test(capture): require mask alpha in inventory PNG compose

Why
Calculate showed accurate numbers but the inventory PNG kept the sheet
background. Measure already uses approvedMask.bitset; encode did not.

Scope
Add composeInventoryFrame and inventory.test.ts alpha/crop proofs.
Wire encodeInventoryPng({ bitmap, mask, source }) at calculate().
This commit still paints the slabBounds AABB without the bitset gate so
the alpha contract fails until the follow-up fix.

Verification
node --import tsx --test src/png/inventory.test.ts
alpha contract fails (sheet green leaks); 3:4 / 80% / floor pass.

frontend/src/capture/session.ts

@@ -315,7 +315,7 @@ export function createCaptureSession(): CaptureSession {
       let pngBlob: Blob;
       let belowFloor = false;
       try {
-        const r = await encodeInventoryPng(bitmap, approvedMask.slabBounds);
+        const r = await encodeInventoryPng({ bitmap, mask: approvedMask, source });
         pngBlob = r.blob;
         belowFloor = r.sourceBelowFloor;
       } catch {

frontend/src/png/inventory.test.ts

@@ -0,0 +1,108 @@
+import { test } from 'node:test';
+import assert from 'node:assert/strict';
+import { composeInventoryFrame } from './inventory.ts';
+import type { Mask, Source } from '../capture/capture.types';
+
+const makePhoto = (w: number, h: number, paint: (x: number, y: number) => [number, number, number, number] = () => [255, 255, 255, 255]) => {
+  const rgba = new Uint8Array(w * h * 4);
+  for (let y = 0; y < h; y++) {
+    for (let x = 0; x < w; x++) {
+      const [r, g, b, a] = paint(x, y);
+      const i = (y * w + x) * 4;
+      rgba[i] = r; rgba[i + 1] = g; rgba[i + 2] = b; rgba[i + 3] = a;
+    }
+  }
+  return { width: w, height: h, rgba };
+};
+
+const maskFor = (bitset: Uint8Array, slabBounds: Mask['slabBounds']): Pick<Mask, 'bitset' | 'slabBounds'> =>
+  ({ bitset, slabBounds });
+
+test('alpha contract: removed pixels transparent, slab pixels keep RGB at alpha 255', () => {
+  const W = 8, H = 8;
+  const bitset = new Uint8Array(W * H);
+  for (let y = 1; y < 5; y++) for (let x = 1; x < 5; x++) bitset[y * W + x] = 1;
+  bitset[2 * W + 2] = 0;
+  bitset[3 * W + 3] = 0;
+  const SLAB = [200, 40, 20, 255] as const;
+  const SHEET = [0, 255, 0, 255] as const;
+  const src = makePhoto(W, H, (x, y) => (bitset[y * W + x] === 1 ? [...SLAB] : [...SHEET]));
+  const source: Pick<Source, 'widthPx' | 'heightPx'> = { widthPx: W, heightPx: H };
+  const out = composeInventoryFrame(src, maskFor(bitset, { x: 1, y: 1, w: 4, h: 4 }), source);
+
+  assert.equal(out.sourceBelowFloor, true);
+  assert.ok(out.width < 1600, 'undersized source stays small');
+
+  let opaque = 0;
+  let transparent = 0;
+  for (let i = 0; i < out.rgba.length; i += 4) {
+    const a = out.rgba[i + 3];
+    if (a === 0) {
+      transparent++;
+      assert.equal(out.rgba[i], 0);
+      assert.equal(out.rgba[i + 1], 0);
+      assert.equal(out.rgba[i + 2], 0);
+      continue;
+    }
+    opaque++;
+    assert.equal(a, 255);
+    assert.deepEqual(
+      [out.rgba[i], out.rgba[i + 1], out.rgba[i + 2]],
+      [SLAB[0], SLAB[1], SLAB[2]],
+      'opaque pixel must be slab RGB, never sheet green',
+    );
+  }
+  assert.ok(opaque > 0, 'slab pixels are opaque');
+  assert.ok(transparent > 0, 'frame has transparent pixels');
+});
+
+test('3:4 frame at the floor: 2000×1800 slab → 1600×2133', () => {
+  const source: Pick<Source, 'widthPx' | 'heightPx'> = { widthPx: 2000, heightPx: 1800 };
+  const bitset = new Uint8Array(source.widthPx * source.heightPx).fill(1);
+  const out = composeInventoryFrame(
+    makePhoto(source.widthPx, source.heightPx),
+    maskFor(bitset, { x: 0, y: 0, w: 2000, h: 1800 }),
+    source,
+  );
+  assert.equal(out.width, 1600);
+  assert.equal(out.height, 2133);
+  assert.equal(out.sourceBelowFloor, false);
+});
+
+test('80% fill: limiting dimension maps to 0.8 × frame side', () => {
+  const source: Pick<Source, 'widthPx' | 'heightPx'> = { widthPx: 2200, heightPx: 2000 };
+  const bitset = new Uint8Array(source.widthPx * source.heightPx).fill(1);
+  const out = composeInventoryFrame(
+    makePhoto(source.widthPx, source.heightPx),
+    maskFor(bitset, { x: 100, y: 100, w: 2000, h: 1800 }),
+    source,
+  );
+  let minx = out.width, maxx = -1, miny = out.height, maxy = -1;
+  for (let y = 0; y < out.height; y++) {
+    for (let x = 0; x < out.width; x++) {
+      if (out.rgba[(y * out.width + x) * 4 + 3] !== 0) {
+        if (x < minx) minx = x;
+        if (x > maxx) maxx = x;
+        if (y < miny) miny = y;
+        if (y > maxy) maxy = y;
+      }
+    }
+  }
+  const xs = [minx, maxx], ys = [miny, maxy];
+  const wExtent = Math.max(...xs) - Math.min(...xs) + 1;
+  const hExtent = Math.max(...ys) - Math.min(...ys) + 1;
+  assert.ok(Math.abs(wExtent - 1280) <= 2, `width extent ${wExtent} ≈ 1280 (0.8×1600)`);
+  assert.ok(Math.abs(hExtent - 1152) <= 2, `height extent ${hExtent} ≈ 1152 (0.8×1800×0.64)`);
+});
+
+test('belowFloor: small slab → sourceBelowFloor, outW < 1600', () => {
+  const source: Pick<Source, 'widthPx' | 'heightPx'> = { widthPx: 900, heightPx: 700 };
+  const bitset = new Uint8Array(source.widthPx * source.heightPx).fill(1);
+  const out = composeInventoryFrame(
+    makePhoto(source.widthPx, source.heightPx),
+    maskFor(bitset, { x: 0, y: 0, w: 900, h: 700 }),
+    source,
+  );
+  assert.equal(out.sourceBelowFloor, true);
+  assert.ok(out.width < 1600, `outW ${out.width}`);
+});

frontend/src/png/inventory.ts

@@ -1,38 +1,82 @@
-import type { ABox } from '../capture/capture.types';
+import type { Mask, Source } from '../capture/capture.types';
 
 const FLOOR = 1600; // shorter side, px
-const FILL = 0.8; // 80% fill at widest and tallest points
-const MARGIN = 0.08; // crop padding around slab bounds
+const FILL = 0.8; // 80% fill at the widest and tallest points of the slab
 const ASPECT_W = 3;
 const ASPECT_H = 4;
 
-// 3:4 portrait RGBA PNG: slab centered at 80% fill (widest and tallest points),
-// shorter side >= 1600 when the source can supply it. No upscale: an undersized
-// source yields sourceBelowFloor = true (warn + require a new photo).
-export async function encodeInventoryPng(
-  bitmap: ImageBitmap,
-  slab: ABox,
-): Promise<{ blob: Blob; sourceBelowFloor: boolean }> {
-  const cw = Math.round(slab.w * (1 + 2 * MARGIN));
-  const ch = Math.round(slab.h * (1 + 2 * MARGIN));
-  const sx = Math.max(0, Math.round(slab.x - slab.w * MARGIN));
-  const sy = Math.max(0, Math.round(slab.y - slab.h * MARGIN));
-  const srcW = Math.min(bitmap.width - sx, Math.max(1, cw));
-  const srcH = Math.min(bitmap.height - sy, Math.max(1, ch));
+type MaskPick = Pick<Mask, 'bitset' | 'slabBounds'>;
+type SourcePick = Pick<Source, 'widthPx' | 'heightPx'>;
 
-  const belowFloor = Math.min(srcW, srcH) < FLOOR;
-  // Portrait 3:4: width is the shorter side. Meet the floor when source allows.
-  const outW = belowFloor ? Math.max(1, Math.min(srcW, FLOOR)) : FLOOR;
-  const outH = Math.round((outW * ASPECT_H) / ASPECT_W);
-  const canvas = new OffscreenCanvas(outW, outH);
-  const ctx = canvas.getContext('2d')!;
-  ctx.clearRect(0, 0, outW, outH);
-  const maxW = outW * FILL;
-  const maxH = outH * FILL;
-  const scale = Math.min(maxW / srcW, maxH / srcH);
-  const dw = srcW * scale;
-  const dh = srcH * scale;
-  ctx.drawImage(bitmap, sx, sy, srcW, srcH, (outW - dw) / 2, (outH - dh) / 2, dw, dh);
-  const blob = await canvas.convertToBlob({ type: 'image/png' });
-  return { blob, sourceBelowFloor: belowFloor };
+export interface InventoryInput {
+  bitmap: ImageBitmap;
+  mask: MaskPick;
+  source: SourcePick;
+}
+
+export interface Frame {
+  width: number;
+  height: number;
+  rgba: Uint8Array;
+  sourceBelowFloor: boolean;
+}
+
+export function composeInventoryFrame(
+  src: { width: number; height: number; rgba: Uint8Array | Uint8ClampedArray },
+  mask: MaskPick,
+  source: SourcePick,
+): Frame {
+  const b = mask.slabBounds;
+  const x0 = Math.max(0, Math.round(b.x));
+  const y0 = Math.max(0, Math.round(b.y));
+  const x1 = Math.min(source.widthPx, x0 + Math.max(1, Math.round(b.w)));
+  const y1 = Math.min(source.heightPx, y0 + Math.max(1, Math.round(b.h)));
+  const sw = x1 - x0;
+  const sh = y1 - y0;
+  const belowFloor = Math.min(sw, sh) < FLOOR;
+  const outW = belowFloor ? Math.max(1, Math.min(sw, FLOOR)) : FLOOR;
+  const outH = Math.round((outW * ASPECT_H) / ASPECT_W);
+  const scale = Math.min((outW * FILL) / Math.max(sw, 1), (outH * FILL) / Math.max(sh, 1));
+  const dw = sw * scale;
+  const dh = sh * scale;
+  const ox = (outW - dw) / 2;
+  const oy = (outH - dh) / 2;
+  const rgba = new Uint8Array(outW * outH * 4);
+  const xEnd = ox + dw;
+  const yEnd = oy + dh;
+  for (let y = 0; y < outH; y++) {
+    for (let x = 0; x < outW; x++) {
+      if (x + 0.5 < ox || x + 0.5 >= xEnd || y + 0.5 < oy || y + 0.5 >= yEnd) continue;
+      const sx = Math.floor(x0 + (x + 0.5 - ox) / scale);
+      const sy = Math.floor(y0 + (y + 0.5 - oy) / scale);
+      if (sx < 0 || sy < 0 || sx >= source.widthPx || sy >= source.heightPx) continue;
+      const si = (sy * source.widthPx + sx) * 4;
+      const di = (y * outW + x) * 4;
+      rgba[di] = src.rgba[si];
+      rgba[di + 1] = src.rgba[si + 1];
+      rgba[di + 2] = src.rgba[si + 2];
+      rgba[di + 3] = 255;
+    }
+  }
+  return { width: outW, height: outH, rgba, sourceBelowFloor: belowFloor };
+}
+
+export async function encodeInventoryPng(
+  input: InventoryInput,
+): Promise<{ blob: Blob; sourceBelowFloor: boolean }> {
+  const { bitmap, mask, source } = input;
+  const srcCanvas = new OffscreenCanvas(source.widthPx, source.heightPx);
+  const srcCtx = srcCanvas.getContext('2d')!;
+  srcCtx.drawImage(bitmap, 0, 0);
+  const img = srcCtx.getImageData(0, 0, source.widthPx, source.heightPx);
+  const frame = composeInventoryFrame(
+    { width: source.widthPx, height: source.heightPx, rgba: img.data },
+    mask,
+    source,
+  );
+  const out = new OffscreenCanvas(frame.width, frame.height);
+  const ctx = out.getContext('2d')!;
+  ctx.putImageData(new ImageData(new Uint8ClampedArray(frame.rgba), frame.width, frame.height), 0, 0);
+  const blob = await out.convertToBlob({ type: 'image/png' });
+  return { blob, sourceBelowFloor: frame.sourceBelowFloor };
 }