnType<typeof rgb> | null {
  if (!hex) return null;
  const h = hex.replace('#', '');
  if (h.length < 6) return null;
  const r = parseInt(h.substring(0, 2), 16) / 255;
  const g = parseInt(h.substring(2, 4), 16) / 255;
  const b = parseInt(h.substring(4, 6), 16) / 255;
  return rgb(r, g, b);
}