fix: include downloaded CAD models in GLB and GLTF exports

cli/build/convert-model-urls-to-file-urls.ts

@@ -1,12 +1,15 @@
+import { existsSync } from "node:fs"
 import path from "node:path"
 import { pathToFileURL } from "node:url"
 
 /**
- * Convert local file paths in model URLs to file:// URLs for fetch() compatibility.
- * The circuit-json-to-gltf library uses fetch() to load GLB/STL/OBJ/GLTF files,
- * which requires proper URLs rather than local file paths.
+ * Resolve local model paths before the converter applies its registry base URL.
+ * Keep assets as file references so loaders can read them on demand.
  */
-export const convertModelUrlsToFileUrls = (circuitJson: any[]): any[] => {
+export const convertModelUrlsToFileUrls = (
+  circuitJson: any[],
+  projectDir = process.cwd(),
+): any[] => {
   const modelUrlKeys = [
     "model_glb_url",
     "glb_model_url",
@@ -30,12 +33,17 @@ export const convertModelUrlsToFileUrls = (circuitJson: any[]): any[] => {
         // Skip values that are already URLs (http://, https://, file://, etc.)
         if (value.match(/^[a-zA-Z]+:\/\//)) continue
 
+        const localPath = path.resolve(projectDir, value)
+        // Uninstalled package assets still need the registry URL resolver.
+        if (/^(\.\/)?node_modules\//.test(value) && !existsSync(localPath))
+          continue
+
         if (value.startsWith("/") || value.match(/^[a-zA-Z]:\\/)) {
           // Absolute path (Unix or Windows)
           updated[key] = pathToFileURL(value).href
-        } else if (value.startsWith(".")) {
+        } else if (value.startsWith(".") || existsSync(localPath)) {
           // Relative path (e.g. ./chip.glb) — resolve against cwd
-          updated[key] = pathToFileURL(path.resolve(process.cwd(), value)).href
+          updated[key] = pathToFileURL(localPath).href
         }
       }
     }

lib/shared/export-snippet.ts

@@ -37,6 +37,7 @@ import { convertCircuitJsonToSchematicPdf } from "./convert-circuit-json-to-sche
 import { convertToKicadLibrary } from "./convert-to-kicad-library"
 import { importFromUserLand } from "./importFromUserLand"
 import { isCircuitJsonFile } from "./is-circuit-json-file"
+import { convertModelUrlsToFileUrls } from "cli/build/convert-model-urls-to-file-urls"
 
 const writeFileAsync = promisify(fs.writeFile)
 
@@ -230,7 +231,7 @@ export const exportSnippet = async ({
     case "gltf":
       outputContent = JSON.stringify(
         await convertCircuitJsonToGltf(
-          circuitJson,
+          convertModelUrlsToFileUrls(circuitJson),
           getCircuitJsonToGltfOptions({ format: "gltf" }),
         ),
         null,
@@ -240,7 +241,7 @@ export const exportSnippet = async ({
     case "glb":
       outputContent = Buffer.from(
         (await convertCircuitJsonToGltf(
-          circuitJson,
+          convertModelUrlsToFileUrls(circuitJson),
           getCircuitJsonToGltfOptions({ format: "glb" }),
         )) as ArrayBuffer,
       )

lib/shared/get-circuit-json-to-gltf-options.ts

@@ -3,6 +3,7 @@ import {
   getSessionToken,
   getSessionTokenFromNpmrc,
 } from "lib/cli-config"
+import { nodeFilesystem } from "./node-filesystem"
 
 type CircuitJsonToGltfFormat = "gltf" | "glb"
 
@@ -16,6 +17,7 @@ export const getCircuitJsonToGltfOptions = ({
   return {
     format,
     projectBaseUrl: getRegistryApiUrl(),
+    fs: nodeFilesystem,
     ...(sessionToken
       ? { authHeaders: { Authorization: `Bearer ${sessionToken}` } }
       : {}),

lib/shared/node-filesystem.ts

@@ -0,0 +1,6 @@
+import { readFile } from "node:fs/promises"
+
+/** Filesystem capability passed to circuit-json-to-gltf for local CAD files. */
+export const nodeFilesystem = {
+  readFile: async (fileUrl: URL) => new Uint8Array(await readFile(fileUrl)),
+}

tests/cli/export/export-downloaded-model.test.ts

@@ -0,0 +1,54 @@
+import { expect, test } from "bun:test"
+import { mkdir, readFile, writeFile } from "node:fs/promises"
+import path from "node:path"
+import { getCliTestFixture } from "../../fixtures/get-cli-test-fixture"
+
+// Same nested static-asset import structure produced by tsci import --download.
+const obj = "v 0 0 0\nv 2 0 0\nv 0 2 0\nf 1 2 3\n"
+
+for (const format of ["glb", "gltf"] as const) {
+  test(`export ${format} includes geometry from a downloaded OBJ`, async () => {
+    const { tmpDir, runCommand } = await getCliTestFixture()
+    const componentDir = path.join(tmpDir, "imports", "DownloadedPart")
+    await mkdir(componentDir, { recursive: true })
+    await writeFile(path.join(componentDir, "part.obj"), obj)
+    await writeFile(
+      path.join(componentDir, "part.tsx"),
+      `
+import objPath from "./part.obj"
+export const DownloadedPart = () => (
+  <chip name="U1" footprint="soic8" cadModel={{ objUrl: objPath }} />
+)
+`,
+    )
+    await writeFile(
+      path.join(tmpDir, "index.tsx"),
+      `
+import { DownloadedPart } from "./imports/DownloadedPart/part"
+export default () => <board width="20mm" height="20mm"><DownloadedPart /></board>
+`,
+    )
+    const result = await runCommand(`tsci export index.tsx -f ${format}`)
+    expect(result.exitCode).toBe(0)
+    const output = await readFile(path.join(tmpDir, `index.${format}`))
+    const gltf = JSON.parse(
+      format === "glb"
+        ? output.subarray(20, 20 + output.readUInt32LE(12)).toString()
+        : output.toString(),
+    )
+    const component = gltf.nodes.find(
+      (node: { name?: string }) => node.name === "U1",
+    )
+    expect(component).toBeDefined()
+    const primitives = gltf.meshes[component.mesh].primitives
+    const vertexCount = primitives.reduce(
+      (total: number, primitive: any) =>
+        total + gltf.accessors[primitive.attributes.POSITION].count,
+      0,
+    )
+    expect(vertexCount).toBe(3)
+    expect(await readFile(path.join(componentDir, "part.obj"), "utf8")).toBe(
+      obj,
+    )
+  }, 30000)
+}

tests/shared/convert-model-urls-to-file-urls.test.ts

@@ -0,0 +1,40 @@
+import { expect, test } from "bun:test"
+import { mkdtemp, rm, writeFile } from "node:fs/promises"
+import { tmpdir } from "node:os"
+import path from "node:path"
+import { pathToFileURL } from "node:url"
+import { convertModelUrlsToFileUrls } from "cli/build/convert-model-urls-to-file-urls"
+
+test("local models remain file references and Circuit JSON is not mutated", async () => {
+  const dir = await mkdtemp(path.join(tmpdir(), "tsci-model-paths-"))
+  try {
+    const file = path.join(dir, "part with spaces.obj")
+    await writeFile(file, "v 0 0 0")
+    const urls = [
+      "./part with spaces.obj",
+      "part with spaces.obj",
+      file,
+      pathToFileURL(file).href,
+    ]
+    const input = urls.map((url) => ({
+      type: "cad_component",
+      model_obj_url: url,
+    }))
+    const output = convertModelUrlsToFileUrls(input, dir)
+    expect(output.map((element) => element.model_obj_url)).toEqual(
+      urls.map(() => pathToFileURL(file).href),
+    )
+    expect(input.map((element) => element.model_obj_url)).toEqual(urls)
+  } finally {
+    await rm(dir, { recursive: true, force: true })
+  }
+})
+
+test("remote URLs and uninstalled registry assets retain their resolver", () => {
+  const input = [
+    { model_obj_url: "https://example.com/part.obj" },
+    { model_obj_url: "data:application/octet-stream;base64,dGVzdA==" },
+    { model_obj_url: "./node_modules/@tsci/not-installed.part/part.obj" },
+  ]
+  expect(convertModelUrlsToFileUrls(input)).toEqual(input)
+})

tests/shared/node-filesystem.test.ts

@@ -0,0 +1,18 @@
+import { expect, test } from "bun:test"
+import { mkdtemp, rm, writeFile } from "node:fs/promises"
+import { tmpdir } from "node:os"
+import path from "node:path"
+import { pathToFileURL } from "node:url"
+import { nodeFilesystem } from "lib/shared/node-filesystem"
+
+test("node filesystem reads exact bytes from a file URL", async () => {
+  const dir = await mkdtemp(path.join(tmpdir(), "tsci-node-fs-"))
+  try {
+    const file = path.join(dir, "model #1%.obj")
+    const bytes = new Uint8Array([0, 127, 128, 255])
+    await writeFile(file, bytes)
+    expect(await nodeFilesystem.readFile(pathToFileURL(file))).toEqual(bytes)
+  } finally {
+    await rm(dir, { recursive: true, force: true })
+  }
+})