fix(pdf): push pdf header and footer closer to page edge and force payload image extraction fallback

scripts/generate-pdf-datasheets-pdf-lib.ts

@@ -2569,7 +2569,9 @@ function resolveMediaToLocalPath(urlOrPath: string | null | undefined): string |
   if (!urlOrPath) return null;
 
   // 1) Already public-relative.
-  if (urlOrPath.startsWith('/')) return urlOrPath;
+  if (urlOrPath.startsWith('/')) {
+    return urlOrPath;
+  }
 
   // 2) Some datasets store "media/..." without leading slash.
   if (/^media\//i.test(urlOrPath)) return `/${urlOrPath}`;
@@ -3120,23 +3122,49 @@ async function loadEmbeddablePng(
   if (!resolved) return null;
 
   try {
-    // Prefer local files for stability and speed.
+    // 1) Try standard local path first
     if (resolved.startsWith('/')) {
       try {
         const bytes = await readBytesFromPublic(resolved);
         return { pngBytes: await toPngBytes(bytes, resolved), debugLabel: resolved };
       } catch {
-        // Fall back to HTTP fetch if file doesn't exist locally (e.g., Payload /api/ route)
+        // Fallback: It might be a Payload API image that we couldn't statically map earlier
+        // Check if we can intercept it manually.
+        if (resolved.startsWith('/api/media/file/')) {
+          try {
+            const uploadFallback = resolved.replace('/api/media/file/', '/uploads/');
+            const bytes = await readBytesFromPublic(uploadFallback);
+            return {
+              pngBytes: await toPngBytes(bytes, uploadFallback),
+              debugLabel: uploadFallback,
+            };
+          } catch {
+            // Check media
+            try {
+              const mediaFallback = resolved.replace('/api/media/file/', '/media/');
+              const bytes = await readBytesFromPublic(mediaFallback);
+              return {
+                pngBytes: await toPngBytes(bytes, mediaFallback),
+                debugLabel: mediaFallback,
+              };
+            } catch {
+              // Ignore inner errors and fall through to network fetch
+            }
+          }
+        }
       }
     }
 
-    // Remote (fallback)
-    const host = process.env.NEXT_PUBLIC_BASE_URL || 'http://localhost:3000';
+    // 2) Remote (network fetch fallback)
+    // IMPORTANT: Node 18+ fetch often resolves `localhost` to `::1` IPv6, which Payload might not be listening on.
+    // Force 127.0.0.1 to guarantee IPv4 resolution for local API fetches during build.
+    const host = process.env.NEXT_PUBLIC_BASE_URL || 'http://127.0.0.1:3000';
     // Ensure we don't end up with `http://localhost:3000http://...`
     const fetchUrl = resolved.startsWith('/') ? `${host.replace(/\/$/, '')}${resolved}` : resolved;
     const bytes = await fetchBytes(fetchUrl);
     return { pngBytes: await toPngBytes(bytes, fetchUrl), debugLabel: fetchUrl };
-  } catch {
+  } catch (err: any) {
+    console.warn(`[PDF Image Warn] Failed to load image: ${src} -> ${resolved}`, err?.message);
     return null;
   }
 }
@@ -3264,7 +3292,8 @@ function drawHeader(ctx: SectionDrawContext, yStart: number): number {
   // Cable-industry look: calm, engineered header with right-aligned meta.
   // Keep header compact to free vertical space for technical tables.
   const headerH = 52;
-  const dividerY = yStart - headerH;
+  const headerTopPadding = 24;
+  const dividerY = ctx.height - headerTopPadding - headerH;
   ctx.headerDividerY = dividerY;
 
   page.drawRectangle({
@@ -3989,10 +4018,15 @@ async function generatePDF(product: ProductData, locale: 'en' | 'de'): Promise<B
     const qrPng = await loadQrPng(productUrl);
     const qrImage = qrPng ? await pdfDoc.embedPng(qrPng.pngBytes) : null;
 
-    // Engineered page frame (A4): slightly narrower margins but consistent rhythm.
-    const margin = 54;
-    const footerY = 54;
-    const contentMinY = footerY + 42; // keep clear of footer + page numbers
+    // Engineered page frame (A4): Push margins slightly closer to the edge.
+    const margin = 48; // Left/right margin
+    const footerY = 28; // Absolute distance from the bottom for the footer line
+    const headerH = 52; // Header background height
+    const headerTopPadding = 24; // Absolute distance from top for the header box
+
+    // Y-coordinate starts from the BOTTOM in pdf-lib. Height is 841.89
+    // `contentMinY` is the lowest point standard body content can reach before overflowing into the footer.
+    const contentMinY = footerY + 36;
     const contentWidth = width - 2 * margin;
 
     const ctx: SectionDrawContext = {
@@ -4038,9 +4072,11 @@ async function generatePDF(product: ProductData, locale: 'en' | 'de'): Promise<B
       const name = stripHtml(product.name);
       const maxW = ctx.contentWidth;
       const line = wrapText(name, fontBold, 12, maxW).slice(0, 1)[0] || name;
+      // Render name a bit lower inside the header space
+      const headerTopPadding = 24;
       p.drawText(line, {
         x: margin,
-        y: yStart,
+        y: height - headerTopPadding - 32,
         size: 12,
         font: fontBold,
         color: navy,
@@ -4056,9 +4092,10 @@ async function generatePDF(product: ProductData, locale: 'en' | 'de'): Promise<B
       syncCtxForPage(page);
       drawPageBackground(page);
       drawFooter(ctx);
-      let yStart = drawHeader(ctx, ctx.height - ctx.margin);
-      if (opts?.includeProductName) yStart = drawProductNameOnPage(page, yStart);
-      return yStart;
+      y = drawHeader(ctx, height); // pass height, we override dividerY internally inside drawHeader
+      // stampProductName(); // Assuming this function is defined elsewhere or will be added.
+      if (opts?.includeProductName) y = drawProductNameOnPage(page, y); // Update y after drawing product name
+      return ctx.headerDividerY - 24; // spacing below header line
     };
 
     const hasSpace = (needed: number) => y - needed >= contentMinY;