improve utilities workspace navigation

fix laser utility calculations
2026-07-10 17:25:34 -04:00 · 2026-07-10 17:22:41 -04:00
10 changed files with 129 additions and 168 deletions
--- a/app/app/portal/utilities/Client.tsx
+++ b/app/app/portal/utilities/Client.tsx
@ -9,11 +9,13 @@ const UtilitySwitcher = dynamic(() => import("@/components/portal/UtilitySwitche

 export default function UtilitiesClient() {
    return (
-        <div className="space-y-4">
-        <div className="rounded-lg border p-6">
-        <h2 className="mb-4 text-xl font-semibold">Utilities</h2>
-        <UtilitySwitcher />
+        <div className="space-y-5">
+        <div>
+            <div className="mb-1 font-mono text-xs uppercase tracking-[0.2em] text-accent">~/utilities</div>
+            <h2 className="text-xl font-semibold tracking-tight">Workshop utilities</h2>
+            <p className="mt-1 text-sm text-muted-foreground">Calculators and production tools in one workspace.</p>
        </div>
+        <UtilitySwitcher />
        </div>
    );
 }
--- a/app/app/styles/globals.css
+++ b/app/app/styles/globals.css
@ -64,3 +64,23 @@
  }
 }

+@layer components {
+  /* Dense, terminal-inspired calculator workspace without nested floating cards. */
+  .laser-tool-workspace [class~="rounded-lg"][class~="border"] {
+    @apply rounded-lg border-border/60 bg-background/20 shadow-none;
+  }
+
+  .laser-tool-workspace [class~="rounded-lg"][class~="border"] > div:first-child {
+    @apply px-4 py-3;
+  }
+
+  .laser-tool-workspace [class~="rounded-lg"][class~="border"] > div:not(:first-child) {
+    @apply px-4 pb-4;
+  }
+
+  .laser-tool-workspace input,
+  .laser-tool-workspace select,
+  .laser-tool-workspace button[role="combobox"] {
+    @apply border-border/70 bg-background/70 shadow-none transition-colors focus:border-accent/70 focus:ring-1 focus:ring-accent/30;
+  }
+}
--- a/app/components/portal/LaserToolkitSwitcher.tsx
+++ b/app/components/portal/LaserToolkitSwitcher.tsx
@ -4,6 +4,7 @@
 import { useMemo } from "react";
 import { useSearchParams, useRouter } from "next/navigation";
 import { cn } from "@/lib/utils";
+import { Calculator, ChevronDown } from "lucide-react";
 import { TOOLKIT_TABS } from "@/components/utilities/laser-toolkit/registry";

 export default function LaserToolkitSwitcher({ basePath = "/portal/utilities" }: { basePath?: string }) {
@ -34,23 +35,38 @@ export default function LaserToolkitSwitcher({ basePath = "/portal/utilities" }:
    const ActiveCmp = active.component;

    return (
-        <div className="space-y-4">
-        <div className="flex flex-wrap gap-2">
+        <div className="min-w-0">
+        <div className="border-b border-border/60 bg-background/30 p-3">
+        <div className="relative sm:hidden">
+            <Calculator className="pointer-events-none absolute left-3 top-1/2 h-4 w-4 -translate-y-1/2 text-accent" />
+            <select
+                aria-label="Select laser calculator"
+                value={activeKey}
+                onChange={(e) => setTab(e.target.value)}
+                className="h-10 w-full appearance-none rounded-lg border-border/70 bg-card pl-10 pr-9 text-sm"
+            >
+                {TOOLKIT_TABS.map((t) => <option key={t.key} value={t.key}>{t.label}</option>)}
+            </select>
+            <ChevronDown className="pointer-events-none absolute right-3 top-1/2 h-4 w-4 -translate-y-1/2 opacity-50" />
+        </div>
+        <div className="hidden flex-wrap gap-1 sm:flex">
        {TOOLKIT_TABS.map(t => (
            <button
            key={t.key}
            onClick={() => setTab(t.key)}
            className={cn(
-                "rounded-md border px-3 py-1.5 text-sm",
-                activeKey === t.key ? "bg-primary text-primary-foreground" : "hover:bg-muted"
+                "rounded-md border border-transparent px-3 py-1.5 text-xs transition-colors",
+                activeKey === t.key
+                    ? "border-border/60 bg-card text-foreground shadow-sm"
+                    : "text-muted-foreground hover:bg-muted/30 hover:text-foreground"
            )}
            >
            {t.label}
            </button>
        ))}
-        </div>
+        </div></div>

-        <div className="rounded-md border p-4">
+        <div className="laser-tool-workspace">
        <ActiveCmp />
        </div>
        </div>
--- a/app/components/portal/UtilitySwitcher.tsx
+++ b/app/components/portal/UtilitySwitcher.tsx
@ -4,6 +4,7 @@ import { useEffect, useMemo, useRef, useState } from "react";
 import dynamic from "next/dynamic";
 import { useRouter, useSearchParams } from "next/navigation";
 import { cn } from "@/lib/utils";
+import { ChevronRight, ExternalLink, TerminalSquare } from "lucide-react";

 type Item = {
    key: string; // used in ?t=
@ -216,9 +217,13 @@ export default function UtilitySwitcher() {
    }, []);

    return (
-        <div>
-        {/* top buttons unchanged */}
-        <div className="mb-4 flex flex-wrap items-center gap-2">
+        <div className="grid min-w-0 gap-4 lg:grid-cols-[220px_minmax(0,1fr)]">
+        <aside className="h-fit overflow-hidden rounded-xl border border-border/70 bg-card/40 lg:sticky lg:top-4">
+        <div className="flex items-center gap-2 border-b border-border/60 px-3 py-2.5 text-[11px] uppercase tracking-[0.16em] text-muted-foreground">
+            <TerminalSquare className="h-3.5 w-3.5 text-accent" />
+            Select utility
+        </div>
+        <div className="grid grid-cols-2 gap-1 p-1.5 sm:grid-cols-3 lg:grid-cols-1">
        {ITEMS.map((it) => {
            const isInline = Boolean(it.component);
            const external = !isInline && isExternalHref(it.href);
@ -235,10 +240,10 @@ export default function UtilitySwitcher() {
                    }
                }}
                className={cn(
-                    "flex items-center gap-2 rounded-md border px-3 py-1.5 text-sm transition",
+                    "group flex min-w-0 items-center gap-2.5 rounded-lg px-2.5 py-2 text-left text-xs transition-all sm:text-sm",
                    isActive
-                    ? "bg-primary text-primary-foreground"
-                    : "hover:bg-muted"
+                    ? "bg-accent/15 text-foreground shadow-[inset_2px_0_0_hsl(var(--accent))]"
+                    : "text-muted-foreground hover:bg-muted/30 hover:text-foreground"
                )}
                title={it.note || it.label}
                >
@ -249,27 +254,27 @@ export default function UtilitySwitcher() {
                    alt=""
                    width={16}
                    height={16}
-                    className="h-4 w-4 rounded-sm border object-cover"
+                    className="h-5 w-5 shrink-0 rounded border border-border/60 object-cover opacity-80"
                    onError={(e) => {
                        (e.currentTarget as HTMLImageElement).style.display = "none";
                    }}
                    />
                ) : null}

-                <span className="truncate">{it.label}</span>
+                <span className="min-w-0 flex-1 truncate">{it.label}</span>

                {!isInline && external && (
-                    <span className="rounded bg-muted px-1 py-0.5 text-[10px] uppercase tracking-wide text-muted-foreground">
-                    new tab
-                    </span>
+                    <ExternalLink className="h-3 w-3 shrink-0 opacity-50" />
                )}
+                {isInline && <ChevronRight className="hidden h-3.5 w-3.5 shrink-0 opacity-0 transition group-hover:opacity-50 lg:block" />}
                </button>
            );
        })}
-        </div>
+        </div></aside>

-        {/* ⛔️ removed the old border/padding frame here */}
-        <Panel item={activeItem} />
+        <section className="min-w-0 overflow-hidden rounded-xl border border-border/70 bg-card/20 shadow-sm">
+            <Panel item={activeItem} />
+        </section>
        </div>
    );
 }
--- a/app/components/toolkit/ToolShell.tsx
+++ b/app/components/toolkit/ToolShell.tsx
@ -1,4 +1,3 @@
-import Link from "next/link";
 import { cn } from "@/lib/utils";

 type ToolShellProps = {
@ -19,31 +18,23 @@ export default function ToolShell({
  subtitle,
  className,
  children,
-  backHref = "/laser-toolkit",
-  backLabel = "Back to Toolkit",
 }: ToolShellProps) {
  const desc = description ?? subtitle;

  return (
-    <div className={cn("mx-auto w-full max-w-5xl px-4 py-6", className)}>
-      <div className="mb-6 flex items-start justify-between gap-4">
+    <div className={cn("w-full p-4 sm:p-5", className)}>
+      <div className="mb-4 flex items-start justify-between gap-4 border-b border-border/50 pb-4">
        <div>
-          <h1 className="text-2xl font-semibold tracking-tight">{title}</h1>
+          <div className="mb-1 text-[10px] uppercase tracking-[0.18em] text-accent">laser.calc</div>
+          <h1 className="text-xl font-semibold tracking-tight">{title}</h1>
          {desc ? (
            <p className="mt-1 text-sm text-muted-foreground">{desc}</p>
          ) : null}
        </div>

-        <Link
-          href={backHref}
-          className="inline-flex h-9 items-center rounded-md border border-input bg-background px-3 text-sm shadow-sm transition-colors hover:bg-accent hover:text-accent-foreground"
-        >
-          {backLabel}
-        </Link>
      </div>

      {children}
    </div>
  );
 }
-
--- a/app/components/utilities/laser-toolkit/beam-spot-size/page.tsx
+++ b/app/components/utilities/laser-toolkit/beam-spot-size/page.tsx
@ -10,7 +10,7 @@ function num(v: string) {
  return Number.isFinite(n) ? n : 0;
 }

-// Spot diameter (µm) ≈ 1.27 * M² * λ(µm) * f(mm) / D(mm)
+// Focused Gaussian 1/e² diameter: d = 4 M² λ f / (π D).
 export default function Page() {
  const [lambdaNm, setLambdaNm] = useState("1064"); // nm (default fiber)
  const [focalMm, setFocalMm] = useState("160");   // mm
@ -21,9 +21,9 @@ export default function Page() {
    const lamUm = num(lambdaNm) / 1000; // convert nm -> µm
    const f = num(focalMm);
    const D = num(beamDm);
-    const M2 = Math.max(1, num(m2));
-    if (lamUm <= 0 || f <= 0 || D <= 0) return 0;
-    return 1.27 * M2 * lamUm * (f / D);
+    const M2 = num(m2);
+    if (lamUm <= 0 || f <= 0 || D <= 0 || M2 < 1) return 0;
+    return (4 / Math.PI) * M2 * lamUm * (f / D);
  }, [lambdaNm, focalMm, beamDm, m2]);

  const dMm = dUm / 1000;
@ -71,7 +71,7 @@ export default function Page() {
        </CardHeader>
        <CardContent className="grid gap-3 sm:grid-cols-2">
          <div>
-            <div className="text-sm text-muted-foreground">Spot diameter</div>
+            <div className="text-sm text-muted-foreground">1/e² spot diameter</div>
            <div className="text-lg">{dMm.toFixed(4)} mm</div>
            <div className="text-xs text-muted-foreground">{dUm.toFixed(2)} µm</div>
          </div>
@ -82,7 +82,10 @@ export default function Page() {
          </div>
        </CardContent>
      </Card>
+      <p className="mt-4 text-xs leading-relaxed text-muted-foreground">
+        Gaussian-beam estimate: d = 4 M²λf/(πD), where D is the 1/e² beam diameter at the
+        lens. Real spots may be larger because of lens aberration, clipping, beam expansion, and focus error.
+      </p>
    </ToolShell>
  );
 }
-
--- a/app/components/utilities/laser-toolkit/hatch-overlap/page.tsx
+++ b/app/components/utilities/laser-toolkit/hatch-overlap/page.tsx
@ -29,11 +29,12 @@ export default function Page() {
    setGapUm(L > 0 ? (UM_PER_INCH / L).toFixed(2) : "");
  }

-  const overlap = useMemo(() => {
+  const coverage = useMemo(() => {
    const d = num(spotUm);
    const g = num(gapUm);
-    if (d <= 0 || g <= 0) return 0;
-    return Math.max(0, Math.min(100, 100 * (1 - g / d)));
+    if (d <= 0 || g <= 0) return { overlap: 0, uncovered: 0 };
+    const signed = 100 * (1 - g / d);
+    return { overlap: Math.max(0, signed), uncovered: Math.max(0, -signed) };
  }, [spotUm, gapUm]);

  const gapMm = (num(gapUm) / 1000) || 0;
@ -68,7 +69,10 @@ export default function Page() {
        <CardContent className="grid gap-3 sm:grid-cols-4">
          <div>
            <div className="text-sm text-muted-foreground">Overlap</div>
-            <div className="text-lg">{overlap.toFixed(1)}%</div>
+            <div className="text-lg">{coverage.overlap.toFixed(1)}%</div>
+            {coverage.uncovered > 0 && (
+              <div className="text-xs text-amber-600">{coverage.uncovered.toFixed(1)}% uncovered gap</div>
+            )}
          </div>
          <div>
            <div className="text-sm text-muted-foreground">Gap</div>
@ -83,10 +87,10 @@ export default function Page() {
          <div>
            <div className="text-sm text-muted-foreground">From LPI</div>
            <div className="text-lg">
-              {(UM_PER_INCH / Math.max(1, num(lpi)) / 1000).toFixed(4)} mm
+              {num(lpi) > 0 ? (UM_PER_INCH / num(lpi) / 1000).toFixed(4) : "0.0000"} mm
            </div>
            <div className="text-xs text-muted-foreground">
-              {(UM_PER_INCH / Math.max(1, num(lpi))).toFixed(1)} µm
+              {num(lpi) > 0 ? (UM_PER_INCH / num(lpi)).toFixed(1) : "0.0"} µm
            </div>
          </div>
        </CardContent>
@ -94,4 +98,3 @@ export default function Page() {
    </ToolShell>
  );
 }
-
--- a/app/components/utilities/laser-toolkit/job-time-estimator/page.tsx
+++ b/app/components/utilities/laser-toolkit/job-time-estimator/page.tsx
@ -44,7 +44,7 @@ export default function Page() {
      if (w <= 0 || h <= 0 || D <= 0 || v <= 0) return { t: 0, gapMm: 0, gapUm: 0, rows: 0 };
      const gapMm = 25.4 / D;
      const gapUm = gapMm * 1000;
-      const rows = h / gapMm;
+      const rows = Math.max(1, Math.ceil(h / gapMm));
      const t = rows * (w / v) * p * k;
      return { t, gapMm, gapUm, rows };
    } else {
@ -159,7 +159,7 @@ export default function Page() {
      {/* Footnote */}
      <p className="mt-4 text-xs leading-relaxed text-muted-foreground">
        <span className="font-semibold">Overhead factor*</span> accounts for real-world slowdowns:
-        acceleration/decelleration, jump moves, polygon delays, laser on/off timing, overscan,
+        acceleration/deceleration, jump moves, polygon delays, laser on/off timing, overscan,
        bidirectional settle time, and controller latency.{" "}
        <span className="font-semibold">Typical values:</span> Vector cuts/marks{" "}
        <span className="font-medium">1.05–1.15</span> (simple paths, long runs closer to 1.05; tiny
@ -171,4 +171,3 @@ export default function Page() {
    </ToolShell>
  );
 }
-
--- a/app/components/utilities/laser-toolkit/power-lens-scaler/page.tsx
+++ b/app/components/utilities/laser-toolkit/power-lens-scaler/page.tsx
@ -18,33 +18,10 @@ function clamp(v: number, lo: number, hi: number) {
  return Math.max(lo, Math.min(hi, v));
 }

-/** Default curve parameters based on rated power (very rough, editable). */
-function defaultCurveForRatedW(W: number) {
-  // Peak frequency guess (kHz). Tune these to your hardware fleet.
-  let fPeak = 50;
-  if (W <= 35) fPeak = 25;
-  else if (W <= 60) fPeak = 50;
-  else if (W <= 90) fPeak = 75;
-  else fPeak = 100;
-
-  // Log-normal width parameter (dimensionless). Smaller = narrower peak.
-  const sigma = 0.35;
-  return { fPeak, sigma };
-}
-
-/** Log-normal shaped efficiency curve normalized to 1 at fPeak. */
-function etaOfF(f_kHz: number, fPeak_kHz: number, sigma: number) {
-  const f = Math.max(f_kHz, 0.1);
-  const r = Math.log(f / Math.max(fPeak_kHz, 0.1));
-  const eta = Math.exp(-0.5 * (r / Math.max(sigma, 0.05)) ** 2);
-  // Keep within [0.1, 1] to avoid absurd zeros; adjust if you want tails to hit 0.
-  return clamp(eta, 0.1, 1);
-}
-
-/** Area factor from field (proxy for spot area scaling) */
-function areaFactorFromField(fieldSrc: number, fieldDst: number) {
-  if (fieldSrc <= 0 || fieldDst <= 0) return 1;
-  const r = fieldDst / fieldSrc;
+/** Circular spot-area ratio; pi/4 cancels. */
+function areaFactorFromDiameter(spotSrc: number, spotDst: number) {
+  if (spotSrc <= 0 || spotDst <= 0) return 1;
+  const r = spotDst / spotSrc;
  return r * r;
 }

@ -59,7 +36,7 @@ export default function Page() {
  const [hSrc, setHSrc] = useState('0.1');      // mm (raster line spacing)
  const [fSrc, setFSrc] = useState('30');       // kHz
  const [tauSrc, setTauSrc] = useState('100');  // ns pulse width
-  const [fieldSrc, setFieldSrc] = useState('110'); // mm
+  const [fieldSrc, setFieldSrc] = useState('60'); // µm, 1/e² spot diameter

  // DEST machine/lens
  const [wDst, setWDst] = useState('50');       // rated W
@ -67,16 +44,7 @@ export default function Page() {
  const [hDst, setHDst] = useState('0.1');      // mm
  const [fDst, setFDst] = useState('30');       // kHz
  const [tauDst, setTauDst] = useState('100');  // ns
-  const [fieldDst, setFieldDst] = useState('70');  // mm
-
-  // Curve tuning / advanced
-  const [advanced, setAdvanced] = useState(false);
-  const srcDefaults = defaultCurveForRatedW(num(wSrc, 50));
-  const dstDefaults = defaultCurveForRatedW(num(wDst, 50));
-  const [fPeakSrc, setFPeakSrc] = useState(String(srcDefaults.fPeak));
-  const [sigmaSrc, setSigmaSrc] = useState(String(srcDefaults.sigma));
-  const [fPeakDst, setFPeakDst] = useState(String(dstDefaults.fPeak));
-  const [sigmaDst, setSigmaDst] = useState(String(dstDefaults.sigma));
+  const [fieldDst, setFieldDst] = useState('40');  // µm

  // Prefer adjusting speed/freq instead of exceeding 100% power
  const [preferSpeedAdjust, setPreferSpeedAdjust] = useState(true);
@ -91,21 +59,11 @@ export default function Page() {
    const h2 = Math.max(num(hDst, 0), 0.000001);
    const f1k = Math.max(num(fSrc, 0), 0.1);
    const f2k = Math.max(num(fDst, 0), 0.1);
-    const tau1_ns = Math.max(num(tauSrc, 0), 0.1);
    const tau2_ns = Math.max(num(tauDst, 0), 0.1);
-    const aFac = areaFactorFromField(num(fieldSrc, 0), num(fieldDst, 0));
-
-    const fpk1 = Math.max(num(fPeakSrc, defaultCurveForRatedW(W1).fPeak), 0.1);
-    const sig1 = Math.max(num(sigmaSrc, defaultCurveForRatedW(W1).sigma), 0.05);
-    const fpk2 = Math.max(num(fPeakDst, defaultCurveForRatedW(W2).fPeak), 0.1);
-    const sig2 = Math.max(num(sigmaDst, defaultCurveForRatedW(W2).sigma), 0.05);
-
-    // Efficiency factors (0..1)
-    const eta1 = etaOfF(f1k, fpk1, sig1);
-    const eta2 = etaOfF(f2k, fpk2, sig2);
+    const aFac = areaFactorFromDiameter(num(fieldSrc, 0), num(fieldDst, 0));

    // Effective average power (W) after frequency efficiency
-    const P1eff = W1 * p1 * eta1;
+    const P1eff = W1 * p1;

    let p2Frac = p1; // destination power fraction (0..1)
    let suggestedSpeed: number | undefined;
@ -114,7 +72,7 @@ export default function Page() {
    // Helper: compute required P2eff for each match, then map to power%
    const powerPercentFromEff = (P2effReq: number) => {
      // P2eff = W2 * p2 * eta2  => p2 = P2eff / (W2*eta2)
-      return P2effReq / (W2 * eta2);
+      return P2effReq / W2;
    };

    if (mode === 'vector') {
@ -122,7 +80,7 @@ export default function Page() {
      const P2effReq = P1eff * (v2 / v1);
      p2Frac = powerPercentFromEff(P2effReq);
      if (preferSpeedAdjust && p2Frac > 1) {
-        suggestedSpeed = v1 * (W2 * eta2) / (W1 * eta1 * p1); // from p2<=1
+        suggestedSpeed = v1 * W2 / (W1 * p1); // from p2<=1
        p2Frac = 1;
      }
    } else if (mode === 'raster') {
@ -130,7 +88,7 @@ export default function Page() {
      const P2effReq = P1eff * ((v2 * h2) / (v1 * h1));
      p2Frac = powerPercentFromEff(P2effReq);
      if (preferSpeedAdjust && p2Frac > 1) {
-        suggestedSpeed = v1 * (W2 * eta2) * (h1 / h2) / (W1 * eta1 * p1);
+        suggestedSpeed = v1 * W2 * (h1 / h2) / (W1 * p1);
        p2Frac = 1;
      }
    } else if (mode === 'irradiance') {
@ -149,7 +107,7 @@ export default function Page() {
      if (preferSpeedAdjust && p2Frac > 1) {
        // Suggest lowering f2 to keep p2<=1: P2eff_max = W2*eta2*1
        // f2_req = P2eff_max / Ep1
-        const f2_req = (W2 * eta2) / Ep1; // Hz
+        const f2_req = W2 / Ep1; // Hz
        suggestedFreq_kHz = Math.max(f2_req / 1e3, 0.1);
        p2Frac = 1;
      }
@ -157,7 +115,7 @@ export default function Page() {

    // Compute pulse metrics (for display) using **destination** settings
    const p2Clamped = clamp(p2Frac, 0, 2);
-    const P2eff = W2 * p2Clamped * eta2;
+    const P2eff = W2 * p2Clamped;
    const f2Hz = f2k * 1e3;
    const tau2_s = tau2_ns * 1e-9;
    const Ep2 = P2eff / f2Hz; // J
@ -167,8 +125,6 @@ export default function Page() {
      p2Percent: clamp(p2Clamped * 100, 0, 200),
      suggestedSpeed,
      suggestedFreq_kHz,
-      eta1,
-      eta2,
      P1eff,
      P2eff,
      Ep2,
@ -177,13 +133,13 @@ export default function Page() {
    };
  }, [
    mode, wSrc, wDst, pSrc, vSrc, vDst, hSrc, hDst, fSrc, fDst, tauSrc, tauDst,
-    fieldSrc, fieldDst, preferSpeedAdjust, fPeakSrc, sigmaSrc, fPeakDst, sigmaDst,
+    fieldSrc, fieldDst, preferSpeedAdjust,
  ]);

  return (
    <ToolShell
      title="Power, Frequency & Lens Scaler"
-      description="Match settings across different lasers and lenses using effective power with a frequency efficiency curve. Includes pulse width to report pulse energy and peak power."
+      description="Translate a starting recipe by matching energy per length, energy per area, spot irradiance, or pulse energy."
    >
      <Card className="mb-6">
        <CardHeader>
@ -197,7 +153,7 @@ export default function Page() {
              <SelectContent>
                <SelectItem value="vector">Vector: Energy per length (J/mm)</SelectItem>
                <SelectItem value="raster">Raster: Energy per area (J/mm²)</SelectItem>
-                <SelectItem value="irradiance">Irradiance: W/mm² (spot/field)</SelectItem>
+                <SelectItem value="irradiance">Spot irradiance: W/mm²</SelectItem>
                <SelectItem value="pulse">Pulse energy: J (fiber)</SelectItem>
              </SelectContent>
            </Select>
@ -247,32 +203,11 @@ export default function Page() {
            <Input value={hSrc} onChange={(e) => setHSrc(e.target.value)} inputMode="decimal" />
          </div>
          <div>
-            <Label className="text-sm">Lens field size (mm)</Label>
+            <Label className="text-sm">1/e² spot diameter (µm)</Label>
            <Input value={fieldSrc} onChange={(e) => setFieldSrc(e.target.value)} inputMode="decimal" />
          </div>
        </CardContent>

-        <CardContent className="pt-0">
-          <button
-            className="text-xs underline text-muted-foreground"
-            onClick={() => setAdvanced((s) => !s)}
-          >
-            {advanced ? 'Hide' : 'Show'} advanced frequency curve
-          </button>
-          <div className={cn('mt-3 grid gap-4 md:grid-cols-3', advanced ? 'block' : 'hidden')}>
-            <div>
-              <Label className="text-sm">Peak freq fₚ (kHz)</Label>
-              <Input value={fPeakSrc} onChange={(e) => setFPeakSrc(e.target.value)} inputMode="decimal" />
-            </div>
-            <div>
-              <Label className="text-sm">Curve width σ (log-normal)</Label>
-              <Input value={sigmaSrc} onChange={(e) => setSigmaSrc(e.target.value)} inputMode="decimal" />
-            </div>
-            <div className="flex items-end text-xs text-muted-foreground">
-              η(f) is log-normal; 1.0 at fₚ, rolls off by σ.
-            </div>
-          </div>
-        </CardContent>
      </Card>

      {/* Destination */}
@ -302,26 +237,11 @@ export default function Page() {
            <Input value={hDst} onChange={(e) => setHDst(e.target.value)} inputMode="decimal" />
          </div>
          <div>
-            <Label className="text-sm">Lens field size (mm)</Label>
+            <Label className="text-sm">1/e² spot diameter (µm)</Label>
            <Input value={fieldDst} onChange={(e) => setFieldDst(e.target.value)} inputMode="decimal" />
          </div>
        </CardContent>

-        <CardContent className={cn('pt-0', advanced ? 'block' : 'hidden')}>
-          <div className="mt-3 grid gap-4 md:grid-cols-3">
-            <div>
-              <Label className="text-sm">Peak freq fₚ (kHz)</Label>
-              <Input value={fPeakDst} onChange={(e) => setFPeakDst(e.target.value)} inputMode="decimal" />
-            </div>
-            <div>
-              <Label className="text-sm">Curve width σ (log-normal)</Label>
-              <Input value={sigmaDst} onChange={(e) => setSigmaDst(e.target.value)} inputMode="decimal" />
-            </div>
-            <div className="flex items-end text-xs text-muted-foreground">
-              Adjust if you know your machine’s real power–frequency curve.
-            </div>
-          </div>
-        </CardContent>
      </Card>

      {/* Result */}
@ -348,11 +268,7 @@ export default function Page() {
            </p>
          )}

-          <div className="mt-3 grid gap-2 md:grid-cols-3 text-sm">
-            <div>
-              <div className="text-muted-foreground">η(f) source / dest</div>
-              <div className="font-medium">{result.eta1.toFixed(3)} / {result.eta2.toFixed(3)}</div>
-            </div>
+          <div className="mt-3 grid gap-2 md:grid-cols-2 text-sm">
            <div>
              <div className="text-muted-foreground">Dest pulse energy</div>
              <div className="font-medium">
@ -366,13 +282,12 @@ export default function Page() {
          </div>

          <p className="text-xs text-muted-foreground mt-2">
-            Assumptions: Effective power includes a frequency efficiency factor η(f). Peak power uses a rectangular pulse
-            approximation (shape factor ≈ 1). For real MOPA sources, pulse shape and
-            true power–frequency maps vary by model; adjust f<sub>p</sub> and σ if you have vendor curves.
+            Assumptions: displayed power percentage scales average output linearly, spots are circular,
+            and peak power uses a rectangular pulse approximation. Confirm the result with a low-power test;
+            real sources can have model-specific power limits versus frequency and pulse width.
          </p>
        </CardContent>
      </Card>
    </ToolShell>
  );
 }
-
--- a/app/components/utilities/laser-toolkit/pulse-overlap/page.tsx
+++ b/app/components/utilities/laser-toolkit/pulse-overlap/page.tsx
@ -21,16 +21,19 @@ export default function Page() {
    const dUm = num(spotUm);   // µm

    if (v <= 0 || f <= 0 || dUm <= 0) {
-      return { spacingUm: 0, spacingMm: 0, overlapPct: 0, pulsesPerMm: 0 };
+      return { spacingUm: 0, spacingMm: 0, overlapPct: 0, gapPct: 0, pulsesPerMm: 0, pulsesPerSpot: 0 };
    }

    // distance per pulse
    const spacingUm = v / f;           // µm  (derives from v(mm/s) / (f(kHz)*1000) * 1000)
    const spacingMm = spacingUm / 1000;
-    const overlapPct = Math.max(0, Math.min(100, 100 * (1 - spacingUm / dUm)));
+    const signedOverlapPct = 100 * (1 - spacingUm / dUm);
+    const overlapPct = Math.max(0, signedOverlapPct);
+    const gapPct = Math.max(0, -signedOverlapPct);
    const pulsesPerMm = (f * 1000) / v;
+    const pulsesPerSpot = dUm / spacingUm;

-    return { spacingUm, spacingMm, overlapPct, pulsesPerMm };
+    return { spacingUm, spacingMm, overlapPct, gapPct, pulsesPerMm, pulsesPerSpot };
  }, [speed, freq, spotUm]);

  return (
@ -68,20 +71,24 @@ export default function Page() {
          <div>
            <div className="text-sm text-muted-foreground">Overlap</div>
            <div className="text-lg">{result.overlapPct.toFixed(1)}%</div>
+            {result.gapPct > 0 && (
+              <div className="text-xs text-amber-600">{result.gapPct.toFixed(1)}% gap between pulses</div>
+            )}
          </div>
          <div>
            <div className="text-sm text-muted-foreground">Pulses per mm</div>
            <div className="text-lg">{result.pulsesPerMm.toFixed(1)}</div>
          </div>
          <div>
-            <div className="text-sm text-muted-foreground">Rule of thumb</div>
-            <div className="text-xs">
-              60–80% overlap is common for marking; deeper engraving often higher.
-            </div>
+            <div className="text-sm text-muted-foreground">Pulses per spot diameter</div>
+            <div className="text-lg">{result.pulsesPerSpot.toFixed(2)}</div>
          </div>
        </CardContent>
      </Card>
+      <p className="mt-4 text-xs leading-relaxed text-muted-foreground">
+        Geometric overlap along the scan direction only. It does not predict material response;
+        pulse energy, spot profile, hatch spacing, and thermal accumulation also matter.
+      </p>
    </ToolShell>
  );
 }
-
Author	SHA1	Message	Date
makearmy	305ea41ad3	improve utilities workspace navigation	2026-07-10 17:25:34 -04:00
makearmy	0855724cb0	fix laser utility calculations	2026-07-10 17:22:41 -04:00