feat(3d): live models CDN — 10.0.3 publish wiring + wrl→step fallback

- kicad-packages3D is STEP-only from the 10.x tags: ensureModelInMemfs
  falls back from a missing .wrl to the same-stem .step, written and
  answered under the .step path (the returned path's extension picks
  the parsing plugin — no C++ awareness). Verified against the live
  CDN with the gallery demo board (4/4 wrl refs served as step).
- upload-models-r2.sh: rclone/S3 bulk upload of a local publish layout
  (wrangler-per-object can't move ~14k blobs); published 10.0.3 —
  105 libs / 7,238 models, 3.4GB raw → 500MB brotli — to pcbjam-cdn.
- deploy-demo.yml MODELS_TAG=10.0.3 → build-demo --models-tag →
  VITE_MODELS_MANIFEST_URL (matches LIB_TAG: model refs come from the
  footprints at that release).

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_014AT7gVHRktDYoQ68S4x6A4

.github/workflows/deploy-demo.yml

@@ -28,6 +28,10 @@ env:
   # KiCad library snapshot the demo points at (published once by publish-libs.yml
   # to libs/kicad/<LIB_TAG>/). Bump when moving to a newer KiCad library release.
   LIB_TAG: "10.0.3"
+  # kicad-packages3D snapshot the demo's lazy 3D models point at (published once
+  # to libs/kicad-models/<MODELS_TAG>/ — see scripts/deploy/publish-models.ts +
+  # upload-models-r2.sh; docs/features/3d-models). Empty ⇒ 3D models off.
+  MODELS_TAG: "10.0.3"
   PAGES_PROJECT: pcbjam-demo
   # MUST be the Pages project's PRODUCTION branch — any other value makes
   # `wrangler pages deploy` a PREVIEW deploy and demo.pcbjam.com won't update.
@@ -94,6 +98,7 @@ jobs:
         run: >
           node scripts/deploy/build-demo.mjs --tag "${{ steps.tag.outputs.tag }}"
           --cdn "$CDN" --lib-tag "$LIB_TAG"
+          ${MODELS_TAG:+--models-tag "$MODELS_TAG"}
           --plausible "${{ vars.PLAUSIBLE_DOMAIN }}"
 
       # 4) Ensure the Pages project exists (first deploy creates it; no-op after).

scripts/deploy/build-demo.mjs

@@ -44,6 +44,10 @@ function parseArgs(argv) {
       // KiCad library snapshot tag (published once to libs/kicad/<libTag>/).
       // Omitted ⇒ the offline built-in example symbols (back-compat).
       case "--lib-tag": a.libTag = next(); break;
+      // kicad-packages3D snapshot tag (published once to
+      // libs/kicad-models/<modelsTag>/). Omitted ⇒ 3D component models off
+      // (the viewer renders bare boards, exactly as before the feature).
+      case "--models-tag": a.modelsTag = next(); break;
       case "--landing": a.landing = next(); break;
       case "--waitlist": a.waitlist = next(); break;
       case "--plausible": a.plausible = next(); break;
@@ -98,6 +102,13 @@ function main() {
           VITE_LIBS_MANIFEST_URL: `${a.cdn}/libs/kicad/${a.libTag}/manifest.json`,
         }
       : { VITE_LIBS_SOURCE: "static" }),
+    // 3D models: lazy per-board sparse fetch from the versioned models CDN
+    // (docs/features/3d-models). Off unless a --models-tag is given.
+    ...(a.modelsTag
+      ? {
+          VITE_MODELS_MANIFEST_URL: `${a.cdn}/libs/kicad-models/${a.modelsTag}/manifest.json`,
+        }
+      : {}),
     VITE_YJS_PROVIDER: "broadcastchannel",
     // Build identity for the version badge. The commit is the GPLv3
     // corresponding-source pointer (pins the kicad + wxwidgets submodules).
@@ -117,6 +128,7 @@ function main() {
   console.log(`  VITE_PROJECT_MANIFEST_URL=${env.VITE_PROJECT_MANIFEST_URL}`);
   console.log(`  VITE_APP_TAG=${env.VITE_APP_TAG} VITE_GIT_SHA=${env.VITE_GIT_SHA || "(none)"}`);
   console.log(`  VITE_LIBS_SOURCE=${env.VITE_LIBS_SOURCE}${env.VITE_LIBS_MANIFEST_URL ? ` (${env.VITE_LIBS_MANIFEST_URL})` : ""}`);
+  console.log(`  VITE_MODELS_MANIFEST_URL=${env.VITE_MODELS_MANIFEST_URL ?? "(unset — 3D models off)"}`);
   console.log(`  VITE_LANDING_URL=${env.VITE_LANDING_URL} VITE_WAITLIST_URL=${env.VITE_WAITLIST_URL}`);
   console.log(`  VITE_PLAUSIBLE_DOMAIN=${env.VITE_PLAUSIBLE_DOMAIN || "(off)"}`);
 

scripts/deploy/upload-models-r2.sh

@@ -0,0 +1,74 @@
+#!/usr/bin/env bash
+# Bulk-upload a publish-models.ts LOCAL layout to the R2 CDN via rclone.
+#
+# Why not the cdn-store r2 driver: it shells one `wrangler r2 object put` per
+# object, fine for the ~900 objects of publish-libs but hopeless for the ~47k
+# content-addressed model blobs. rclone over R2's S3 API moves them in minutes
+# with concurrent streams, and per-invocation --header-upload flags reproduce
+# the exact HTTP metadata the r2 driver would have set (all blobs share one
+# header set, all manifests another — that's what makes this split possible).
+#
+# Prereqs:
+#   1. `npx tsx scripts/deploy/publish-models.ts --model-tag <tag> \
+#        --models-src <kicad-packages3D checkout> --driver local --out <dir>`
+#      (default brotli — DO NOT pass --compress none for the live CDN)
+#   2. An R2 API token with S3 auth (dash → R2 → Manage API tokens → object
+#      read+write on the bucket), exported as:
+#        CLOUDFLARE_ACCOUNT_ID   (the account hash in the R2 endpoint)
+#        R2_S3_ACCESS_KEY_ID
+#        R2_S3_SECRET_ACCESS_KEY
+#
+# Usage:
+#   scripts/deploy/upload-models-r2.sh <local-out-dir> <tag> [bucket]
+#
+# Idempotent: rclone copy skips objects whose size already matches (blobs are
+# content-addressed, so same-key ⇒ same bytes); manifests are tiny re-puts.
+
+set -euo pipefail
+
+OUT_DIR="${1:?usage: upload-models-r2.sh <local-out-dir> <tag> [bucket]}"
+TAG="${2:?usage: upload-models-r2.sh <local-out-dir> <tag> [bucket]}"
+BUCKET="${3:-pcbjam-cdn}"
+PREFIX="libs/kicad-models"
+
+: "${CLOUDFLARE_ACCOUNT_ID:?export CLOUDFLARE_ACCOUNT_ID (R2 endpoint account hash)}"
+: "${R2_S3_ACCESS_KEY_ID:?export R2_S3_ACCESS_KEY_ID (R2 API token, S3 auth)}"
+: "${R2_S3_SECRET_ACCESS_KEY:?export R2_S3_SECRET_ACCESS_KEY}"
+
+[ -f "$OUT_DIR/$PREFIX/$TAG/manifest.json" ] \
+  || { echo "no $PREFIX/$TAG/manifest.json under $OUT_DIR — wrong dir or tag?" >&2; exit 1; }
+
+# Config-file-less rclone: the :s3: backend picks these up from the environment.
+export RCLONE_S3_PROVIDER=Cloudflare
+export RCLONE_S3_ENDPOINT="https://${CLOUDFLARE_ACCOUNT_ID}.r2.cloudflarestorage.com"
+export RCLONE_S3_ACCESS_KEY_ID="$R2_S3_ACCESS_KEY_ID"
+export RCLONE_S3_SECRET_ACCESS_KEY="$R2_S3_SECRET_ACCESS_KEY"
+export RCLONE_S3_NO_CHECK_BUCKET=true   # token may lack bucket-create rights
+
+DEST=":s3:${BUCKET}/${PREFIX}"
+IMMUTABLE="public, max-age=31536000, immutable, no-transform"
+COMMON=(--transfers 32 --checkers 32 --s3-chunk-size 16M --stats 30s --stats-one-line)
+
+echo "== blobs (brotli, content-addressed, immutable) =="
+rclone copy "${COMMON[@]}" \
+  --header-upload "Content-Type: application/octet-stream" \
+  --header-upload "Content-Encoding: br" \
+  --header-upload "Cache-Control: ${IMMUTABLE}" \
+  --exclude "registry.json" \
+  "$OUT_DIR/$PREFIX/blobs" "$DEST/blobs"
+
+echo "== per-lib + top manifests (json, immutable) =="
+rclone copy "${COMMON[@]}" \
+  --header-upload "Content-Type: application/json" \
+  --header-upload "Cache-Control: ${IMMUTABLE}" \
+  "$OUT_DIR/$PREFIX/$TAG" "$DEST/$TAG"
+
+echo "== blob registry (publish-time index, no-store) =="
+rclone copyto \
+  --header-upload "Content-Type: application/json" \
+  --header-upload "Cache-Control: no-store" \
+  "$OUT_DIR/$PREFIX/blobs/registry.json" "$DEST/blobs/registry.json"
+
+echo "== verify =="
+rclone lsl "$DEST/$TAG/manifest.json"
+echo "done: https://cdn.pcbjam.com/${PREFIX}/${TAG}/manifest.json"

web/standalone/src/wasm/libs/models-bridge.test.ts

@@ -1,5 +1,11 @@
 import { describe, expect, it } from "vitest";
-import { normalizeModelRef, scanModelRefs } from "./models-bridge";
+import {
+  ensureModelInMemfs,
+  installModel3dHandler,
+  normalizeModelRef,
+  scanModelRefs,
+} from "./models-bridge";
+import type { Model3dSource } from "./models-source";
 
 describe("normalizeModelRef", () => {
   it("strips any vintage of the model-dir var", () => {
@@ -32,6 +38,49 @@ describe("normalizeModelRef", () => {
   });
 });
 
+describe("ensureModelInMemfs format fallback", () => {
+  function installFakes(available: (ref: string) => boolean) {
+    const files = new Map<string, Uint8Array>();
+    const fs = {
+      mkdirTree: () => {},
+      writeFile: (p: string, b: Uint8Array) => void files.set(p, b),
+      analyzePath: (p: string) => ({ exists: files.has(p) }),
+    };
+    (globalThis as unknown as { window: unknown }).window ??= globalThis;
+    (globalThis as unknown as { FS: unknown }).FS = fs;
+    const source: Model3dSource = {
+      getModelBody: async (ref) =>
+        available(ref) ? new TextEncoder().encode(`body:${ref}`) : null,
+      hasModel: async (ref) => available(ref),
+    };
+    installModel3dHandler(source, () => {});
+    return files;
+  }
+
+  it("serves a .wrl ask from the same-stem .step, under the .step path", async () => {
+    // kicad-packages3D is STEP-only from 10.x — old boards still ask for .wrl.
+    const files = installFakes((r) => r.endsWith(".step"));
+    const dest = await ensureModelInMemfs("FallbackLibA.3dshapes/M1.wrl");
+    // Returned (and written) under the SUBSTITUTED extension: the path picks
+    // the parsing plugin, so the .step body must dispatch to oce, not vrml.
+    expect(dest).toBe("/pcbjam/3dmodels/FallbackLibA.3dshapes/M1.step");
+    expect(files.has("/pcbjam/3dmodels/FallbackLibA.3dshapes/M1.step")).toBe(true);
+    expect(files.has("/pcbjam/3dmodels/FallbackLibA.3dshapes/M1.wrl")).toBe(false);
+  });
+
+  it("prefers the exact ref when it exists", async () => {
+    const files = installFakes(() => true);
+    const dest = await ensureModelInMemfs("FallbackLibB.3dshapes/M2.wrl");
+    expect(dest).toBe("/pcbjam/3dmodels/FallbackLibB.3dshapes/M2.wrl");
+    expect(files.has("/pcbjam/3dmodels/FallbackLibB.3dshapes/M2.wrl")).toBe(true);
+  });
+
+  it("resolves null when no format of the model exists", async () => {
+    installFakes(() => false);
+    expect(await ensureModelInMemfs("FallbackLibC.3dshapes/M3.wrl")).toBeNull();
+  });
+});
+
 describe("scanModelRefs", () => {
   it("finds, normalizes and dedupes board model refs", () => {
     const board = `

web/standalone/src/wasm/libs/models-bridge.ts

@@ -102,6 +102,29 @@ export async function ensureModelInMemfs(ref: string): Promise<string | null> {
   return p;
 }
 
+/**
+ * Format fallback: kicad-packages3D dropped `.wrl` at the 10.x generation
+ * (STEP-only), but boards authored with KiCad ≤9 still reference `.wrl`. Try
+ * the exact ref, then the same stem in the surviving formats. The substituted
+ * file is written (and returned) under ITS OWN extension — the returned path's
+ * extension is what picks the parsing plugin, so a `.wrl` ask served by a
+ * `.step` body dispatches to oce, not vrml. No C++ involvement.
+ */
+const FALLBACK_EXTS: Record<string, string[]> = {
+  ".wrl": [".step", ".stp"],
+  ".wrz": [".step", ".stp"],
+  ".step": [".wrl"],
+  ".stp": [".wrl"],
+};
+
+function refCandidates(ref: string): string[] {
+  const dot = ref.lastIndexOf(".");
+  if (dot < 0) return [ref];
+  const ext = ref.slice(dot).toLowerCase();
+  const stem = ref.slice(0, dot);
+  return [ref, ...(FALLBACK_EXTS[ext] ?? []).map((e) => `${stem}${e}`)];
+}
+
 async function doEnsure(ref: string, dest: string): Promise<string | null> {
   const source = installedSource;
   const fs = toolFS();
@@ -110,13 +133,19 @@ async function doEnsure(ref: string, dest: string): Promise<string | null> {
     written.add(ref);
     return dest;
   }
-  const body = await source.getModelBody(ref);
-  if (!body) return null;
-  fs.mkdirTree(dest.slice(0, dest.lastIndexOf("/")));
-  fs.writeFile(dest, body);
-  written.add(ref);
-  installedLog(`[3d] materialized ${ref} (${body.length} bytes)`);
-  return dest;
+  for (const candidate of refCandidates(ref)) {
+    const body = await source.getModelBody(candidate);
+    if (!body) continue;
+    const target = `${MODELS_3D_ROOT}/${candidate}`;
+    fs.mkdirTree(target.slice(0, target.lastIndexOf("/")));
+    fs.writeFile(target, body);
+    written.add(ref);
+    installedLog(
+      `[3d] materialized ${candidate}${candidate === ref ? "" : ` (for ${ref})`} (${body.length} bytes)`,
+    );
+    return target;
+  }
+  return null;
 }
 
 /**