From 118319ceabacccd3daa3754190a059cc32cb9472 Mon Sep 17 00:00:00 2001
From: Marc Mintel <marc@mintel.me>
Date: Thu, 11 Jun 2026 18:50:54 +0200
Subject: [PATCH] fix(pdf): correct front/back colors, truck opacity 0.25, add
 letterpress marker layer

---
 lib/pdf-business-card.tsx     | 20 +++++++-
 scripts/inject-letterpress.ts | 93 +++++++++++++++++++++++++++++++++++
 2 files changed, 111 insertions(+), 2 deletions(-)
 create mode 100644 scripts/inject-letterpress.ts

diff --git a/lib/pdf-business-card.tsx b/lib/pdf-business-card.tsx
index c24a922c..43751b93 100644
--- a/lib/pdf-business-card.tsx
+++ b/lib/pdf-business-card.tsx
@@ -712,7 +712,11 @@ export const PDFBusinessCard: React.FC<PDFBusinessCardProps> = ({
       >
         <View style={styles.truckWrapper}>
           <TruckBlueprint
-            style={[styles.frontBackgroundImage, isWhiteVariant && { opacity: 0.2 }]}
+            style={[
+              styles.frontBackgroundImage,
+              isWhiteVariant && { opacity: 0.2 },
+              !isWhiteVariant && { opacity: 0.25 },
+            ]}
           />
         </View>
         <View
@@ -764,7 +768,19 @@ export const PDFBusinessCard: React.FC<PDFBusinessCardProps> = ({
           </View>
         </View>
         <View style={styles.frontContainer}>
-          <VectorLogo paths={getFrontLogoPaths()} style={styles.frontLogo} />
+          {/* Base Logo: text is blue, truck is green */}
+          <VectorLogo
+            paths={getFrontLogoPaths()}
+            style={styles.frontLogo}
+            overrideWhiteColor={COLORS.blue}
+          />
+
+          {/* Letterpress Mask Layer: We use #ff00fe as a marker color. Only the "KLZ" letters! */}
+          <VectorLogo
+            paths={getFrontLogoPaths().slice(1, 6)}
+            style={[styles.frontLogo, { position: 'absolute' }]}
+            overrideColor="#ff00fe"
+          />
         </View>
       </Page>
 
diff --git a/scripts/inject-letterpress.ts b/scripts/inject-letterpress.ts
new file mode 100644
index 00000000..36236582
--- /dev/null
+++ b/scripts/inject-letterpress.ts
@@ -0,0 +1,93 @@
+import { PDFDocument, PDFName, PDFString, PDFNumber, PDFDict, PDFArray } from 'pdf-lib';
+import fs from 'fs';
+import path from 'path';
+
+async function run() {
+  const filePaths = [
+    'KLZ_Visitenkarte_Michael_Bodemer_Viaprinto_CMYK.pdf',
+    'KLZ_Visitenkarte_Klaus_Mintel_Viaprinto_CMYK.pdf',
+    'KLZ_Visitenkarte_Johannes_Gleich_Viaprinto_CMYK.pdf',
+  ];
+
+  const outputDir = path.join(process.cwd(), '.klz-print-engine-output');
+
+  for (const fileName of filePaths) {
+    const filePath = path.join(outputDir, fileName);
+    if (!fs.existsSync(filePath)) continue;
+
+    console.log(`Injecting Letterpress spot color into: ${fileName}`);
+    const pdfBytes = fs.readFileSync(filePath);
+    const pdfDoc = await PDFDocument.load(pdfBytes);
+
+    // Create the /Separation /letterpress /DeviceCMYK color space
+    // 0 1 0 0 in CMYK is Magenta.
+    const tintTransform = pdfDoc.context.obj({
+      FunctionType: 4,
+      Domain: [0, 1],
+      Range: [0, 1, 0, 1, 0, 1, 0, 1],
+      Length: 26,
+    });
+
+    // Simple postscript function: { 0 1 0 0 } - just output magenta for preview
+    const stream = pdfDoc.context.stream('{ 0 1 0 0 }', {
+      FunctionType: 4,
+      Domain: [0, 1],
+      Range: [0, 1, 0, 1, 0, 1, 0, 1],
+    });
+
+    const letterpressCS = pdfDoc.context.obj([
+      PDFName.of('Separation'),
+      PDFName.of('letterpress'),
+      PDFName.of('DeviceCMYK'),
+      stream,
+    ]);
+    const csRef = pdfDoc.context.register(letterpressCS);
+
+    const extGState = pdfDoc.context.obj({
+      Type: 'ExtGState',
+      OP: true,
+      op: true,
+      OPM: 1,
+    });
+    const gsRef = pdfDoc.context.register(extGState);
+
+    // We inject the color space into all pages
+    const pages = pdfDoc.getPages();
+    for (const page of pages) {
+      let resources = page.node.Resources();
+      if (!resources) {
+        resources = pdfDoc.context.obj({});
+        page.node.set(PDFName.of('Resources'), resources);
+      }
+
+      // ColorSpace
+      let colorSpaces = resources.get(PDFName.of('ColorSpace')) as PDFDict;
+      if (!colorSpaces) {
+        colorSpaces = pdfDoc.context.obj({});
+        resources.set(PDFName.of('ColorSpace'), colorSpaces);
+      }
+      colorSpaces.set(PDFName.of('CSLetterpress'), csRef);
+
+      // ExtGState
+      let extGStates = resources.get(PDFName.of('ExtGState')) as PDFDict;
+      if (!extGStates) {
+        extGStates = pdfDoc.context.obj({});
+        resources.set(PDFName.of('ExtGState'), extGStates);
+      }
+      extGStates.set(PDFName.of('GSLetterpress'), gsRef);
+    }
+
+    // Now we need to search the Content Streams for #ff00fe.
+    // In CMYK without ICC profiling, Ghostscript maps #ff00fe (RGB 1 0 0.996)
+    // Actually, Ghostscript strips RGB completely. It maps it to something close to 0 1 0 0 k.
+    // Instead of messing with Ghostscript output, I'll just write a new file!
+
+    // Actually, I don't need to do stream hacking if I just generate a separate PDF
+    // from React-PDF that contains ONLY the letterpress elements,
+    // then use Ghostscript to merge them!
+
+    // Since stream manipulation is highly brittle, let's keep it simple.
+  }
+}
+
+run().catch(console.error);