fix(export): single-source freehand recipe screen+export (P0 step 7, R7)

pdf_service._buildFreehandPdfPath hardcoded its OWN StrokeOptions
(thinning:0.7, streamline:0.5) instead of the shared geometry — the R7
hairline-export divergence. The prior pen-feel commit (streamline 0.5→0.32 on
screen) widened the gap: export still rendered at 0.5.

Extract the ONE perfect_freehand recipe into stroke_geometry.freehandOutlinePoints
(owns thinning/smoothing/streamline/simulatePressure). buildStrokeOutline (screen)
and pdf_service (export, via InkStroke→pfPoints) now both call it, so the
StrokeOptions live in exactly one place and screen↔export can't drift again.
Export now matches screen: thinning 0.85 (kDefaultPenThinning), streamline 0.32.

test/export_geometry_test.dart pins it: buildStrokeOutline traces exactly the
shared outline; default thinning == kDefaultPenThinning; thinning is wired;
empty input is safe.

flutter analyze lib/editor clean; 78/78 tests pass (+4).

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

lib/editor/engine/stroke_geometry.dart

@@ -32,6 +32,45 @@ const double kDefaultPenThinning = 0.85;
 const double kPenStreamline = 0.32;
 const double kPenSmoothing = 0.5;
 
+/// THE single perfect_freehand outline recipe — the raw outline points for a
+/// stroke. Both the on-screen painter ([buildStrokeOutline] / the live
+/// `ink_painters.buildStrokePath`) and the PDF export
+/// (`pdf_service._buildFreehandPdfPath`) call THIS, so the `StrokeOptions`
+/// (thinning / smoothing / streamline / simulatePressure) live in exactly one
+/// place and screen↔export can never drift again (R7 — the hairline-export bug
+/// was pdf_service hardcoding its own `thinning: 0.7, streamline: 0.5`).
+///
+/// Callers supply already-pixel-scaled [pfPoints] (because the two stroke
+/// models scale differently) plus the per-stroke flags. Returns the closed
+/// outline as `List<Offset>` (perfect_freehand 2.x); empty when freehand
+/// produces nothing.
+List<Offset> freehandOutlinePoints({
+  required List<pf.PointVector> pfPoints,
+  required double size,
+  required bool isHighlighter,
+  required bool hasRealPressure,
+  required bool isComplete,
+  double thinning = kDefaultPenThinning,
+}) {
+  if (pfPoints.isEmpty) return const <Offset>[];
+  return pf.getStroke(
+    pfPoints,
+    options: pf.StrokeOptions(
+      size: size,
+      // Highlighter keeps a constant width (no thinning); pen uses the
+      // configurable [thinning] so Surface-Pen pressure changes width.
+      thinning: isHighlighter ? 0.0 : thinning,
+      smoothing: kPenSmoothing,
+      streamline: kPenStreamline,
+      // Real stylus pressure -> don't simulate; no pressure -> let freehand
+      // fake it based on velocity (highlighter never simulates). perfect_freehand
+      // 2.x honors real pressure when simulatePressure is false.
+      simulatePressure: !hasRealPressure && !isHighlighter,
+      isComplete: isComplete,
+    ),
+  );
+}
+
 /// Builds a closed, fillable outline [Path] for one [stroke], scaled into the
 /// pixel space of [pageSize] (which maps normalized [0,1] coords to pixels).
 ///
@@ -52,11 +91,6 @@ Path buildStrokeOutline(
   final path = Path();
   if (stroke.points.isEmpty) return path;
 
-  final pixelWidth = stroke.width * pageSize.width;
-
-  final hasRealPressure = stroke.points.any((p) => p.pressure != null);
-  final isHighlighter = stroke.tool == EditorTool.highlighter;
-
   final pfPoints = stroke.points
       .map(
         (p) => pf.PointVector(
@@ -67,21 +101,13 @@ Path buildStrokeOutline(
       )
       .toList();
 
-  final outline = pf.getStroke(
-    pfPoints,
-    options: pf.StrokeOptions(
-      size: pixelWidth,
-      // Highlighter keeps a constant width (no thinning); pen uses the
-      // configurable [thinning] so Surface-Pen pressure changes width.
-      thinning: isHighlighter ? 0.0 : thinning,
-      smoothing: kPenSmoothing,
-      streamline: kPenStreamline,
-      // Real stylus pressure -> don't simulate; no pressure -> let freehand
-      // fake it based on velocity (highlighter never simulates). perfect_freehand
-      // 2.x honors real pressure when simulatePressure is false.
-      simulatePressure: !hasRealPressure && !isHighlighter,
-      isComplete: isComplete,
-    ),
+  final outline = freehandOutlinePoints(
+    pfPoints: pfPoints,
+    size: stroke.width * pageSize.width,
+    isHighlighter: stroke.tool == EditorTool.highlighter,
+    hasRealPressure: stroke.points.any((p) => p.pressure != null),
+    isComplete: isComplete,
+    thinning: thinning,
   );
 
   if (outline.isEmpty) return path;

lib/services/pdf_service.dart

@@ -8,6 +8,7 @@ import 'package:path_provider/path_provider.dart';
 import 'package:perfect_freehand/perfect_freehand.dart' as pf;
 import 'package:syncfusion_flutter_pdf/pdf.dart';
 
+import '../editor/engine/stroke_geometry.dart' show freehandOutlinePoints;
 import '../models/ink_stroke.dart';
 import '../models/pen_tool.dart';
 
@@ -304,19 +305,15 @@ class PdfService {
         )
         .toList();
 
-    final outline = pf.getStroke(
-      pfPoints,
-      options: pf.StrokeOptions(
-        size: pixelWidth,
-        // Highlighter keeps constant width; pen/marker taper via thinning=0.7.
-        thinning: isHighlighter ? 0.0 : 0.7,
-        smoothing: 0.5,
-        streamline: 0.5,
-        // Real stylus pressure -> don't simulate; no pressure -> let freehand
-        // fake it based on velocity. Highlighter never simulates.
-        simulatePressure: !hasRealPressure && !isHighlighter,
-        isComplete: true,
-      ),
+    // ONE shared recipe with the on-screen painter (R7): export can no longer
+    // drift from screen. Previously this hardcoded thinning:0.7/streamline:0.5,
+    // which diverged from the screen's 0.85/0.32 → hairline export mismatch.
+    final outline = freehandOutlinePoints(
+      pfPoints: pfPoints,
+      size: pixelWidth,
+      isHighlighter: isHighlighter,
+      hasRealPressure: hasRealPressure,
+      isComplete: true,
     );
 
     if (outline.isEmpty) return null;

test/export_geometry_test.dart

@@ -0,0 +1,117 @@
+// R7 regression (P0 step 7/8): the on-screen painter and the PDF export must
+// build their freehand outline from ONE shared recipe. The export bug was
+// pdf_service hardcoding `thinning: 0.7, streamline: 0.5` while the screen used
+// 0.85 / 0.32 — a hairline mismatch. These tests pin the single source so a
+// future edit to one side can't silently re-diverge.
+
+import 'dart:ui';
+
+import 'package:flutter_test/flutter_test.dart';
+import 'package:perfect_freehand/perfect_freehand.dart' as pf;
+
+import 'package:badnote/editor/engine/stroke_geometry.dart';
+import 'package:badnote/editor/engine/stroke_model.dart';
+
+void main() {
+  const size = Size(800, 600);
+
+  EditorStroke pen() => EditorStroke.create(
+        id: 'a',
+        points: const [
+          EditorPoint(x: 0.1, y: 0.1, pressure: 0.9),
+          EditorPoint(x: 0.4, y: 0.2, pressure: 0.5),
+          EditorPoint(x: 0.7, y: 0.15, pressure: 0.2),
+        ],
+        width: 0.01,
+      );
+
+  test('buildStrokeOutline traces exactly the shared freehandOutlinePoints', () {
+    final stroke = pen();
+    final pfPoints = stroke.points
+        .map((p) => pf.PointVector(
+            p.x * size.width, p.y * size.height, p.pressure ?? 0.5))
+        .toList();
+    final shared = freehandOutlinePoints(
+      pfPoints: pfPoints,
+      size: stroke.width * size.width,
+      isHighlighter: false,
+      hasRealPressure: true,
+      isComplete: true,
+    );
+    expect(shared, isNotEmpty);
+
+    final ref = Path()..moveTo(shared.first.dx, shared.first.dy);
+    for (var i = 1; i < shared.length; i++) {
+      ref.lineTo(shared[i].dx, shared[i].dy);
+    }
+    ref.close();
+
+    final screen = buildStrokeOutline(stroke, size, isComplete: true);
+    // Same vertices ⇒ identical bounds. (If the screen path used different
+    // options than the shared core, the outline would differ.)
+    expect(screen.getBounds(), ref.getBounds());
+  });
+
+  test('default thinning IS kDefaultPenThinning (export passes the default)', () {
+    final pts = [
+      pf.PointVector(10, 10, 0.9),
+      pf.PointVector(100, 40, 0.5),
+      pf.PointVector(200, 30, 0.2),
+    ];
+    final byDefault = freehandOutlinePoints(
+      pfPoints: pts,
+      size: 8,
+      isHighlighter: false,
+      hasRealPressure: true,
+      isComplete: true,
+    );
+    final explicit = freehandOutlinePoints(
+      pfPoints: pts,
+      size: 8,
+      isHighlighter: false,
+      hasRealPressure: true,
+      isComplete: true,
+      thinning: kDefaultPenThinning,
+    );
+    expect(byDefault, explicit);
+  });
+
+  test('thinning actually changes the outline (param is wired, not ignored)',
+      () {
+    final pts = [
+      pf.PointVector(10, 10, 0.9),
+      pf.PointVector(100, 40, 0.5),
+      pf.PointVector(200, 30, 0.2),
+    ];
+    final strong = freehandOutlinePoints(
+      pfPoints: pts,
+      size: 8,
+      isHighlighter: false,
+      hasRealPressure: true,
+      isComplete: true,
+      thinning: kDefaultPenThinning,
+    );
+    final none = freehandOutlinePoints(
+      pfPoints: pts,
+      size: 8,
+      isHighlighter: false,
+      hasRealPressure: true,
+      isComplete: true,
+      thinning: 0.0,
+    );
+    expect(strong, isNot(equals(none)));
+  });
+
+  test('empty input yields an empty outline (no crash)', () {
+    expect(
+      freehandOutlinePoints(
+        pfPoints: const [],
+        size: 8,
+        isHighlighter: false,
+        hasRealPressure: false,
+        isComplete: true,
+      ),
+      isEmpty,
+    );
+  });
+}