Service caps stitch objects at 50,000 (and the design's maxStitchCount is 200,000) but the export dialog has no client-side guard — large designs fail at export with a 422 instead of pre-flight warning #169

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opened 2026-10-03 17:30:29 +00:00 by Mark · 1 comment

Mark commented

2026-10-03 17:30:29 +00:00

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Finding

The service's StitchObject schema declares maxItems: 50000 for the stitchObjects array (POST /v1/export). The machine profile's limits.maxStitchCount is 200,000 (per src/lib/easystitch-client.ts:36-78, all 6 machines cap at 200k).

The Export dialog (src/components/workspace/ExportDialog.tsx) does not pre-check the design's stitch count or object count before calling exportPES. A user with a dense design that exceeds the limit:

Configures format, picks PES
Clicks Export
The service returns 422 with a maxItems violation
The dialog's useAsyncState catches the error, dispatches an error toast with the service message
The user sees "Export failed: ... 50,000 maxItems" — they have to figure out the implication (this isn't a transient failure, the design is too large)

The user should see a pre-flight warning: "This design has 78,000 stitches, which exceeds the 50,000 limit. Consider reducing density or splitting the design." before they click Export.

Where

Service schema: POST /v1/export request body, stitchObjects field (verified at runtime via /openapi.json)
Machine profile limits: src/lib/easystitch-client.ts:36-78 (200,000 across all 6 machines)
Export dialog: src/components/workspace/ExportDialog.tsx:exportRequest (line 64-75) — no pre-flight check
Service response: returns 422 with extra_forbidden / maxItems violation

Suggested fix shape

Add a pre-flight check to exportRequest in ExportDialog.tsx:

Compute stitch count from stitchObjects:

const totalStitches = stitchObjects.reduce((sum, o) => sum + (o.stitchCount ?? 0), 0);

Check against limits:

const profile = MACHINE_PROFILES[designSettings.machineProfile];
const objLimit = 50_000; // service's maxItems for the request body
if (stitchObjects.length > objLimit) {
  throw new Error(`Too many objects: ${stitchObjects.length} > ${objLimit}`);
}
if (totalStitches > profile.limits.maxStitchCount) {
  throw new Error(`Too many stitches: ${totalStitches} > ${profile.limits.maxStitchCount}`);
}

Surface in the UI: in the dialog's body, near the format buttons, render:
```
This design: 45,231 stitches across 12 objects (PR-1050X limit: 200,000 stitches)
```
If the design is over the limit, render an inline warning (similar to the inlineError at line 295) and disable the Export button.
Show the count from the design — the workspace already tracks stitchCount per object; the total is a sum.

Severity

Medium. Users with realistic designs hit this and get a confusing error. Pre-flight checking makes the limit visible before the user clicks Export.

Discovered by

Gap analysis (2026-10-02) of export affordances.

#114 (closed) — verified the export flow works. Didn't include the size cap test.
#136 (closed) — added machine profile definitions. The limits field is now defined; this issue consumes it.

## Finding The service's `StitchObject` schema declares `maxItems: 50000` for the `stitchObjects` array (`POST /v1/export`). The machine profile's `limits.maxStitchCount` is 200,000 (per `src/lib/easystitch-client.ts:36-78`, all 6 machines cap at 200k). The Export dialog (`src/components/workspace/ExportDialog.tsx`) does not pre-check the design's stitch count or object count before calling `exportPES`. A user with a dense design that exceeds the limit: 1. Configures format, picks PES 2. Clicks Export 3. The service returns 422 with a `maxItems` violation 4. The dialog's `useAsyncState` catches the error, dispatches an error toast with the service message 5. The user sees "Export failed: ... 50,000 maxItems" — they have to figure out the implication (this isn't a transient failure, the design is too large) The user should see a pre-flight warning: "This design has 78,000 stitches, which exceeds the 50,000 limit. Consider reducing density or splitting the design." before they click Export. ## Where - Service schema: `POST /v1/export` request body, `stitchObjects` field (verified at runtime via `/openapi.json`) - Machine profile limits: `src/lib/easystitch-client.ts:36-78` (200,000 across all 6 machines) - Export dialog: `src/components/workspace/ExportDialog.tsx:exportRequest` (line 64-75) — no pre-flight check - Service response: returns 422 with `extra_forbidden` / `maxItems` violation ## Suggested fix shape Add a pre-flight check to `exportRequest` in `ExportDialog.tsx`: 1. **Compute stitch count** from `stitchObjects`: ```ts const totalStitches = stitchObjects.reduce((sum, o) => sum + (o.stitchCount ?? 0), 0); ``` 2. **Check against limits**: ```ts const profile = MACHINE_PROFILES[designSettings.machineProfile]; const objLimit = 50_000; // service's maxItems for the request body if (stitchObjects.length > objLimit) { throw new Error(`Too many objects: ${stitchObjects.length} > ${objLimit}`); } if (totalStitches > profile.limits.maxStitchCount) { throw new Error(`Too many stitches: ${totalStitches} > ${profile.limits.maxStitchCount}`); } ``` 3. **Surface in the UI**: in the dialog's body, near the format buttons, render: ``` This design: 45,231 stitches across 12 objects (PR-1050X limit: 200,000 stitches) ``` If the design is over the limit, render an inline warning (similar to the `inlineError` at line 295) and disable the Export button. 4. **Show the count from the design** — the workspace already tracks `stitchCount` per object; the total is a sum. ## Severity Medium. Users with realistic designs hit this and get a confusing error. Pre-flight checking makes the limit visible before the user clicks Export. ## Discovered by Gap analysis (2026-10-02) of export affordances. ## Related - #114 (closed) — verified the export flow works. Didn't include the size cap test. - #136 (closed) — added machine profile definitions. The `limits` field is now defined; this issue consumes it.

Mark added the

feature-request

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2026-10-03 17:30:29 +00:00

Mark referenced this issue from a commit

2026-10-03 18:06:47 +00:00

fix(#169): pre-flight size guard in Export dialog

Mark commented

2026-10-03 18:06:54 +00:00

Author

Owner

Fixed via 61239e2 on main. Pre-flight size guard added to ExportDialog:

New size summary line under the hoop confirmation showing stitch + object totals and the active machine limit (data-testid export-size-summary); goes red when over the stitch cap.
Export button disabled when either limit is exceeded.
handleExport short-circuits with the existing inline-error banner when either limit trips, with a clear remediation hint.

24/24 ExportDialog tests, 711/711 repo tests, clean tsc + eslint.

Fixed via 61239e2 on main. Pre-flight size guard added to ExportDialog: - New size summary line under the hoop confirmation showing stitch + object totals and the active machine limit (data-testid `export-size-summary`); goes red when over the stitch cap. - Export button disabled when either limit is exceeded. - handleExport short-circuits with the existing inline-error banner when either limit trips, with a clear remediation hint. 24/24 ExportDialog tests, 711/711 repo tests, clean tsc + eslint.

Mark closed this issue

2026-10-03 18:07:03 +00:00