Improve board sizing and page packing

scripts/boards.py

@@ -1,9 +1,32 @@
-import math
 from pathlib import Path
 
 from .assets import load_json, load_rgb
 from .settings import BOARD_DECK, DECKS_DIR, BuildConfig
 
+ORIGINAL_BOARD_MM = (88.9, 139.7)
+TRIMMED_BOARD_ASPECT_RATIO = ORIGINAL_BOARD_MM[0] / ORIGINAL_BOARD_MM[1]
+BOARD_SIZE_OPTIONS_MM = {
+    "original": ORIGINAL_BOARD_MM,
+    "a6": (105.0, 148.0),
+    "a5": (148.0, 210.0),
+    "a4": (210.0, 297.0),
+    "half-letter": (139.7, 215.9),
+    "letter": (215.9, 279.4),
+}
+BOARD_MODE_CHOICES = tuple(
+    [name for name in BOARD_SIZE_OPTIONS_MM]
+    + [f"{name}-fit" for name in BOARD_SIZE_OPTIONS_MM]
+    + ["custom", "custom-fit"]
+)
+VISIBLE_BOARD_MODE_CHOICES = ("original", "a6", "a6-fit", "a5", "a5-fit", "half-letter", "half-letter-fit", "custom")
+
+
+def fit_size_inside(box_mm: tuple[float, float], ratio: float = TRIMMED_BOARD_ASPECT_RATIO) -> tuple[float, float]:
+    max_w, max_h = box_mm
+    if ratio > max_w / max_h:
+        return max_w, max_w / ratio
+    return max_h * ratio, max_h
+
 
 def board_target_mm_for_mode(
     board_path: Path,
@@ -11,29 +34,16 @@ def board_target_mm_for_mode(
     board_custom_mm: tuple[float, float] | None = None,
 ) -> tuple[float, float]:
     if board_custom_mm is not None:
+        if board_mode == "custom-fit":
+            return fit_size_inside(board_custom_mm)
         return board_custom_mm
-    ratio = board_aspect_ratio(board_path)
-    if board_mode == "a4-fit":
-        max_w, max_h = 210.0, 297.0
-        if ratio > max_w / max_h:
-            return max_w, max_w / ratio
-        return max_h * ratio, max_h
-    if board_mode == "a5-fit":
-        max_w, max_h = 148.0, 210.0
-        if ratio > max_w / max_h:
-            return max_w, max_w / ratio
-        return max_h * ratio, max_h
 
-    # Default: preserve aspect ratio while using approximately A5 area,
-    # capped to fit inside A4.
-    a5_area = 148.0 * 210.0
-    width = math.sqrt(a5_area * ratio)
-    height = math.sqrt(a5_area / ratio)
-    if width > 210.0 or height > 297.0:
-        scale = min(210.0 / width, 297.0 / height)
-        width *= scale
-        height *= scale
-    return width, height
+    if board_mode.endswith("-fit"):
+        base_mode = board_mode.removesuffix("-fit")
+        if base_mode in BOARD_SIZE_OPTIONS_MM and base_mode != "original":
+            return fit_size_inside(BOARD_SIZE_OPTIONS_MM[base_mode])
+
+    return BOARD_SIZE_OPTIONS_MM.get(board_mode, ORIGINAL_BOARD_MM)
 
 
 def board_aspect_ratio(board_path: Path) -> float:
@@ -50,16 +60,33 @@ def board_target_mm(board_path: Path, config: BuildConfig) -> tuple[float, float
     return board_target_mm_for_mode(board_path, config.board_mode, config.board_custom_mm)
 
 
-def board_mode_fits_paper(board_mode: str, paper_mm: tuple[float, float], margin_mm: float) -> bool:
+def board_size_fits_paper(
+    board_mode: str,
+    board_custom_mm: tuple[float, float] | None,
+    paper_mm: tuple[float, float],
+    margin_mm: float,
+) -> bool:
     usable_w = paper_mm[0] - 2 * margin_mm
     usable_h = paper_mm[1] - 2 * margin_mm
     board_paths = sorted((DECKS_DIR / BOARD_DECK).glob("*-jumbo-front.png"))
     if not board_paths:
         return True
     for board_path in board_paths:
-        board_w, board_h = board_target_mm_for_mode(board_path, board_mode)
+        board_w, board_h = board_target_mm_for_mode(board_path, board_mode, board_custom_mm)
         fits_upright = board_w <= usable_w and board_h <= usable_h
         fits_rotated = board_h <= usable_w and board_w <= usable_h
         if not (fits_upright or fits_rotated):
             return False
     return True
+
+
+def board_mode_fits_paper(board_mode: str, paper_mm: tuple[float, float], margin_mm: float) -> bool:
+    return board_size_fits_paper(board_mode, None, paper_mm, margin_mm)
+
+
+def crop_board_bleed(img):
+    target_w = round(img.width * (3.5 / 3.75))
+    target_h = round(img.height * (5.5 / 5.75))
+    left = max(0, (img.width - target_w) // 2)
+    top = max(0, (img.height - target_h) // 2)
+    return img.crop((left, top, left + target_w, top + target_h))