feat: Wire Supply Chain BOM and 3D Print Farm modules to Postgres and REST API

main.ts

@@ -2,6 +2,8 @@ import { Hono } from "hono";
 import { serveStatic } from "hono/deno";
 import { sql, initDb } from "./src/db/connection.ts";
 import { qaRoutes } from "./src/routes/qa.ts";
+import { bomRoutes } from "./src/routes/bom.ts";
+import { printFarmRoutes } from "./src/routes/printfarm.ts";
 
 const app = new Hono();
 
@@ -25,6 +27,8 @@ app.get("/api/status", async (c) => {
 
 // Mount modular sub-routes
 app.route("/api/qa", qaRoutes);
+app.route("/api/bom", bomRoutes);
+app.route("/api/print-farm", printFarmRoutes);
 
 // Serve the 3D Viewer frontend
 app.use("/*", serveStatic({ root: "./" }));

src/db/bom.ts

@@ -0,0 +1,50 @@
+import { sql } from "./connection.ts";
+
+export interface BomItem {
+  id: string;
+  component_name: string;
+  mpn: string;
+  vendor: string;
+  unit_price: number;
+  quantity: number;
+  lead_time_days: number;
+  status: "in_stock" | "ordered" | "backordered";
+  category: "compute" | "storage" | "power" | "mechanical" | "cables" | "fasteners";
+  notes?: string;
+  updated_at?: string;
+}
+
+export const getBomItems = async (category?: string): Promise<BomItem[]> => {
+  if (category) {
+    return await sql<BomItem[]>`
+      SELECT * FROM bom_items WHERE category = ${category} ORDER BY category, component_name ASC
+    `;
+  }
+  return await sql<BomItem[]>`
+    SELECT * FROM bom_items ORDER BY category, component_name ASC
+  `;
+};
+
+export const getBomSummary = async () => {
+  const result = await sql`
+    SELECT 
+      COUNT(*) as total_parts,
+      SUM(quantity) as total_units,
+      SUM(unit_price * quantity) as total_cost,
+      MAX(lead_time_days) as max_lead_time,
+      COUNT(CASE WHEN status = 'in_stock' THEN 1 END) as in_stock_count,
+      COUNT(CASE WHEN status = 'ordered' THEN 1 END) as ordered_count,
+      COUNT(CASE WHEN status = 'backordered' THEN 1 END) as backordered_count
+    FROM bom_items
+  `;
+  return result[0];
+};
+
+export const updateBomItemStatus = async (id: string, status: string): Promise<BomItem[]> => {
+  return await sql<BomItem[]>`
+    UPDATE bom_items 
+    SET status = ${status}, updated_at = CURRENT_TIMESTAMP
+    WHERE id = ${id}
+    RETURNING *
+  `;
+};

src/db/connection.ts

@@ -14,6 +14,7 @@ export const sql = postgres({
 export async function initDb(retries = 5, delayMs = 2000) {
   for (let i = 0; i < retries; i++) {
     try {
+      // 1. QA Checklists
       await sql`
         CREATE TABLE IF NOT EXISTS qa_checklists (
           id VARCHAR(50) PRIMARY KEY,
@@ -23,17 +24,87 @@ export async function initDb(retries = 5, delayMs = 2000) {
         );
       `;
       
-      const count = await sql`SELECT count(*) FROM qa_checklists`;
+      const qaCount = await sql`SELECT count(*) FROM qa_checklists`;
-      if (count[0].count === "0") {
+      if (qaCount[0].count === "0") {
         await sql`
           INSERT INTO qa_checklists (id, label, is_completed) VALUES
-          ('qa-cap', 'Supercap mounted & isolated', false),
+          ('qa-inserts', 'Thermal insertion of 56x M3/M4 brass threaded inserts into 3D facade & fan wall', false),
-          ('qa-sas', 'Broadcom SAS seated in PCIe', false),
+          ('qa-frame', '2020 Aluminum frame assembly and squaring (Torque M5 bolts to 4.5 N·m)', false),
-          ('qa-cool', 'Waterblock pressure tested', false),
+          ('qa-fans', '3x 120mm PWM fan wall installation with EPDM pneumatic perimeter gasket', false),
-          ('qa-zfs', 'ZFS pool scrub baseline passed', false)
+          ('qa-pcba', 'Baseboard PCBA mounting and MCIO 8i twinaxial cable routing', false),
+          ('qa-skins', 'SendCutSend 5052 aluminum skins fastening & 6U rack ear installation', false),
+          ('qa-supercap', 'Supercapacitor PLP holdup validation (LTC3350 PFI) & Rust firmware flashing', false)
         `;
       }
-      console.log("✅ Database schema initialized successfully");
+
+      // 2. Bill of Materials (BOM) & Supply Chain
+      await sql`
+        CREATE TABLE IF NOT EXISTS bom_items (
+          id VARCHAR(50) PRIMARY KEY,
+          component_name TEXT NOT NULL,
+          mpn VARCHAR(100) NOT NULL,
+          vendor VARCHAR(100) NOT NULL,
+          unit_price NUMERIC(10,2) NOT NULL,
+          quantity INTEGER NOT NULL DEFAULT 1,
+          lead_time_days INTEGER NOT NULL DEFAULT 0,
+          status VARCHAR(20) NOT NULL DEFAULT 'in_stock',
+          category VARCHAR(50) NOT NULL,
+          notes TEXT,
+          updated_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP
+        );
+      `;
+
+      const bomCount = await sql`SELECT count(*) FROM bom_items`;
+      if (bomCount[0].count === "0") {
+        await sql`
+          INSERT INTO bom_items (id, component_name, mpn, vendor, unit_price, quantity, lead_time_days, status, category, notes) VALUES
+          ('bom-cm3i', 'Radxa CM3I SoM (4G/16G)', 'CM3I-4G16G', 'Ameridroid', 38.00, 1, 3, 'in_stock', 'compute', 'Rockchip RK3568 quad-core host'),
+          ('bom-sas3408', 'Broadcom SAS3408 Tri-Mode IOC', 'SAS3408-BGA484', 'Avnet / Arrow', 32.00, 1, 14, 'ordered', 'storage', 'PCIe 3.1 x8 to 8-PHY SAS/SATA/NVMe'),
+          ('bom-rp2040', 'RP2040 Dual MCU', 'RP2040-QFN56', 'DigiKey', 0.95, 1, 2, 'in_stock', 'compute', 'OpenBMC & hardware supervisor'),
+          ('bom-ltc3350', 'LTC3350 Supercap Manager IC', 'LTC3350EUHF#PBF', 'Mouser', 7.45, 1, 5, 'in_stock', 'power', 'Supercap PLP buck-boost balancer'),
+          ('bom-supercaps', 'Eaton 10.0F 2.7V Supercapacitors', 'B0510-2R7105-R', 'Mouser', 4.40, 4, 2, 'in_stock', 'power', '4-cell series stack (10.8V holdup)'),
+          ('bom-efuse', 'TPS25982 15A Smart eFuse', 'TPS259827ONRGER', 'DigiKey', 1.85, 2, 2, 'in_stock', 'power', 'Hot-swap inrush limiter & fault clamp'),
+          ('bom-diode', 'LM74700 Ideal Diode Controller', 'LM74700QDBVRQ1', 'Mouser', 0.95, 2, 2, 'in_stock', 'power', 'Reverse polarity & low-loss ORing'),
+          ('bom-mcio', 'Amphenol MCIO 8i Connectors (74-Pin)', 'G88MP08102CEEU', 'DigiKey', 7.60, 2, 4, 'in_stock', 'cables', 'PCIe Gen4 / SAS4 high-density interconnect'),
+          ('bom-u3', 'Amphenol U.3 SFF-TA-1001 Sockets', '10148784-101LF', 'Mouser', 11.20, 8, 7, 'in_stock', 'storage', 'Tri-mode SAS/SATA/NVMe drive bays'),
+          ('bom-pcb-base', 'Carrier Baseboard 6-Layer PCBA', 'PCB-BASE-01', 'MacroFab', 16.50, 1, 12, 'ordered', 'mechanical', 'Controlled impedance ENIG finish'),
+          ('bom-pcb-bp', 'Passive U.3 Drive Backplane PCBA', 'PCB-BP-01', 'MacroFab', 12.50, 1, 12, 'ordered', 'mechanical', '2oz copper power distribution plane'),
+          ('bom-2020', '2020 T-Slot Aluminum Extrusions', '20-2020-KIT', '80/20 Inc.', 14.00, 1, 3, 'in_stock', 'mechanical', 'Anodized 6063-T6 framing'),
+          ('bom-skins', 'SendCutSend 5052 Aluminum Outer Panels', 'SMP-ALL-01', 'SendCutSend', 26.80, 1, 4, 'in_stock', 'mechanical', 'Laser cut 2.0mm 5052-H32 with countersinks'),
+          ('bom-fasteners', 'Black Oxide M3/M4 Fastener & Insert Kit', 'FAST-KIT-01', 'McMaster-Carr', 16.00, 1, 1, 'in_stock', 'fasteners', 'Class 12.9 alloy steel hardware')
+        `;
+      }
+
+      // 3. 3D Print Farm Jobs
+      await sql`
+        CREATE TABLE IF NOT EXISTS print_farm_jobs (
+          id VARCHAR(50) PRIMARY KEY,
+          part_name TEXT NOT NULL,
+          printer_model VARCHAR(50) NOT NULL,
+          material VARCHAR(30) NOT NULL,
+          print_time_hours NUMERIC(4,1) NOT NULL,
+          weight_grams INTEGER NOT NULL,
+          cost_estimate NUMERIC(6,2) NOT NULL,
+          status VARCHAR(20) NOT NULL DEFAULT 'queued',
+          bed_fit VARCHAR(30) NOT NULL,
+          notes TEXT,
+          updated_at TIMESTAMP DEFAULT CURRENT_TIMESTAMP
+        );
+      `;
+
+      const pfCount = await sql`SELECT count(*) FROM print_farm_jobs`;
+      if (pfCount[0].count === "0") {
+        await sql`
+          INSERT INTO print_farm_jobs (id, part_name, printer_model, material, print_time_hours, weight_grams, cost_estimate, status, bed_fit, notes) VALUES
+          ('pf-facade', '6U Hexagonal Intake Airflow Facade', 'Prusa Core One (L)', 'Prusament PETG V0', 14.5, 412, 14.20, 'completed', 'Fit (298x298mm)', 'Flame retardant UL94-V0 compliance'),
+          ('pf-fanwall', '3x 120mm Isolated PWM Fan Duct Wall', 'Bambu Lab X1-Carbon', 'Polymaker PA6-CF', 8.2, 245, 18.50, 'printing', 'Fit (250x250mm)', 'Carbon fiber stiffness to eliminate harmonic resonance'),
+          ('pf-caddy-1-4', 'U.3 Toolless Drive Caddies (Bays 1-4)', 'Voron 2.4 350', 'eSUN ABS+', 6.8, 180, 5.40, 'queued', 'Batch Fit (350x350mm)', 'Spring-loaded latch with light pipe inserts'),
+          ('pf-caddy-5-8', 'U.3 Toolless Drive Caddies (Bays 5-8)', 'Voron 2.4 350', 'eSUN ABS+', 6.8, 180, 5.40, 'queued', 'Batch Fit (350x350mm)', 'Spring-loaded latch with light pipe inserts'),
+          ('pf-shroud', 'Radxa CM3I & SAS3408 Passive Air Shroud', 'Bambu Lab X1-Carbon', 'Prusament PC-Blend', 4.1, 115, 8.90, 'queued', 'Fit (140x110mm)', '115°C HDT rating for high thermal exhaust ducting')
+        `;
+      }
+
+      console.log("✅ All database schemas and seed data initialized successfully");
       return;
     } catch (err: any) {
       console.warn(`⚠️ Database init attempt ${i + 1}/${retries} failed: ${err.message}`);

src/db/printfarm.ts

@@ -0,0 +1,37 @@
+import { sql } from "./connection.ts";
+
+export interface PrintJob {
+  id: string;
+  part_name: string;
+  printer_model: string;
+  material: string;
+  print_time_hours: number;
+  weight_grams: number;
+  cost_estimate: number;
+  status: "completed" | "printing" | "queued";
+  bed_fit: string;
+  notes?: string;
+  updated_at?: string;
+}
+
+export const getPrintJobs = async (): Promise<PrintJob[]> => {
+  return await sql<PrintJob[]>`
+    SELECT * FROM print_farm_jobs ORDER BY 
+      CASE status
+        WHEN 'printing' THEN 1
+        WHEN 'queued' THEN 2
+        WHEN 'completed' THEN 3
+        ELSE 4
+      END,
+      id ASC
+  `;
+};
+
+export const updatePrintJobStatus = async (id: string, status: string): Promise<PrintJob[]> => {
+  return await sql<PrintJob[]>`
+    UPDATE print_farm_jobs
+    SET status = ${status}, updated_at = CURRENT_TIMESTAMP
+    WHERE id = ${id}
+    RETURNING *
+  `;
+};

src/routes/bom.ts

@@ -0,0 +1,38 @@
+import { Hono } from "hono";
+import { getBomItems, getBomSummary, updateBomItemStatus } from "../db/bom.ts";
+
+export const bomRoutes = new Hono();
+
+bomRoutes.get("/", async (c) => {
+  try {
+    const category = c.req.query("category");
+    const items = await getBomItems(category);
+    return c.json(items);
+  } catch (error: any) {
+    return c.json({ error: error.message }, 500);
+  }
+});
+
+bomRoutes.get("/summary", async (c) => {
+  try {
+    const summary = await getBomSummary();
+    return c.json(summary);
+  } catch (error: any) {
+    return c.json({ error: error.message }, 500);
+  }
+});
+
+bomRoutes.put("/:id/status", async (c) => {
+  const id = c.req.param("id");
+  try {
+    const body = await c.req.json();
+    if (!body.status) {
+      return c.json({ error: "Missing status field" }, 400);
+    }
+    const updated = await updateBomItemStatus(id, body.status);
+    if (updated.length === 0) return c.json({ error: "BOM item not found" }, 404);
+    return c.json(updated[0]);
+  } catch (error: any) {
+    return c.json({ error: error.message }, 500);
+  }
+});

src/routes/printfarm.ts

@@ -0,0 +1,28 @@
+import { Hono } from "hono";
+import { getPrintJobs, updatePrintJobStatus } from "../db/printfarm.ts";
+
+export const printFarmRoutes = new Hono();
+
+printFarmRoutes.get("/", async (c) => {
+  try {
+    const jobs = await getPrintJobs();
+    return c.json(jobs);
+  } catch (error: any) {
+    return c.json({ error: error.message }, 500);
+  }
+});
+
+printFarmRoutes.put("/:id/status", async (c) => {
+  const id = c.req.param("id");
+  try {
+    const body = await c.req.json();
+    if (!body.status) {
+      return c.json({ error: "Missing status field" }, 400);
+    }
+    const updated = await updatePrintJobStatus(id, body.status);
+    if (updated.length === 0) return c.json({ error: "Job not found" }, 404);
+    return c.json(updated[0]);
+  } catch (error: any) {
+    return c.json({ error: error.message }, 500);
+  }
+});

viewer/bom.js

@@ -0,0 +1,87 @@
+// BOM & Supply Chain API Client
+let liveBomData = [];
+
+async function loadBomData() {
+    try {
+        const res = await fetch('/api/bom');
+        if (!res.ok) throw new Error("Failed to load BOM data");
+        liveBomData = await res.json();
+        
+        renderBomTable();
+        updateBOMCalculations();
+    } catch (err) {
+        console.error("BOM Loading Error:", err);
+    }
+}
+
+function renderBomTable() {
+    const tbody = document.getElementById('bom-table-body');
+    if (!tbody) return;
+    tbody.innerHTML = '';
+
+    liveBomData.forEach(item => {
+        const tr = document.createElement('tr');
+        
+        let statusBadge = '<span style="color:var(--accent-emerald); font-weight:600;"><i class="fa-solid fa-check"></i> In Stock</span>';
+        if (item.status === 'ordered') {
+            statusBadge = `<span style="color:var(--accent-amber); font-weight:600;"><i class="fa-solid fa-clock"></i> Ordered (${item.lead_time_days}d)</span>`;
+        } else if (item.status === 'backordered') {
+            statusBadge = `<span style="color:var(--accent-rose); font-weight:600;"><i class="fa-solid fa-triangle-exclamation"></i> Backorder (${item.lead_time_days}d)</span>`;
+        }
+
+        tr.innerHTML = `
+            <td>
+                <strong>${item.component_name}</strong>
+                <div style="font-size:0.65rem; color:var(--text-muted);">${item.notes || ''}</div>
+            </td>
+            <td>
+                ${item.vendor}
+                <div>${statusBadge}</div>
+            </td>
+            <td><code style="color:var(--accent-cyan);">${item.mpn}</code></td>
+            <td style="font-weight:700; color:var(--accent-emerald);">$${parseFloat(item.unit_price).toFixed(2)}</td>
+        `;
+        tbody.appendChild(tr);
+    });
+}
+
+function updateBOMCalculations() {
+    const batchSlider = document.getElementById('batch-slider');
+    const batchQty = batchSlider ? parseInt(batchSlider.value) : 100;
+    const batchLabel = document.getElementById('batch-qty-label');
+    if (batchLabel) batchLabel.innerText = `${batchQty} Units`;
+
+    let discountFactor = 1.0;
+    if (batchQty >= 1000) discountFactor = 0.85;
+    else if (batchQty >= 100) discountFactor = 0.92;
+    else if (batchQty >= 10) discountFactor = 0.96;
+
+    const baseTotal = liveBomData.length > 0
+        ? liveBomData.reduce((acc, i) => acc + (parseFloat(i.unit_price) * (i.quantity || 1)), 0)
+        : 241.20;
+
+    const unitCost = baseTotal * discountFactor;
+    const totalBatch = unitCost * batchQty;
+
+    const unitEl = document.getElementById('rollup-unit-cost');
+    const batchEl = document.getElementById('rollup-total-cost');
+    if (unitEl) unitEl.innerText = `$${unitCost.toFixed(2)}`;
+    if (batchEl) batchEl.innerText = `$${totalBatch.toLocaleString('en-US', {minimumFractionDigits:2, maximumFractionDigits:2})}`;
+}
+
+function exportBOMCSV() {
+    let csv = "Component,MPN,Supplier,Quantity,UnitPriceUSD,Status,Notes\n";
+    liveBomData.forEach(i => {
+        csv += `"${i.component_name}","${i.mpn}","${i.vendor}",${i.quantity || 1},${parseFloat(i.unit_price).toFixed(2)},"${i.status}","${i.notes || ''}"\n`;
+    });
+    const blob = new Blob([csv], { type: 'text/csv' });
+    const url = window.URL.createObjectURL(blob);
+    const a = document.createElement('a');
+    a.setAttribute('href', url);
+    a.setAttribute('download', '6U_Storage_Array_Master_PO.csv');
+    a.click();
+}
+
+window.loadBomData = loadBomData;
+window.updateBOMCalculations = updateBOMCalculations;
+window.exportBOMCSV = exportBOMCSV;

viewer/index.html

@@ -923,6 +923,8 @@
 
     <!-- Master Interactive JavaScript Application -->
     <script src="./qa.js"></script>
+    <script src="./bom.js"></script>
+    <script src="./printfarm.js"></script>
     <script>
         let scene, camera, renderer, controls;
         let groupSkeleton, groupSheets, groupFacade, groupDrives, groupFans, groupPcba, groupIsolatedPart;
@@ -2223,6 +2225,8 @@
         
         window.onload = function() {
             loadQaChecklist();
+            loadBomData();
+            loadPrintFarmData();
             init3D();
             updatePrintFarmStats();
             updateMaterialPhysics();

viewer/printfarm.js

@@ -0,0 +1,61 @@
+// 3D Print Farm API Client
+let livePrintJobs = [];
+
+async function loadPrintFarmData() {
+    try {
+        const res = await fetch('/api/print-farm');
+        if (!res.ok) throw new Error("Failed to load Print Farm data");
+        livePrintJobs = await res.json();
+        
+        renderPrintFarmQueue();
+        updatePrintFarmStats();
+    } catch (err) {
+        console.error("Print Farm Loading Error:", err);
+    }
+}
+
+function renderPrintFarmQueue() {
+    let container = document.getElementById('pf-jobs-container');
+    if (!container) {
+        const card = document.querySelector('#print-farm .card');
+        if (card) {
+            const queueCard = document.createElement('div');
+            queueCard.className = 'card';
+            queueCard.innerHTML = `
+                <div class="card-header"><i class="fa-solid fa-list-check"></i> Active Print Farm Job Queue</div>
+                <div id="pf-jobs-container" style="display:flex; flex-direction:column; gap:0.5rem;"></div>
+            `;
+            card.parentNode.insertBefore(queueCard, card.nextSibling);
+            container = document.getElementById('pf-jobs-container');
+        }
+    }
+    
+    if (!container) return;
+    container.innerHTML = '';
+
+    livePrintJobs.forEach(job => {
+        const div = document.createElement('div');
+        div.style.cssText = 'background:#0b0f17; padding:0.6rem 0.8rem; border-radius:6px; font-size:0.75rem; display:flex; justify-content:space-between; align-items:center;';
+        
+        let statusBadge = '<span style="color:var(--accent-emerald); font-weight:700;"><i class="fa-solid fa-check"></i> Complete</span>';
+        if (job.status === 'printing') {
+            statusBadge = '<span style="color:var(--accent-cyan); font-weight:700;"><i class="fa-solid fa-spinner fa-spin"></i> Printing</span>';
+        } else if (job.status === 'queued') {
+            statusBadge = '<span style="color:var(--text-muted); font-weight:600;"><i class="fa-solid fa-hourglass"></i> Queued</span>';
+        }
+
+        div.innerHTML = `
+            <div>
+                <strong>${job.part_name}</strong>
+                <div style="font-size:0.65rem; color:var(--text-muted);">${job.printer_model} • ${job.material} • ${job.weight_grams}g</div>
+            </div>
+            <div style="text-align:right;">
+                ${statusBadge}
+                <div style="font-size:0.65rem; color:var(--accent-amber); font-weight:600;">${job.print_time_hours}h ($${parseFloat(job.cost_estimate).toFixed(2)})</div>
+            </div>
+        `;
+        container.appendChild(div);
+    });
+}
+
+window.loadPrintFarmData = loadPrintFarmData;