Phase 8: High-Resolution Export

- Server-side export endpoint using node-canvas
- 300x300px preview -> 4500x4500px export (15"x15" @ 300 DPI)
- Exports images and text elements with proper scaling
- useExport hook with progress indicator
- Export button in canvas header
- Automatic download of exported PNG
- Error handling with dismissible error banner

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

client/src/App.jsx

@@ -3,6 +3,7 @@ import { DesignCanvas } from './components/canvas/DesignCanvas';
 import { Sidebar } from './components/sidebar/Sidebar';
 import { PropertiesPanel } from './components/properties/PropertiesPanel';
 import { useDesignEditor } from './hooks/useDesignEditor';
+import { useExport } from './hooks/useExport';
 
 function App() {
   const {
@@ -20,6 +21,8 @@ function App() {
     initializeHistory,
   } = useDesignEditor();
 
+  const { exporting, progress, exportDesign, error, clearExport } = useExport();
+
   const selectedElement = elements.find((el) => el.id === selectedId);
 
   // Initialize history on mount
@@ -116,6 +119,7 @@ function App() {
             <h1 className="app-title">Apparel Designer</h1>
             <p className="app-subtitle">T-shirt customization editor</p>
           </div>
+          <div className="canvas-actions">
             <div className="undo-redo-buttons">
               <button
                 className={`icon-btn ${!canUndo ? 'disabled' : ''}`}
@@ -134,7 +138,28 @@ function App() {
                 ↷ Redo
               </button>
             </div>
+            <button
+              className="export-btn"
+              onClick={() => exportDesign(elements, 'tshirt-design')}
+              disabled={exporting || elements.length === 0}
+            >
+              {exporting ? (
+                <>
+                  <span className="spinner-small" />
+                  Exporting... {progress}%
+                </>
+              ) : (
+                <>⬇ Export HD</>
+              )}
+            </button>
           </div>
+        </div>
+        {error && (
+          <div className="export-error">
+            <p>⚠️ Export failed: {error}</p>
+            <button onClick={clearExport} className="close-error">✕</button>
+          </div>
+        )}
         <div className="canvas-wrapper">
           <DesignCanvas
             elements={elements}

client/src/hooks/useExport.js

@@ -0,0 +1,69 @@
+import { useState, useCallback } from 'react';
+
+export function useExport() {
+  const [exporting, setExporting] = useState(false);
+  const [progress, setProgress] = useState(0);
+  const [exportUrl, setExportUrl] = useState(null);
+  const [error, setError] = useState(null);
+
+  const exportDesign = useCallback(async (elements, designName = 'design') => {
+    setExporting(true);
+    setProgress(0);
+    setError(null);
+    setExportUrl(null);
+
+    try {
+      // Simulate progress during export
+      const progressInterval = setInterval(() => {
+        setProgress((prev) => Math.min(prev + 10, 90));
+      }, 200);
+
+      const response = await fetch('/api/export', {
+        method: 'POST',
+        headers: {
+          'Content-Type': 'application/json',
+        },
+        body: JSON.stringify({ elements, designName }),
+      });
+
+      clearInterval(progressInterval);
+      setProgress(100);
+
+      if (!response.ok) {
+        const errorData = await response.json();
+        throw new Error(errorData.error || 'Export failed');
+      }
+
+      const data = await response.json();
+      setExportUrl(data.export.url);
+
+      // Trigger download
+      const link = document.createElement('a');
+      link.href = data.export.url;
+      link.download = data.export.filename;
+      link.click();
+
+      setExporting(false);
+      return data;
+    } catch (err) {
+      console.error('Export failed:', err);
+      setError(err.message);
+      setExporting(false);
+      throw err;
+    }
+  }, []);
+
+  const clearExport = useCallback(() => {
+    setExportUrl(null);
+    setError(null);
+  }, []);
+
+  return {
+    exporting,
+    progress,
+    exportUrl,
+    error,
+    exportDesign,
+    clearExport,
+  };
+}

client/src/index.css

@@ -121,6 +121,12 @@ input, textarea, select {
   max-width: 400px;
 }
 
+.canvas-actions {
+  display: flex;
+  gap: 0.75rem;
+  align-items: center;
+}
+
 .undo-redo-buttons {
   display: flex;
   gap: 0.5rem;
@@ -153,6 +159,64 @@ input, textarea, select {
   cursor: not-allowed;
 }
 
+.export-btn {
+  padding: 0.5rem 1rem;
+  background: linear-gradient(135deg, #22c55e, #16a34a);
+  color: white;
+  border: none;
+  border-radius: var(--radius-md);
+  font-size: 0.875rem;
+  font-weight: 500;
+  cursor: pointer;
+  transition: all 0.2s;
+  display: flex;
+  align-items: center;
+  gap: 0.5rem;
+}
+
+.export-btn:hover:not(:disabled) {
+  transform: translateY(-1px);
+  box-shadow: var(--shadow-md);
+}
+
+.export-btn:disabled {
+  opacity: 0.6;
+  cursor: not-allowed;
+}
+
+.export-error {
+  display: flex;
+  align-items: center;
+  justify-content: space-between;
+  padding: 0.75rem 1rem;
+  background: #fef2f2;
+  border: 1px solid #fecaca;
+  border-radius: var(--radius-md);
+  color: #dc2626;
+  font-size: 0.875rem;
+  margin-bottom: 1rem;
+  width: 100%;
+  max-width: 400px;
+}
+
+.export-error p {
+  margin: 0;
+}
+
+.close-error {
+  background: transparent;
+  border: none;
+  color: #dc2626;
+  cursor: pointer;
+  font-size: 1.25rem;
+  padding: 0;
+  line-height: 1;
+}
+
+.close-error:hover {
+  color: #991b1b;
+}
+
 .canvas-wrapper {
   margin-bottom: 1rem;
 }

server/index.js

@@ -3,9 +3,10 @@ import cors from 'cors';
 import multer from 'multer';
 import { v4 as uuidv4 } from 'uuid';
 import sharp from 'sharp';
+import { createCanvas, loadImage, registerFont } from 'canvas';
 import { fileURLToPath } from 'module';
 import { dirname, join } from 'path';
-import { mkdirSync, existsSync } from 'fs';
+import { mkdirSync, existsSync, writeFileSync } from 'fs';
 
 const __filename = fileURLToPath(import.meta.url);
 const __dirname = dirname(__filename);
@@ -120,6 +121,92 @@ app.use((err, req, res, next) => {
   next(err);
 });
 
+// High-resolution export endpoint
+// Canvas: 300x300px preview -> 4500x4500px export (15"x15" @ 300 DPI)
+const EXPORT_SCALE = 15; // 300px * 15 = 4500px
+const EXPORT_SIZE = 4500;
+
+app.post('/api/export', async (req, res) => {
+  try {
+    const { elements, designName = 'design' } = req.body;
+
+    if (!elements || !Array.isArray(elements)) {
+      return res.status(400).json({ error: 'Elements array is required' });
+    }
+
+    // Create high-resolution canvas
+    const canvas = createCanvas(EXPORT_SIZE, EXPORT_SIZE);
+    const ctx = canvas.getContext('2d');
+
+    // White background
+    ctx.fillStyle = '#ffffff';
+    ctx.fillRect(0, 0, EXPORT_SIZE, EXPORT_SIZE);
+
+    // Render each element
+    for (const el of elements) {
+      ctx.save();
+
+      // Transform: translate to element position, rotate, then draw
+      const x = (el.x || 0) * EXPORT_SCALE;
+      const y = (el.y || 0) * EXPORT_SCALE;
+      const centerX = x + ((el.width || el.fontSize || 100) * EXPORT_SCALE) / 2;
+      const centerY = y + ((el.height || el.fontSize || 100) * EXPORT_SCALE) / 2;
+
+      ctx.translate(centerX, centerY);
+      ctx.rotate((el.rotation || 0) * Math.PI / 180);
+      ctx.translate(-centerX, -centerY);
+
+      if (el.type === 'image' && el.src) {
+        try {
+          // Load image from URL or local path
+          const imgUrl = el.src.startsWith('/')
+            ? join(__dirname, el.src.replace('/uploads', 'uploads'))
+            : el.src;
+
+          const img = await loadImage(imgUrl);
+          const width = (el.width || 100) * EXPORT_SCALE;
+          const height = (el.height || 100) * EXPORT_SCALE;
+
+          ctx.drawImage(img, x, y, width, height);
+        } catch (imgError) {
+          console.error('Failed to load image for export:', imgError);
+        }
+      } else if (el.type === 'text') {
+        const fontSize = (el.fontSize || 32) * EXPORT_SCALE / 32;
+        ctx.font = `${fontSize}px "${el.fontFamily || 'Arial'}"`;
+        ctx.fillStyle = el.fill || '#000000';
+        ctx.textAlign = 'center';
+        ctx.textBaseline = 'middle';
+        ctx.fillText(el.text || '', centerX, centerY);
+      }
+
+      ctx.restore();
+    }
+
+    // Save to file
+    const exportFilename = `${designName.replace(/[^a-z0-9]/gi, '_')}_${uuidv4()}.png`;
+    const exportPath = join(exportsDir, exportFilename);
+    const buffer = canvas.toBuffer('image/png');
+    writeFileSync(exportPath, buffer);
+
+    res.json({
+      success: true,
+      export: {
+        url: `/exports/${exportFilename}`,
+        path: exportPath,
+        filename: exportFilename,
+        width: EXPORT_SIZE,
+        height: EXPORT_SIZE,
+        dpi: 300,
+        sizeInches: '15x15'
+      }
+    });
+  } catch (error) {
+    console.error('Export error:', error);
+    res.status(500).json({ error: 'Failed to export design', details: error.message });
+  }
+});
+
 app.listen(PORT, () => {
   console.log(`Server running on http://localhost:${PORT}`);
   console.log(`Health check: http://localhost:${PORT}/api/health`);