fix(queue): update queue item status before archive lookup early return

The queue item status update (printing → completed/failed) was placed
after `if not archive_id: return` in on_print_complete. When archive
lookup failed (app restart mid-print, manual deletion), the function
returned early and the queue item stayed stuck in "printing" forever.

Over multiple print cycles, stale items accumulated — showing double
the actual printer count in the "Printing" stat and completed prints
remaining in the "Currently Printing" section.

Move the entire queue item status update block (status transition,
MQTT relay, queue-completed notification, auto-power-off) to before
the archive_id early return, matching the pattern used for SD card
cleanup.

CHANGELOG.md

@@ -41,6 +41,7 @@ All notable changes to Bambuddy will be documented in this file.
 - **K-Profile Auto-Select Fails for Non-BL Spools on Dual-Nozzle Printers** — When assigning a third-party spool to an AMS slot on dual-nozzle printers (H2D, H2D Pro), the MQTT auto-configure step crashed with `'SpoolKProfile' object has no attribute 'extruder_id'`. The K-profile model uses `extruder` (not `extruder_id`). Fixed the attribute name so K-profile matching correctly filters by nozzle on dual-extruder printers.
 - **Loose Archive Name Matching Could Cause Wrong Archive Reuse** ([#374](https://github.com/maziggy/bambuddy/issues/374)) — The `on_print_start` callback used `ilike('%{name}%')` to find existing "printing" archives, which meant a print named "Clip" could incorrectly match "Cable Clip" or "Clip Stand". This could cause a new print to reuse the wrong archive or skip creating one. Tightened to exact `print_name` match or exact filename variants (`.3mf`, `.gcode.3mf`).
 - **Phantom Prints on Power Cycle** ([#374](https://github.com/maziggy/bambuddy/issues/374)) — The print queue uploaded `.3mf` files to the printer's SD card root (`/`) but never deleted them after the print finished. Some printers (e.g. P1S) auto-start files found in the root directory on power cycle, causing ghost prints on every reboot. Now deletes the uploaded file from the SD card after print completion (best-effort, non-blocking). The cleanup also tries `.gcode` files and retries up to 3 times with a 2-second delay to handle printers that briefly lock the filesystem after a print ends. Runs before the archive lookup so it works even when auto-archiving is disabled.
+- **Queue Items Stuck in "Printing" After Print Completes** — The queue item status update (from `printing` to `completed`/`failed`) was placed after an early return that exits when the archive record cannot be found. If the archive lookup failed (e.g. app restart mid-print, manual archive deletion), the function returned early and the queue item stayed in `printing` forever. Over multiple print cycles, stale items accumulated — causing the "Printing" count to show double the actual printers and completed prints to remain in the "Currently Printing" section. Moved the queue item status update (including MQTT relay notification, queue-completed notification, and auto-power-off) to before the archive lookup early return so it always runs.
 - **Spool Form Scrollbar Flicker in Edge** ([#364](https://github.com/maziggy/bambuddy/issues/364)) — The Add/Edit Spool modal's scrollable area used `overflow-y: auto`, which on Windows Edge (where scrollbars take layout space) caused the scrollbar to appear and disappear on hover — making the color picker unusable at certain zoom levels. Added `scrollbar-gutter: stable` to reserve scrollbar space and prevent layout thrashing.
 - **Archive Duplicate Badge Misses Name-Based Duplicates** ([#315](https://github.com/maziggy/bambuddy/issues/315)) — The duplicate badge on archive cards only matched by file content hash, so re-sliced prints of the same model (different GCODE, same print name) were not flagged as duplicates. Now also matches by print name (case-insensitive), consistent with the detail view's duplicate detection.
 - **Schedule Print Allows No Plate Selected for Multi-Plate Files** ([#394](https://github.com/maziggy/bambuddy/issues/394)) — When scheduling a multi-plate file from the file manager, the modal showed a "Selection required" warning but still allowed submission without selecting a plate. The job defaulted to plate 1, but the queue item didn't indicate which plate, and editing showed no plate selected. Now auto-selects the first plate by default when plates load, and the submit button validation applies to both archive and library files.

backend/app/main.py

@@ -2132,6 +2132,98 @@ async def on_print_complete(printer_id: int, data: dict):
 
     log_timing("SD card cleanup")
 
+    # Update queue item status early — must run before the archive_id early-return
+    # so queue items don't get stuck in "printing" when archive lookup fails.
+    try:
+        async with async_session() as db:
+            from backend.app.models.print_queue import PrintQueueItem
+
+            result = await db.execute(
+                select(PrintQueueItem)
+                .where(PrintQueueItem.printer_id == printer_id)
+                .where(PrintQueueItem.status == "printing")
+            )
+            printing_items = list(result.scalars().all())
+            if len(printing_items) > 1:
+                logger.warning(
+                    "BUG: Multiple queue items in 'printing' status for printer %s: %s",
+                    printer_id,
+                    [(i.id, i.archive_id, i.library_file_id) for i in printing_items],
+                )
+            queue_item = printing_items[0] if printing_items else None
+            if queue_item:
+                queue_status = data.get("status", "completed")
+                queue_item.status = queue_status
+                queue_item.completed_at = datetime.now()
+                await db.commit()
+                logger.info("Updated queue item %s status to %s", queue_item.id, queue_status)
+
+                # MQTT relay - publish queue job completed
+                try:
+                    printer_info = printer_manager.get_printer(printer_id)
+                    await mqtt_relay.on_queue_job_completed(
+                        job_id=queue_item.id,
+                        filename=filename or subtask_name,
+                        printer_id=printer_id,
+                        printer_name=printer_info.name if printer_info else "Unknown",
+                        status=queue_status,
+                    )
+                except Exception:
+                    pass  # Don't fail if MQTT fails
+
+                # Check if queue is now empty and send notification
+                try:
+                    from sqlalchemy import func as sa_func
+
+                    count_result = await db.execute(
+                        select(sa_func.count(PrintQueueItem.id)).where(PrintQueueItem.status == "pending")
+                    )
+                    pending_count = count_result.scalar() or 0
+
+                    if pending_count == 0:
+                        today_start = datetime.now().replace(hour=0, minute=0, second=0, microsecond=0)
+                        completed_result = await db.execute(
+                            select(sa_func.count(PrintQueueItem.id)).where(
+                                PrintQueueItem.status.in_(["completed", "failed", "skipped"]),
+                                PrintQueueItem.completed_at >= today_start,
+                            )
+                        )
+                        completed_count = completed_result.scalar() or 1
+
+                        await notification_service.on_queue_completed(
+                            completed_count=completed_count,
+                            db=db,
+                        )
+                except Exception:
+                    pass  # Don't fail if notification fails
+
+                # Handle auto_off_after - power off printer if requested (after cooldown)
+                if queue_item.auto_off_after:
+                    result = await db.execute(select(SmartPlug).where(SmartPlug.printer_id == printer_id))
+                    plug = result.scalar_one_or_none()
+                    if plug and plug.enabled:
+                        logger.info("Auto-off requested for printer %s, waiting for cooldown...", printer_id)
+
+                        async def cooldown_and_poweroff(pid: int, plug_id: int):
+                            # Wait for nozzle to cool down
+                            await printer_manager.wait_for_cooldown(pid, target_temp=50.0, timeout=600)
+                            # Re-fetch plug in new session
+                            async with async_session() as new_db:
+                                result = await new_db.execute(select(SmartPlug).where(SmartPlug.id == plug_id))
+                                p = result.scalar_one_or_none()
+                                if p and p.enabled:
+                                    success = await tasmota_service.turn_off(p)
+                                    if success:
+                                        logger.info("Powered off printer %s via smart plug '%s'", pid, p.name)
+                                    else:
+                                        logger.warning("Failed to power off printer %s via smart plug", pid)
+
+                        asyncio.create_task(cooldown_and_poweroff(printer_id, plug.id))
+    except Exception as e:
+        logging.getLogger(__name__).warning(f"Queue item update failed: {e}")
+
+    log_timing("Queue item update")
+
     if not archive_id:
         logger.warning("Could not find archive for print complete: filename=%s, subtask=%s", filename, subtask_name)
         return
@@ -2727,101 +2819,6 @@ async def on_print_complete(printer_id: int, data: dict):
         asyncio.create_task(_scan_for_timelapse_with_retries(archive_id, baseline))
         log_timing("Timelapse scan scheduled")
 
-    # Update queue item if this was a scheduled print
-    try:
-        async with async_session() as db:
-            from backend.app.models.print_queue import PrintQueueItem
-            # Note: SmartPlug is already imported at module level (line 56)
-            # Do NOT import it here as it would shadow the module-level import
-            # and cause "cannot access local variable" errors earlier in this function
-
-            result = await db.execute(
-                select(PrintQueueItem)
-                .where(PrintQueueItem.printer_id == printer_id)
-                .where(PrintQueueItem.status == "printing")
-            )
-            printing_items = list(result.scalars().all())
-            if len(printing_items) > 1:
-                logger.warning(
-                    "BUG: Multiple queue items in 'printing' status for printer %s: %s",
-                    printer_id,
-                    [(i.id, i.archive_id, i.library_file_id) for i in printing_items],
-                )
-            queue_item = printing_items[0] if printing_items else None
-            if queue_item:
-                status = data.get("status", "completed")
-                queue_item.status = status
-                queue_item.completed_at = datetime.now()
-                await db.commit()
-                logger.info("Updated queue item %s status to %s", queue_item.id, status)
-
-                # MQTT relay - publish queue job completed
-                try:
-                    printer_info = printer_manager.get_printer(printer_id)
-                    await mqtt_relay.on_queue_job_completed(
-                        job_id=queue_item.id,
-                        filename=filename or subtask_name,
-                        printer_id=printer_id,
-                        printer_name=printer_info.name if printer_info else "Unknown",
-                        status=status,
-                    )
-                except Exception:
-                    pass  # Don't fail if MQTT fails
-
-                # Check if queue is now empty and send notification
-                try:
-                    from sqlalchemy import func
-
-                    # Count remaining pending items
-                    count_result = await db.execute(
-                        select(func.count(PrintQueueItem.id)).where(PrintQueueItem.status == "pending")
-                    )
-                    pending_count = count_result.scalar() or 0
-
-                    if pending_count == 0:
-                        # Count how many completed today (rough approximation)
-                        today_start = datetime.now().replace(hour=0, minute=0, second=0, microsecond=0)
-                        completed_result = await db.execute(
-                            select(func.count(PrintQueueItem.id)).where(
-                                PrintQueueItem.status.in_(["completed", "failed", "skipped"]),
-                                PrintQueueItem.completed_at >= today_start,
-                            )
-                        )
-                        completed_count = completed_result.scalar() or 1
-
-                        await notification_service.on_queue_completed(
-                            completed_count=completed_count,
-                            db=db,
-                        )
-                except Exception:
-                    pass  # Don't fail if notification fails
-
-                # Handle auto_off_after - power off printer if requested (after cooldown)
-                if queue_item.auto_off_after:
-                    result = await db.execute(select(SmartPlug).where(SmartPlug.printer_id == printer_id))
-                    plug = result.scalar_one_or_none()
-                    if plug and plug.enabled:
-                        logger.info("Auto-off requested for printer %s, waiting for cooldown...", printer_id)
-
-                        async def cooldown_and_poweroff(pid: int, plug_id: int):
-                            # Wait for nozzle to cool down
-                            await printer_manager.wait_for_cooldown(pid, target_temp=50.0, timeout=600)
-                            # Re-fetch plug in new session
-                            async with async_session() as new_db:
-                                result = await new_db.execute(select(SmartPlug).where(SmartPlug.id == plug_id))
-                                p = result.scalar_one_or_none()
-                                if p and p.enabled:
-                                    success = await tasmota_service.turn_off(p)
-                                    if success:
-                                        logger.info("Powered off printer %s via smart plug '%s'", pid, p.name)
-                                    else:
-                                        logger.warning("Failed to power off printer %s via smart plug", pid)
-
-                        asyncio.create_task(cooldown_and_poweroff(printer_id, plug.id))
-    except Exception as e:
-        logging.getLogger(__name__).warning(f"Queue item update failed: {e}")
-
-    log_timing("Queue item update")
     logger.info("[CALLBACK] on_print_complete finished for printer %s, archive %s", printer_id, archive_id)