feat: Manufacturing-grade door geometry + photorealistic materials
🏗️ Architecture (@Logic-Architect): - Created lib/door-models.ts with exact manufacturing specs - PROFILE_WIDTH = 40mm, PROFILE_DEPTH = 40mm (real steel tubes) - GLASS_OFFSET = 18mm for proper centering - Physical parts system (stiles, rails, dividers, glass) - generateDoorAssembly() returns manufacturable parts list - Validation for structural integrity limits 🎨 Visuals (@3D-Visual-Lead): - Aluwdoors texture loading with vertical steel grain - MeshStandardMaterial: roughness 0.6, metalness 0.7 - Photorealistic glass: transmission 0.98, IOR 1.5 - RoundedBox with 2mm radius for all profiles - Suspense boundaries for progressive texture loading - Studio environment preset + enhanced contact shadows 🔧 Technical: - UseMemo for door assembly generation - mmToMeters() conversion utility - PhysicalPartComponent renderer - Backward compatibility with glass patterns - Fallback materials when textures fail Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
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lib/door-models.ts
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317
lib/door-models.ts
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/**
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* Door Manufacturing Specifications
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* Based on "Metalworks" market analysis
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* All dimensions in millimeters (mm)
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*/
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// ============================================
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// MANUFACTURING CONSTANTS
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// ============================================
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/**
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* Steel Profile Dimensions (40x40mm Square Tube)
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* Standard industrial steel door profile
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*/
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export const PROFILE_WIDTH = 40; // mm - Face width
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export const PROFILE_DEPTH = 40; // mm - Tube depth
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export const PROFILE_CORNER_RADIUS = 2; // mm - Rounded corners for welding
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/**
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* Glass Specifications
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*/
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export const GLASS_THICKNESS = 10; // mm - Standard tempered glass
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export const GLASS_OFFSET = 18; // mm - Center glass in 40mm profile (40-10)/2 - 2mm clearance
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/**
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* Rail Height Variations
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*/
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export const RAIL_HEIGHT_SLIM = 20; // mm - Slim horizontal rails
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export const RAIL_HEIGHT_ROBUST = 40; // mm - Standard robust rails (same as profile)
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// ============================================
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// PHYSICAL PART TYPES
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// ============================================
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export type PartType = 'stile' | 'rail' | 'glass' | 'divider';
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export type DoorModel = 'taats' | 'scharnier' | 'paneel';
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export type GridLayout = '3-vlak' | '4-vlak' | 'geen';
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/**
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* Physical Door Component
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* Represents an actual steel part that will be manufactured
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*/
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export interface PhysicalPart {
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type: PartType;
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// Position in 3D space (in mm, relative to door center)
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x: number;
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y: number;
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z: number;
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// Dimensions in mm
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width: number;
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height: number;
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depth: number;
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// Metadata
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label?: string;
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isGlass?: boolean;
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}
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/**
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* Complete Door Assembly
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*/
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export interface DoorAssembly {
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modelId: DoorModel;
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gridLayout: GridLayout;
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doorWidth: number; // mm - Actual door leaf width
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doorHeight: number; // mm - Door height
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parts: PhysicalPart[];
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}
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// ============================================
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// LAYOUT GENERATION
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// ============================================
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/**
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* Generate physical parts list for door manufacturing
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*
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* @param modelId - Door model (taats, scharnier, paneel)
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* @param gridLayout - Grid division (3-vlak, 4-vlak, geen)
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* @param doorWidth - Door leaf width in mm
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* @param doorHeight - Door height in mm
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* @returns Complete assembly with all physical parts
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*/
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export function generateDoorAssembly(
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modelId: DoorModel,
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gridLayout: GridLayout,
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doorWidth: number,
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doorHeight: number
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): DoorAssembly {
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const parts: PhysicalPart[] = [];
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// ============================================
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// PERIMETER FRAME (All door types)
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// ============================================
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// LEFT STILE (Vertical)
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parts.push({
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type: 'stile',
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x: -doorWidth / 2 + PROFILE_WIDTH / 2,
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y: 0,
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z: 0,
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width: PROFILE_WIDTH,
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height: doorHeight,
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depth: PROFILE_DEPTH,
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label: 'Left Stile',
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});
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// RIGHT STILE (Vertical)
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parts.push({
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type: 'stile',
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x: doorWidth / 2 - PROFILE_WIDTH / 2,
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y: 0,
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z: 0,
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width: PROFILE_WIDTH,
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height: doorHeight,
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depth: PROFILE_DEPTH,
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label: 'Right Stile',
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});
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// TOP RAIL (Horizontal)
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const topRailWidth = doorWidth - PROFILE_WIDTH * 2;
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parts.push({
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type: 'rail',
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x: 0,
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y: doorHeight / 2 - RAIL_HEIGHT_ROBUST / 2,
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z: 0,
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width: topRailWidth,
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height: RAIL_HEIGHT_ROBUST,
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depth: PROFILE_DEPTH,
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label: 'Top Rail',
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});
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// BOTTOM RAIL (Horizontal)
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parts.push({
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type: 'rail',
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x: 0,
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y: -doorHeight / 2 + RAIL_HEIGHT_ROBUST / 2,
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z: 0,
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width: topRailWidth,
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height: RAIL_HEIGHT_ROBUST,
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depth: PROFILE_DEPTH,
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label: 'Bottom Rail',
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});
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// ============================================
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// GRID DIVIDERS (Based on layout)
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// ============================================
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if (gridLayout === '3-vlak') {
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// Two horizontal dividers at 1/3 and 2/3 height
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const divider1Y = doorHeight / 2 - doorHeight / 3;
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const divider2Y = doorHeight / 2 - (2 * doorHeight) / 3;
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parts.push({
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type: 'divider',
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x: 0,
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y: divider1Y,
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z: 0,
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width: topRailWidth,
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height: RAIL_HEIGHT_SLIM,
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depth: PROFILE_DEPTH,
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label: 'Divider 1/3',
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});
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parts.push({
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type: 'divider',
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x: 0,
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y: divider2Y,
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z: 0,
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width: topRailWidth,
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height: RAIL_HEIGHT_SLIM,
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depth: PROFILE_DEPTH,
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label: 'Divider 2/3',
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});
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} else if (gridLayout === '4-vlak') {
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// Three horizontal dividers at 1/4, 1/2, 3/4 height
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const divider1Y = doorHeight / 2 - doorHeight / 4;
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const divider2Y = 0;
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const divider3Y = doorHeight / 2 - (3 * doorHeight) / 4;
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parts.push({
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type: 'divider',
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x: 0,
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y: divider1Y,
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z: 0,
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width: topRailWidth,
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height: RAIL_HEIGHT_SLIM,
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depth: PROFILE_DEPTH,
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label: 'Divider 1/4',
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});
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parts.push({
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type: 'divider',
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x: 0,
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y: divider2Y,
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z: 0,
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width: topRailWidth,
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height: RAIL_HEIGHT_SLIM,
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depth: PROFILE_DEPTH,
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label: 'Divider 1/2',
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});
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parts.push({
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type: 'divider',
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x: 0,
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y: divider3Y,
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z: 0,
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width: topRailWidth,
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height: RAIL_HEIGHT_SLIM,
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depth: PROFILE_DEPTH,
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label: 'Divider 3/4',
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});
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}
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// ============================================
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// VERTICAL CENTER DIVIDER (Paneel type only)
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// ============================================
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if (modelId === 'paneel') {
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const verticalDividerHeight = doorHeight - RAIL_HEIGHT_ROBUST * 2;
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parts.push({
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type: 'divider',
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x: 0,
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y: 0,
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z: 0,
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width: PROFILE_WIDTH,
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height: verticalDividerHeight,
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depth: PROFILE_DEPTH,
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label: 'Center Vertical Divider',
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});
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}
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// ============================================
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// GLASS PANELS
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// ============================================
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// Calculate glass dimensions (inside frame with offset)
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const glassWidth = doorWidth - PROFILE_WIDTH * 2 - GLASS_OFFSET * 2;
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const glassHeight = doorHeight - RAIL_HEIGHT_ROBUST * 2 - GLASS_OFFSET * 2;
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parts.push({
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type: 'glass',
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x: 0,
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y: 0,
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z: 0,
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width: glassWidth,
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height: glassHeight,
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depth: GLASS_THICKNESS,
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label: 'Main Glass Panel',
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isGlass: true,
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});
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return {
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modelId,
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gridLayout,
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doorWidth,
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doorHeight,
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parts,
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};
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}
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/**
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* Convert mm to meters for Three.js 3D scene
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*/
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export function mmToMeters(mm: number): number {
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return mm / 1000;
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}
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/**
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* Get divider positions in meters (for backward compatibility)
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*/
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export function getDividerPositions(
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gridLayout: GridLayout,
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doorHeight: number
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): number[] {
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const doorHeightMeters = mmToMeters(doorHeight);
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if (gridLayout === '3-vlak') {
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return [-doorHeightMeters / 3, doorHeightMeters / 3];
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} else if (gridLayout === '4-vlak') {
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return [-doorHeightMeters / 2, 0, doorHeightMeters / 2];
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}
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return [];
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}
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/**
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* Validation: Check if door dimensions are manufacturable
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*/
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export function validateDoorDimensions(
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doorWidth: number,
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doorHeight: number
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): { valid: boolean; errors: string[] } {
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const errors: string[] = [];
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// Minimum dimensions check
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if (doorWidth < PROFILE_WIDTH * 3) {
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errors.push(`Door width too small (min: ${PROFILE_WIDTH * 3}mm)`);
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}
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if (doorHeight < RAIL_HEIGHT_ROBUST * 3) {
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errors.push(`Door height too small (min: ${RAIL_HEIGHT_ROBUST * 3}mm)`);
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}
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// Maximum dimensions check (based on steel profile strength)
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if (doorWidth > 1200) {
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errors.push('Door width exceeds maximum (1200mm) - structural integrity');
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}
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if (doorHeight > 3000) {
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errors.push('Door height exceeds maximum (3000mm) - structural integrity');
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}
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return {
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valid: errors.length === 0,
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errors,
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};
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}
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