bambuddy/backend/app/main.py

import asyncio
import logging
from contextlib import asynccontextmanager
from datetime import UTC, datetime, timedelta
from logging.handlers import RotatingFileHandler

from fastapi import FastAPI

# Import settings first for logging configuration
from backend.app.core.config import APP_VERSION, settings as app_settings

# Configure logging based on settings
# DEBUG=true -> DEBUG level, else use LOG_LEVEL setting
log_level_str = "DEBUG" if app_settings.debug else app_settings.log_level.upper()
log_level = getattr(logging, log_level_str, logging.INFO)
log_format = "%(asctime)s %(levelname)s [%(name)s] %(message)s"

# Create root logger
root_logger = logging.getLogger()
root_logger.setLevel(log_level)

# Console handler - always enabled
console_handler = logging.StreamHandler()
console_handler.setLevel(log_level)
console_handler.setFormatter(logging.Formatter(log_format))
root_logger.addHandler(console_handler)

# File handler - only in production or if explicitly enabled
if app_settings.log_to_file:
    log_file = app_settings.log_dir / "bambuddy.log"
    file_handler = RotatingFileHandler(
        log_file,
        maxBytes=5 * 1024 * 1024,  # 5MB
        backupCount=3,
        encoding="utf-8",
    )
    file_handler.setLevel(log_level)
    file_handler.setFormatter(logging.Formatter(log_format))
    root_logger.addHandler(file_handler)
    logging.info(f"Logging to file: {log_file}")

# Reduce noise from third-party libraries in production
if not app_settings.debug:
    logging.getLogger("sqlalchemy.engine").setLevel(logging.WARNING)
    logging.getLogger("httpcore").setLevel(logging.WARNING)
    logging.getLogger("httpx").setLevel(logging.WARNING)

logging.info(f"Bambuddy starting - debug={app_settings.debug}, log_level={log_level_str}")
from fastapi.responses import FileResponse
from fastapi.staticfiles import StaticFiles
from sqlalchemy import delete, or_, select

from backend.app.api.routes import (
    ams_history,
    api_keys,
    archives,
    camera,
    cloud,
    discovery,
    external_links,
    filaments,
    firmware,
    kprofiles,
    maintenance,
    notification_templates,
    notifications,
    pending_uploads,
    print_queue,
    printers,
    projects,
    settings as settings_routes,
    smart_plugs,
    spoolman,
    support,
    system,
    updates,
    webhook,
    websocket,
)
from backend.app.api.routes.maintenance import _get_printer_maintenance_internal, ensure_default_types
from backend.app.api.routes.support import init_debug_logging
from backend.app.core.database import async_session, init_db
from backend.app.core.websocket import ws_manager
from backend.app.models.smart_plug import SmartPlug
from backend.app.services.archive import ArchiveService
from backend.app.services.bambu_ftp import download_file_async
from backend.app.services.bambu_mqtt import PrinterState
from backend.app.services.notification_service import notification_service
from backend.app.services.print_scheduler import scheduler as print_scheduler
from backend.app.services.printer_manager import (
    init_printer_connections,
    printer_manager,
    printer_state_to_dict,
)
from backend.app.services.smart_plug_manager import smart_plug_manager
from backend.app.services.spoolman import close_spoolman_client, get_spoolman_client, init_spoolman_client
from backend.app.services.tasmota import tasmota_service
from backend.app.services.telemetry import start_telemetry_loop

# Track active prints: {(printer_id, filename): archive_id}
_active_prints: dict[tuple[int, str], int] = {}

# Track expected prints from reprint/scheduled (skip auto-archiving for these)
# {(printer_id, filename): archive_id}
_expected_prints: dict[tuple[int, str], int] = {}

# Track starting energy for prints: {archive_id: starting_kwh}
_print_energy_start: dict[int, float] = {}


def register_expected_print(printer_id: int, filename: str, archive_id: int):
    """Register an expected print from reprint/scheduled so we don't create duplicate archives."""
    # Store with multiple filename variations to catch different naming patterns
    _expected_prints[(printer_id, filename)] = archive_id
    # Also store without .3mf extension if present
    if filename.endswith(".3mf"):
        base = filename[:-4]
        _expected_prints[(printer_id, base)] = archive_id
        _expected_prints[(printer_id, f"{base}.gcode")] = archive_id
    logging.getLogger(__name__).info(
        f"Registered expected print: printer={printer_id}, file={filename}, archive={archive_id}"
    )


_last_status_broadcast: dict[int, str] = {}
_nozzle_count_updated: set[int] = set()  # Track printers where we've updated nozzle_count


async def _report_spoolman_usage(printer_id: int, archive_id: int, logger):
    """Report filament usage to Spoolman after print completion.

    This finds the spool by RFID tag_uid from current AMS state and reports
    the filament_used_grams from the archive metadata.
    """
    async with async_session() as db:
        from backend.app.api.routes.settings import get_setting
        from backend.app.models.archive import PrintArchive

        # Check if Spoolman is enabled
        spoolman_enabled = await get_setting(db, "spoolman_enabled")
        if not spoolman_enabled or spoolman_enabled.lower() != "true":
            return

        # Get Spoolman URL
        spoolman_url = await get_setting(db, "spoolman_url")
        if not spoolman_url:
            return

        # Get or create Spoolman client
        client = await get_spoolman_client()
        if not client:
            client = await init_spoolman_client(spoolman_url)

        # Check if Spoolman is reachable
        if not await client.health_check():
            logger.warning("Spoolman not reachable for usage reporting")
            return

        # Get archive to find filament usage
        result = await db.execute(select(PrintArchive).where(PrintArchive.id == archive_id))
        archive = result.scalar_one_or_none()
        if not archive or not archive.filament_used_grams:
            logger.debug(f"No filament usage data for archive {archive_id}")
            return

        filament_used = archive.filament_used_grams
        logger.info(f"[SPOOLMAN] Archive {archive_id} used {filament_used}g of filament")

        # Get current AMS state from printer to find the active spool
        state = printer_manager.get_status(printer_id)
        if not state or not state.raw_data:
            logger.debug("No printer state available for usage reporting")
            return

        ams_data = state.raw_data.get("ams")
        if not ams_data:
            logger.debug("No AMS data available for usage reporting")
            return

        # Find spools with RFID tags in Spoolman and report usage
        # For now, we report usage to the first spool found with a matching tag
        # TODO: In future, track which specific trays were used during the print
        spools_updated = 0
        for ams_unit in ams_data:
            trays = ams_unit.get("tray", [])

            for tray_data in trays:
                tag_uid = tray_data.get("tag_uid")
                if not tag_uid:
                    continue

                # Find spool in Spoolman by tag
                spool = await client.find_spool_by_tag(tag_uid)
                if spool:
                    # Report usage to Spoolman
                    result = await client.use_spool(spool["id"], filament_used)
                    if result:
                        logger.info(
                            f"[SPOOLMAN] Reported {filament_used}g usage to spool {spool['id']} (tag: {tag_uid})"
                        )
                        spools_updated += 1
                        # Only report to one spool for single-material prints
                        # Multi-material prints would need more sophisticated tracking
                        return

        if spools_updated == 0:
            logger.debug(f"No matching Spoolman spools found for printer {printer_id}")


async def on_printer_status_change(printer_id: int, state: PrinterState):
    """Handle printer status changes - broadcast via WebSocket."""
    # Only broadcast if something meaningful changed (reduce WebSocket spam)
    # Include rounded temperatures to detect meaningful temp changes (within 1 degree)
    temps = state.temperatures or {}
    nozzle_temp = round(temps.get("nozzle", 0))
    bed_temp = round(temps.get("bed", 0))
    nozzle_2_temp = round(temps.get("nozzle_2", 0)) if "nozzle_2" in temps else ""
    chamber_temp = round(temps.get("chamber", 0)) if "chamber" in temps else ""

    # Auto-detect dual-nozzle printers from MQTT temperature data
    if "nozzle_2" in temps and printer_id not in _nozzle_count_updated:
        _nozzle_count_updated.add(printer_id)
        # Update nozzle_count in database
        async with async_session() as db:
            from backend.app.models.printer import Printer

            result = await db.execute(select(Printer).where(Printer.id == printer_id))
            printer = result.scalar_one_or_none()
            if printer and printer.nozzle_count != 2:
                printer.nozzle_count = 2
                await db.commit()
                logging.getLogger(__name__).info(
                    f"Auto-detected dual-nozzle printer {printer_id}, updated nozzle_count=2"
                )

    # Include target temps for heating phase detection
    bed_target = round(temps.get("bed_target", 0))
    nozzle_target = round(temps.get("nozzle_target", 0))

    status_key = (
        f"{state.connected}:{state.state}:{state.progress}:{state.layer_num}:"
        f"{nozzle_temp}:{bed_temp}:{nozzle_2_temp}:{chamber_temp}:"
        f"{state.stg_cur}:{bed_target}:{nozzle_target}:"
        f"{state.cooling_fan_speed}:{state.big_fan1_speed}:{state.big_fan2_speed}"
    )
    if _last_status_broadcast.get(printer_id) == status_key:
        return  # No change, skip broadcast

    _last_status_broadcast[printer_id] = status_key

    await ws_manager.send_printer_status(
        printer_id,
        printer_state_to_dict(state, printer_id),
    )


async def on_ams_change(printer_id: int, ams_data: list):
    """Handle AMS data changes - sync to Spoolman if enabled and auto mode."""
    import logging

    logger = logging.getLogger(__name__)

    try:
        async with async_session() as db:
            from backend.app.api.routes.settings import get_setting
            from backend.app.models.printer import Printer

            # Check if Spoolman is enabled
            spoolman_enabled = await get_setting(db, "spoolman_enabled")
            if not spoolman_enabled or spoolman_enabled.lower() != "true":
                return

            # Check sync mode
            sync_mode = await get_setting(db, "spoolman_sync_mode")
            if sync_mode and sync_mode != "auto":
                return  # Only sync on auto mode

            # Get Spoolman URL
            spoolman_url = await get_setting(db, "spoolman_url")
            if not spoolman_url:
                return

            # Get or create Spoolman client
            client = await get_spoolman_client()
            if not client:
                client = await init_spoolman_client(spoolman_url)

            # Check if Spoolman is reachable
            if not await client.health_check():
                logger.warning(f"Spoolman not reachable at {spoolman_url}")
                return

            # Get printer name for location
            result = await db.execute(select(Printer).where(Printer.id == printer_id))
            printer = result.scalar_one_or_none()
            printer_name = printer.name if printer else f"Printer {printer_id}"

            # Sync each AMS tray
            synced = 0
            for ams_unit in ams_data:
                ams_id = int(ams_unit.get("id", 0))
                trays = ams_unit.get("tray", [])

                for tray_data in trays:
                    tray = client.parse_ams_tray(ams_id, tray_data)
                    if not tray:
                        continue  # Empty tray

                    try:
                        result = await client.sync_ams_tray(tray, printer_name)
                        if result:
                            synced += 1
                    except Exception as e:
                        logger.error(f"Error syncing AMS {ams_id} tray {tray.tray_id}: {e}")

            if synced > 0:
                logger.info(f"Auto-synced {synced} AMS trays to Spoolman for printer {printer_id}")

    except Exception as e:
        import logging

        logging.getLogger(__name__).warning(f"Spoolman AMS sync failed: {e}")


async def _send_print_start_notification(
    printer_id: int,
    data: dict,
    archive_data: dict | None = None,
    logger=None,
):
    """Helper to send print start notification with optional archive data."""
    if logger is None:
        import logging

        logger = logging.getLogger(__name__)

    try:
        async with async_session() as db:
            from backend.app.models.printer import Printer

            result = await db.execute(select(Printer).where(Printer.id == printer_id))
            printer = result.scalar_one_or_none()
            printer_name = printer.name if printer else f"Printer {printer_id}"
            await notification_service.on_print_start(printer_id, printer_name, data, db, archive_data=archive_data)
    except Exception as e:
        logger.warning(f"Notification on_print_start failed: {e}")


def _load_objects_from_archive(archive, printer_id: int, logger) -> None:
    """Extract printable objects from an archive's 3MF file and store in printer state."""
    try:
        from backend.app.services.archive import extract_printable_objects_from_3mf

        file_path = app_settings.base_dir / archive.file_path
        if file_path.exists() and str(file_path).endswith(".3mf"):
            with open(file_path, "rb") as f:
                threemf_data = f.read()
            # Extract with positions for UI overlay
            printable_objects, bbox_all = extract_printable_objects_from_3mf(threemf_data, include_positions=True)
            if printable_objects:
                client = printer_manager.get_client(printer_id)
                if client:
                    client.state.printable_objects = printable_objects
                    client.state.printable_objects_bbox_all = bbox_all
                    client.state.skipped_objects = []
                    logger.info(f"Loaded {len(printable_objects)} printable objects for printer {printer_id}")
    except Exception as e:
        logger.debug(f"Failed to extract printable objects from archive: {e}")


async def on_print_start(printer_id: int, data: dict):
    """Handle print start - archive the 3MF file immediately."""
    import logging

    logger = logging.getLogger(__name__)

    logger.info(f"[CALLBACK] on_print_start called for printer {printer_id}, data keys: {list(data.keys())}")

    await ws_manager.send_print_start(printer_id, data)

    # Track if notification was sent (to avoid sending twice)
    notification_sent = False

    # Smart plug automation: turn on plug when print starts
    try:
        async with async_session() as db:
            await smart_plug_manager.on_print_start(printer_id, db)
    except Exception as e:
        logger.warning(f"Smart plug on_print_start failed: {e}")

    async with async_session() as db:
        from backend.app.models.printer import Printer
        from backend.app.services.bambu_ftp import list_files_async

        result = await db.execute(select(Printer).where(Printer.id == printer_id))
        printer = result.scalar_one_or_none()

        if not printer or not printer.auto_archive:
            # Send notification without archive data (auto-archive disabled)
            logger.info(
                f"[CALLBACK] Skipping archive - printer: {printer is not None}, auto_archive: {printer.auto_archive if printer else 'N/A'}"
            )
            if not notification_sent:
                await _send_print_start_notification(printer_id, data, logger=logger)
            return

        # Get the filename and subtask_name
        filename = data.get("filename", "")
        subtask_name = data.get("subtask_name", "")

        logger.info(f"[CALLBACK] Print start detected - filename: {filename}, subtask: {subtask_name}")

        if not filename and not subtask_name:
            # Send notification without archive data (no filename)
            logger.info("[CALLBACK] Skipping archive - no filename or subtask_name")
            if not notification_sent:
                await _send_print_start_notification(printer_id, data, logger=logger)
            return

        # Check if this is an expected print from reprint/scheduled
        # Build list of possible keys to check
        expected_keys = []
        if subtask_name:
            expected_keys.append((printer_id, subtask_name))
            expected_keys.append((printer_id, f"{subtask_name}.3mf"))
            expected_keys.append((printer_id, f"{subtask_name}.gcode.3mf"))
        if filename:
            fname = filename.split("/")[-1] if "/" in filename else filename
            expected_keys.append((printer_id, fname))
            # Strip extensions to match
            base = fname.replace(".gcode", "").replace(".3mf", "")
            expected_keys.append((printer_id, base))
            expected_keys.append((printer_id, f"{base}.3mf"))

        expected_archive_id = None
        for key in expected_keys:
            expected_archive_id = _expected_prints.pop(key, None)
            if expected_archive_id:
                # Clean up other possible keys for this print
                for other_key in expected_keys:
                    _expected_prints.pop(other_key, None)
                break

        if expected_archive_id:
            # This is a reprint/scheduled print - use existing archive, don't create new one
            logger.info(f"Using expected archive {expected_archive_id} for print (skipping duplicate)")
            from backend.app.models.archive import PrintArchive

            result = await db.execute(select(PrintArchive).where(PrintArchive.id == expected_archive_id))
            archive = result.scalar_one_or_none()

            if archive:
                # Update archive status to printing
                archive.status = "printing"
                archive.started_at = datetime.now()
                await db.commit()

                # Track as active print
                _active_prints[(printer_id, archive.filename)] = archive.id
                if subtask_name:
                    _active_prints[(printer_id, f"{subtask_name}.3mf")] = archive.id

                # Set up energy tracking
                try:
                    plug_result = await db.execute(select(SmartPlug).where(SmartPlug.printer_id == printer_id))
                    plug = plug_result.scalar_one_or_none()
                    logger.info(
                        f"[ENERGY] Print start - archive {archive.id}, printer {printer_id}, plug found: {plug is not None}"
                    )
                    if plug:
                        energy = await tasmota_service.get_energy(plug)
                        logger.info(f"[ENERGY] Energy response from plug: {energy}")
                        if energy and energy.get("total") is not None:
                            _print_energy_start[archive.id] = energy["total"]
                            logger.info(
                                f"[ENERGY] Recorded starting energy for archive {archive.id}: {energy['total']} kWh"
                            )
                        else:
                            logger.warning(f"[ENERGY] No 'total' in energy response for archive {archive.id}")
                    else:
                        logger.info(f"[ENERGY] No smart plug found for printer {printer_id}")
                except Exception as e:
                    logger.warning(f"Failed to record starting energy: {e}")

                await ws_manager.send_archive_updated(
                    {
                        "id": archive.id,
                        "status": "printing",
                    }
                )

                # Send notification with archive data (reprint/scheduled)
                if not notification_sent:
                    archive_data = {"print_time_seconds": archive.print_time_seconds}
                    await _send_print_start_notification(printer_id, data, archive_data, logger)

                # Extract printable objects from the archived 3MF file
                _load_objects_from_archive(archive, printer_id, logger)

            return  # Skip creating a new archive

        # Check if there's already a "printing" archive for this printer/file
        # This prevents duplicates when backend restarts during an active print
        from backend.app.models.archive import PrintArchive

        check_name = subtask_name or filename.split("/")[-1].replace(".gcode", "").replace(".3mf", "")
        existing = await db.execute(
            select(PrintArchive)
            .where(PrintArchive.printer_id == printer_id)
            .where(PrintArchive.status == "printing")
            .where(PrintArchive.print_name.ilike(f"%{check_name}%"))
            .order_by(PrintArchive.created_at.desc())
            .limit(1)
        )
        existing_archive = existing.scalar_one_or_none()
        if existing_archive:
            # Check if archive is stale (older than 4 hours) - likely a failed/cancelled print
            # that didn't get properly updated
            archive_age = datetime.now(UTC) - existing_archive.created_at.replace(tzinfo=UTC)
            if archive_age.total_seconds() > 4 * 60 * 60:  # 4 hours
                logger.warning(
                    f"Found stale 'printing' archive {existing_archive.id} (age: {archive_age}), "
                    f"marking as cancelled and creating new archive"
                )
                existing_archive.status = "cancelled"
                existing_archive.failure_reason = "Stale - print likely cancelled or failed without status update"
                await db.commit()
                # Fall through to create new archive (don't return)
                existing_archive = None  # Clear so we don't use stale archive
            else:
                logger.info(
                    f"Skipping duplicate - already have printing archive {existing_archive.id} for {check_name}"
                )
                # Track this as the active print
                _active_prints[(printer_id, existing_archive.filename)] = existing_archive.id
                # Also set up energy tracking if not already tracked
                if existing_archive.id not in _print_energy_start:
                    try:
                        plug_result = await db.execute(select(SmartPlug).where(SmartPlug.printer_id == printer_id))
                        plug = plug_result.scalar_one_or_none()
                        if plug:
                            energy = await tasmota_service.get_energy(plug)
                            if energy and energy.get("total") is not None:
                                _print_energy_start[existing_archive.id] = energy["total"]
                                logger.info(
                                    f"Recorded starting energy for existing archive {existing_archive.id}: {energy['total']} kWh"
                                )
                    except Exception as e:
                        logger.warning(f"Failed to record starting energy for existing archive: {e}")
                # Send notification with archive data (existing archive)
                if not notification_sent:
                    archive_data = {"print_time_seconds": existing_archive.print_time_seconds}
                    await _send_print_start_notification(printer_id, data, archive_data, logger)
                # Extract printable objects from the archived 3MF file
                _load_objects_from_archive(existing_archive, printer_id, logger)
                return

        # Build list of possible 3MF filenames to try
        possible_names = []

        # Bambu printers typically store files as "Name.gcode.3mf"
        # The subtask_name is usually the best source for the filename
        if subtask_name:
            # Try common Bambu naming patterns
            possible_names.append(f"{subtask_name}.gcode.3mf")
            possible_names.append(f"{subtask_name}.3mf")

        # Try original filename with .3mf extension
        if filename:
            # Extract just the filename part, not the full path
            fname = filename.split("/")[-1] if "/" in filename else filename
            if fname.endswith(".3mf"):
                possible_names.append(fname)
            elif fname.endswith(".gcode"):
                base = fname.rsplit(".", 1)[0]
                possible_names.append(f"{base}.gcode.3mf")
                possible_names.append(f"{base}.3mf")
            else:
                possible_names.append(f"{fname}.gcode.3mf")
                possible_names.append(f"{fname}.3mf")

        # Remove duplicates while preserving order
        seen = set()
        possible_names = [x for x in possible_names if not (x in seen or seen.add(x))]

        logger.info(f"Trying filenames: {possible_names}")

        # Try to find and download the 3MF file
        temp_path = None
        downloaded_filename = None

        for try_filename in possible_names:
            if not try_filename.endswith(".3mf"):
                continue

            remote_paths = [
                f"/cache/{try_filename}",
                f"/model/{try_filename}",
                f"/{try_filename}",
            ]

            temp_path = app_settings.archive_dir / "temp" / try_filename
            temp_path.parent.mkdir(parents=True, exist_ok=True)

            for remote_path in remote_paths:
                logger.debug(f"Trying FTP download: {remote_path}")
                try:
                    if await download_file_async(
                        printer.ip_address,
                        printer.access_code,
                        remote_path,
                        temp_path,
                    ):
                        downloaded_filename = try_filename
                        logger.info(f"Downloaded: {remote_path}")
                        break
                except Exception as e:
                    logger.debug(f"FTP download failed for {remote_path}: {e}")

            if downloaded_filename:
                break

        # If still not found, try listing /cache to find matching file
        if not downloaded_filename and (filename or subtask_name):
            search_term = (subtask_name or filename).lower().replace(".gcode", "").replace(".3mf", "")
            logger.info(f"Direct FTP download failed, listing /cache to find '{search_term}'")
            try:
                cache_files = await list_files_async(printer.ip_address, printer.access_code, "/cache")
                threemf_files = [f.get("name") for f in cache_files if f.get("name", "").endswith(".3mf")]
                logger.info(
                    f"Found {len(threemf_files)} 3MF files in /cache: {threemf_files[:5]}{'...' if len(threemf_files) > 5 else ''}"
                )
                for f in cache_files:
                    if f.get("is_directory"):
                        continue
                    fname = f.get("name", "")
                    if fname.endswith(".3mf") and search_term in fname.lower():
                        logger.info(f"Found matching file: {fname}")
                        temp_path = app_settings.archive_dir / "temp" / fname
                        temp_path.parent.mkdir(parents=True, exist_ok=True)
                        if await download_file_async(
                            printer.ip_address,
                            printer.access_code,
                            f"/cache/{fname}",
                            temp_path,
                        ):
                            downloaded_filename = fname
                            logger.info(f"Found and downloaded from cache: {fname}")
                            break
            except Exception as e:
                logger.warning(f"Failed to list cache: {e}")

        if not downloaded_filename or not temp_path:
            logger.warning(f"Could not find 3MF file for print: {filename or subtask_name}")
            # Create a fallback archive without 3MF data so the print is still tracked
            # This commonly happens with P1S/A1 printers where FTP has file size limitations
            try:
                from backend.app.models.archive import PrintArchive

                # Derive print name from subtask_name or filename
                print_name = subtask_name or filename
                if print_name:
                    # Clean up the name (remove extensions, path parts)
                    print_name = print_name.split("/")[-1]
                    print_name = print_name.replace(".gcode.3mf", "").replace(".gcode", "").replace(".3mf", "")
                else:
                    print_name = "Unknown Print"

                # Create minimal archive entry
                fallback_archive = PrintArchive(
                    printer_id=printer_id,
                    filename=filename or f"{print_name}.3mf",
                    file_path="",  # Empty - no 3MF file available
                    file_size=0,
                    print_name=print_name,
                    status="printing",
                    started_at=datetime.now(),
                    extra_data={"no_3mf_available": True, "original_subtask": subtask_name, "_print_data": data},
                )

                db.add(fallback_archive)
                await db.commit()
                await db.refresh(fallback_archive)

                logger.info(f"Created fallback archive {fallback_archive.id} for {print_name} (no 3MF available)")

                # Track as active print
                _active_prints[(printer_id, fallback_archive.filename)] = fallback_archive.id
                if filename:
                    _active_prints[(printer_id, filename)] = fallback_archive.id
                if subtask_name:
                    _active_prints[(printer_id, f"{subtask_name}.3mf")] = fallback_archive.id
                    _active_prints[(printer_id, subtask_name)] = fallback_archive.id

                # Record starting energy if smart plug available
                try:
                    plug_result = await db.execute(select(SmartPlug).where(SmartPlug.printer_id == printer_id))
                    plug = plug_result.scalar_one_or_none()
                    if plug:
                        energy = await tasmota_service.get_energy(plug)
                        if energy and energy.get("total") is not None:
                            _print_energy_start[fallback_archive.id] = energy["total"]
                            logger.info(
                                f"[ENERGY] Recorded starting energy for fallback archive {fallback_archive.id}: {energy['total']} kWh"
                            )
                except Exception as e:
                    logger.warning(f"Failed to record starting energy for fallback: {e}")

                # Send WebSocket notification
                await ws_manager.send_archive_created(
                    {
                        "id": fallback_archive.id,
                        "printer_id": fallback_archive.printer_id,
                        "filename": fallback_archive.filename,
                        "print_name": fallback_archive.print_name,
                        "status": fallback_archive.status,
                    }
                )

                # Send notification without archive data (file not found)
                if not notification_sent:
                    await _send_print_start_notification(printer_id, data, logger=logger)
                return
            except Exception as e:
                logger.error(f"Failed to create fallback archive: {e}")
                # Send notification without archive data (file not found)
                if not notification_sent:
                    await _send_print_start_notification(printer_id, data, logger=logger)
                return

        try:
            # Archive the file with status "printing"
            service = ArchiveService(db)
            archive = await service.archive_print(
                printer_id=printer_id,
                source_file=temp_path,
                print_data={**data, "status": "printing"},
            )

            if archive:
                # Track this active print (use both original filename and downloaded filename)
                _active_prints[(printer_id, downloaded_filename)] = archive.id
                if filename and filename != downloaded_filename:
                    _active_prints[(printer_id, filename)] = archive.id
                if subtask_name:
                    _active_prints[(printer_id, f"{subtask_name}.3mf")] = archive.id

                logger.info(f"Created archive {archive.id} for {downloaded_filename}")

                # Record starting energy from smart plug if available
                try:
                    plug_result = await db.execute(select(SmartPlug).where(SmartPlug.printer_id == printer_id))
                    plug = plug_result.scalar_one_or_none()
                    logger.info(
                        f"[ENERGY] Auto-archive print start - archive {archive.id}, printer {printer_id}, plug found: {plug is not None}"
                    )
                    if plug:
                        energy = await tasmota_service.get_energy(plug)
                        logger.info(f"[ENERGY] Auto-archive energy response: {energy}")
                        if energy and energy.get("total") is not None:
                            _print_energy_start[archive.id] = energy["total"]
                            logger.info(
                                f"[ENERGY] Recorded starting energy for archive {archive.id}: {energy['total']} kWh"
                            )
                        else:
                            logger.warning(f"[ENERGY] No 'total' in energy response for archive {archive.id}")
                    else:
                        logger.info(f"[ENERGY] No smart plug found for printer {printer_id}")
                except Exception as e:
                    logger.warning(f"Failed to record starting energy: {e}")

                await ws_manager.send_archive_created(
                    {
                        "id": archive.id,
                        "printer_id": archive.printer_id,
                        "filename": archive.filename,
                        "print_name": archive.print_name,
                        "status": archive.status,
                    }
                )

                # Send notification with archive data (new archive created)
                if not notification_sent:
                    archive_data = {"print_time_seconds": archive.print_time_seconds}
                    await _send_print_start_notification(printer_id, data, archive_data, logger)
                    notification_sent = True

                # Extract printable objects for skip object functionality
                try:
                    from backend.app.services.archive import extract_printable_objects_from_3mf

                    with open(temp_path, "rb") as f:
                        threemf_data = f.read()
                    # Extract with positions for UI overlay
                    printable_objects, bbox_all = extract_printable_objects_from_3mf(
                        threemf_data, include_positions=True
                    )
                    if printable_objects:
                        # Store objects in printer state
                        client = printer_manager.get_client(printer_id)
                        if client:
                            client.state.printable_objects = printable_objects
                            client.state.printable_objects_bbox_all = bbox_all
                            client.state.skipped_objects = []  # Reset skipped objects for new print
                            logger.info(f"Loaded {len(printable_objects)} printable objects for printer {printer_id}")
                except Exception as e:
                    logger.debug(f"Failed to extract printable objects: {e}")
        finally:
            if temp_path and temp_path.exists():
                temp_path.unlink()


async def _scan_for_timelapse_with_retries(archive_id: int):
    """
    Scan for timelapse with retries.

    The printer encodes the timelapse quickly after print completion.
    We just need a short delay then grab the most recent file.

    Since we KNOW timelapse was active (from MQTT ipcam data), the most recent
    file in /timelapse is our target. Retries handle FTP connection issues.
    """
    import logging

    logger = logging.getLogger(__name__)

    # Short delays - printer usually finishes encoding within seconds
    retry_delays = [5, 10, 20]

    for attempt, delay in enumerate(retry_delays, 1):
        logger.info(
            f"[TIMELAPSE] Attempt {attempt}/{len(retry_delays)}: waiting {delay}s before scanning for archive {archive_id}"
        )
        await asyncio.sleep(delay)

        try:
            async with async_session() as db:
                from backend.app.models.printer import Printer
                from backend.app.services.bambu_ftp import download_file_bytes_async, list_files_async

                # Get archive (ArchiveService from module-level import)
                service = ArchiveService(db)
                archive = await service.get_archive(archive_id)

                if not archive:
                    logger.warning(f"[TIMELAPSE] Archive {archive_id} not found, stopping retries")
                    return
                if archive.timelapse_path:
                    logger.info(f"[TIMELAPSE] Archive {archive_id} already has timelapse attached, stopping retries")
                    return
                if not archive.printer_id:
                    logger.warning(f"[TIMELAPSE] Archive {archive_id} has no printer, stopping retries")
                    return

                # Get printer
                result = await db.execute(select(Printer).where(Printer.id == archive.printer_id))
                printer = result.scalar_one_or_none()

                if not printer:
                    logger.warning(f"[TIMELAPSE] Printer not found for archive {archive_id}, stopping retries")
                    return

                # Scan timelapse directory on printer
                # H2D may store in different locations than X1C
                files = []
                found_path = None
                for timelapse_path in ["/timelapse", "/timelapse/video", "/record", "/recording"]:
                    try:
                        found_files = await list_files_async(printer.ip_address, printer.access_code, timelapse_path)
                        if found_files:
                            files = found_files
                            found_path = timelapse_path
                            logger.info(f"[TIMELAPSE] Attempt {attempt}: Found {len(files)} files in {timelapse_path}")
                            break
                    except Exception as e:
                        logger.debug(f"[TIMELAPSE] Path {timelapse_path} failed: {e}")
                        continue

                if not files:
                    logger.info(f"[TIMELAPSE] Attempt {attempt}: No timelapse files found on printer, will retry")
                    continue

                mp4_files = [f for f in files if not f.get("is_directory") and f.get("name", "").endswith(".mp4")]

                # Log ALL mp4 files found for debugging
                logger.info(f"[TIMELAPSE] Attempt {attempt}: Found {len(mp4_files)} MP4 files in {found_path}")
                for f in mp4_files[:5]:  # Log first 5
                    logger.info(f"[TIMELAPSE]   - {f.get('name')}, mtime={f.get('mtime')}")

                if not mp4_files:
                    logger.info(f"[TIMELAPSE] Attempt {attempt}: No MP4 files found, will retry")
                    continue

                # Sort by mtime descending to get most recent file
                mp4_files_with_mtime = [f for f in mp4_files if f.get("mtime")]
                if not mp4_files_with_mtime:
                    logger.info(f"[TIMELAPSE] Attempt {attempt}: No MP4 files with mtime found, will retry")
                    continue

                mp4_files_with_mtime.sort(key=lambda x: x.get("mtime"), reverse=True)
                most_recent = mp4_files_with_mtime[0]

                file_name = most_recent.get("name")
                logger.info(f"[TIMELAPSE] Attempt {attempt}: Most recent file: {file_name}")

                # Since we KNOW timelapse was active (from MQTT), just grab the most recent file
                remote_path = most_recent.get("path") or f"/timelapse/{file_name}"
                logger.info(f"[TIMELAPSE] Downloading {file_name} for archive {archive_id}")
                timelapse_data = await download_file_bytes_async(printer.ip_address, printer.access_code, remote_path)

                if timelapse_data:
                    success = await service.attach_timelapse(archive_id, timelapse_data, file_name)
                    if success:
                        logger.info(f"[TIMELAPSE] Successfully attached timelapse to archive {archive_id}")
                        await ws_manager.send_archive_updated({"id": archive_id, "timelapse_attached": True})
                        return  # Success!
                    else:
                        logger.warning(f"[TIMELAPSE] Failed to attach timelapse to archive {archive_id}")
                else:
                    logger.warning(f"[TIMELAPSE] Attempt {attempt}: Failed to download, will retry")

        except Exception as e:
            logger.warning(f"[TIMELAPSE] Attempt {attempt} failed with error: {e}")

    logger.warning(f"[TIMELAPSE] All {len(retry_delays)} attempts exhausted for archive {archive_id}, giving up")


async def on_print_complete(printer_id: int, data: dict):
    """Handle print completion - update the archive status."""
    import logging
    import time

    logger = logging.getLogger(__name__)
    start_time = time.time()

    def log_timing(section: str):
        elapsed = time.time() - start_time
        logger.info(f"[TIMING] {section}: {elapsed:.3f}s elapsed")

    logger.info(f"[CALLBACK] on_print_complete started for printer {printer_id}")

    try:
        ws_data = {
            "status": data.get("status"),
            "filename": data.get("filename"),
            "subtask_name": data.get("subtask_name"),
            "timelapse_was_active": data.get("timelapse_was_active"),
        }
        await ws_manager.send_print_complete(printer_id, ws_data)
        log_timing("WebSocket send_print_complete")
    except Exception as e:
        logger.warning(f"[CALLBACK] WebSocket send_print_complete failed: {e}")

    filename = data.get("filename", "")
    subtask_name = data.get("subtask_name", "")

    if not filename and not subtask_name:
        logger.warning("Print complete without filename or subtask_name")
        return

    logger.info(f"Print complete - filename: {filename}, subtask: {subtask_name}, status: {data.get('status')}")

    # Build list of possible keys to try (matching how they were registered in on_print_start)
    possible_keys = []

    # Try subtask_name variations first (most reliable for matching)
    if subtask_name:
        possible_keys.append((printer_id, f"{subtask_name}.3mf"))
        possible_keys.append((printer_id, f"{subtask_name}.gcode.3mf"))
        possible_keys.append((printer_id, subtask_name))

    # Try filename variations
    if filename:
        # Extract just the filename if it's a path
        fname = filename.split("/")[-1] if "/" in filename else filename

        if fname.endswith(".3mf"):
            possible_keys.append((printer_id, fname))
        elif fname.endswith(".gcode"):
            base_name = fname.rsplit(".", 1)[0]
            possible_keys.append((printer_id, f"{base_name}.gcode.3mf"))
            possible_keys.append((printer_id, f"{base_name}.3mf"))
            possible_keys.append((printer_id, fname))
        else:
            possible_keys.append((printer_id, f"{fname}.gcode.3mf"))
            possible_keys.append((printer_id, f"{fname}.3mf"))
            possible_keys.append((printer_id, fname))

        # Also try full path versions
        if filename.endswith(".3mf"):
            possible_keys.append((printer_id, filename))
        elif filename.endswith(".gcode"):
            base_name = filename.rsplit(".", 1)[0]
            possible_keys.append((printer_id, f"{base_name}.3mf"))
            possible_keys.append((printer_id, filename))
        else:
            possible_keys.append((printer_id, f"{filename}.3mf"))
            possible_keys.append((printer_id, filename))

    # Find the archive for this print
    logger.info(f"Looking for archive in _active_prints, keys to try: {possible_keys[:5]}...")
    logger.info(f"Current _active_prints: {list(_active_prints.keys())}")
    archive_id = None
    for key in possible_keys:
        archive_id = _active_prints.pop(key, None)
        if archive_id:
            logger.info(f"Found archive {archive_id} with key {key}")
            # Also clean up any other keys pointing to this archive
            keys_to_remove = [k for k, v in _active_prints.items() if v == archive_id]
            for k in keys_to_remove:
                _active_prints.pop(k, None)
            break

    if not archive_id:
        # Try to find by filename or subtask_name if not tracked (for prints started before app)
        async with async_session() as db:
            from backend.app.models.archive import PrintArchive

            # Try matching by subtask_name (stored as print_name) first
            if subtask_name:
                result = await db.execute(
                    select(PrintArchive)
                    .where(PrintArchive.printer_id == printer_id)
                    .where(PrintArchive.status == "printing")
                    .where(
                        or_(
                            PrintArchive.print_name.ilike(f"%{subtask_name}%"),
                            PrintArchive.filename.ilike(f"%{subtask_name}%"),
                        )
                    )
                    .order_by(PrintArchive.created_at.desc())
                    .limit(1)
                )
                archive = result.scalar_one_or_none()
                if archive:
                    archive_id = archive.id
                    logger.info(f"Found archive {archive_id} by subtask_name match: {subtask_name}")

            # Also try by filename
            if not archive_id and filename:
                result = await db.execute(
                    select(PrintArchive)
                    .where(PrintArchive.printer_id == printer_id)
                    .where(PrintArchive.filename == filename)
                    .where(PrintArchive.status == "printing")
                    .order_by(PrintArchive.created_at.desc())
                    .limit(1)
                )
                archive = result.scalar_one_or_none()
                if archive:
                    archive_id = archive.id

    if not archive_id:
        logger.warning(f"Could not find archive for print complete: filename={filename}, subtask={subtask_name}")
        return

    log_timing("Archive lookup")

    # Update archive status
    logger.info(f"[ARCHIVE] Updating archive {archive_id} status...")
    try:
        async with async_session() as db:
            service = ArchiveService(db)
            status = data.get("status", "completed")

            # Auto-detect failure reason
            failure_reason = None
            if status == "aborted":
                failure_reason = "User cancelled"
                logger.info("[ARCHIVE] Print was aborted by user, setting failure_reason='User cancelled'")
            elif status == "failed":
                # Try to determine failure reason from HMS errors
                hms_errors = data.get("hms_errors", [])
                if hms_errors:
                    logger.info(f"[ARCHIVE] HMS errors at failure: {hms_errors}")
                    # Map known HMS error modules to failure reasons
                    # Module 0x07 = Filament, 0x0C = MC (Motion Controller), etc.
                    for err in hms_errors:
                        module = err.get("module", 0)
                        if module == 0x07:  # Filament module
                            failure_reason = "Filament runout"
                            break
                        elif module == 0x0C:  # Motion controller
                            failure_reason = "Layer shift"
                            break
                        elif module == 0x05:  # Nozzle/extruder
                            failure_reason = "Clogged nozzle"
                            break
                    if failure_reason:
                        logger.info(f"[ARCHIVE] Detected failure_reason from HMS: {failure_reason}")
                else:
                    logger.info("[ARCHIVE] No HMS errors available to determine failure reason")

            await service.update_archive_status(
                archive_id,
                status=status,
                completed_at=datetime.now() if status in ("completed", "failed", "aborted") else None,
                failure_reason=failure_reason,
            )
            logger.info(f"[ARCHIVE] Archive {archive_id} status updated to {status}, failure_reason={failure_reason}")

            await ws_manager.send_archive_updated(
                {
                    "id": archive_id,
                    "status": status,
                }
            )
            logger.info(f"[ARCHIVE] WebSocket notification sent for archive {archive_id}")
    except Exception as e:
        logger.error(f"[ARCHIVE] Failed to update archive {archive_id} status: {e}", exc_info=True)
        # Continue with other operations even if archive update fails

    log_timing("Archive status update")

    # Report filament usage to Spoolman if print completed successfully
    if data.get("status") == "completed":
        try:
            await _report_spoolman_usage(printer_id, archive_id, logger)
            log_timing("Spoolman usage report")
        except Exception as e:
            logger.warning(f"Spoolman usage reporting failed: {e}")

    # Run slow operations as background tasks to avoid blocking the event loop
    # These operations can take 5-10+ seconds and would freeze the UI if awaited
    starting_kwh = _print_energy_start.pop(archive_id, None)

    async def _background_energy_calculation():
        """Calculate and save energy usage in background."""
        try:
            logger.info(f"[ENERGY-BG] Starting energy calculation for archive {archive_id}")
            async with async_session() as db:
                plug_result = await db.execute(select(SmartPlug).where(SmartPlug.printer_id == printer_id))
                plug = plug_result.scalar_one_or_none()

                if plug:
                    energy = await tasmota_service.get_energy(plug)
                    logger.info(f"[ENERGY-BG] Energy response: {energy}")

                    energy_used = None
                    if starting_kwh is not None and energy and energy.get("total") is not None:
                        ending_kwh = energy["total"]
                        energy_used = round(ending_kwh - starting_kwh, 4)
                        logger.info(f"[ENERGY-BG] Per-print energy: {energy_used} kWh")

                    if energy_used is not None and energy_used >= 0:
                        from backend.app.api.routes.settings import get_setting

                        energy_cost_per_kwh = await get_setting(db, "energy_cost_per_kwh")
                        cost_per_kwh = float(energy_cost_per_kwh) if energy_cost_per_kwh else 0.15
                        energy_cost = round(energy_used * cost_per_kwh, 2)

                        from backend.app.models.archive import PrintArchive

                        result = await db.execute(select(PrintArchive).where(PrintArchive.id == archive_id))
                        archive = result.scalar_one_or_none()
                        if archive:
                            archive.energy_kwh = energy_used
                            archive.energy_cost = energy_cost
                            await db.commit()
                            logger.info(f"[ENERGY-BG] Saved: {energy_used} kWh, cost={energy_cost}")
                else:
                    logger.info(f"[ENERGY-BG] No smart plug for printer {printer_id}")
        except Exception as e:
            logger.warning(f"[ENERGY-BG] Failed: {e}")

    async def _background_finish_photo():
        """Capture finish photo in background."""
        try:
            logger.info(f"[PHOTO-BG] Starting finish photo capture for archive {archive_id}")

            from backend.app.api.routes.camera import _active_streams, get_buffered_frame

            async with async_session() as db:
                from backend.app.api.routes.settings import get_setting

                capture_enabled = await get_setting(db, "capture_finish_photo")

                if capture_enabled is None or capture_enabled.lower() == "true":
                    from backend.app.models.printer import Printer

                    result = await db.execute(select(Printer).where(Printer.id == printer_id))
                    printer = result.scalar_one_or_none()

                    if printer and archive_id:
                        from backend.app.models.archive import PrintArchive

                        result = await db.execute(select(PrintArchive).where(PrintArchive.id == archive_id))
                        archive = result.scalar_one_or_none()

                        if archive:
                            import uuid
                            from datetime import datetime
                            from pathlib import Path

                            archive_dir = app_settings.base_dir / Path(archive.file_path).parent
                            photo_filename = None

                            # Check if camera stream is active - use buffered frame to avoid freeze
                            active_for_printer = [k for k in _active_streams if k.startswith(f"{printer_id}-")]
                            buffered_frame = get_buffered_frame(printer_id)

                            if active_for_printer and buffered_frame:
                                # Use frame from active stream
                                logger.info("[PHOTO-BG] Using buffered frame from active stream")
                                photos_dir = archive_dir / "photos"
                                photos_dir.mkdir(parents=True, exist_ok=True)
                                timestamp = datetime.now().strftime("%Y%m%d_%H%M%S")
                                photo_filename = f"finish_{timestamp}_{uuid.uuid4().hex[:8]}.jpg"
                                photo_path = photos_dir / photo_filename
                                await asyncio.to_thread(photo_path.write_bytes, buffered_frame)
                                logger.info(f"[PHOTO-BG] Saved buffered frame: {photo_filename}")
                            else:
                                # No active stream - capture new frame
                                from backend.app.services.camera import capture_finish_photo

                                photo_filename = await capture_finish_photo(
                                    printer_id=printer_id,
                                    ip_address=printer.ip_address,
                                    access_code=printer.access_code,
                                    model=printer.model,
                                    archive_dir=archive_dir,
                                )

                            if photo_filename:
                                photos = archive.photos or []
                                photos.append(photo_filename)
                                archive.photos = photos
                                await db.commit()
                                logger.info(f"[PHOTO-BG] Saved: {photo_filename}")
        except Exception as e:
            logger.warning(f"[PHOTO-BG] Failed: {e}")

    asyncio.create_task(_background_energy_calculation())
    asyncio.create_task(_background_finish_photo())  # Skips if camera stream active
    log_timing("Background tasks scheduled (energy, photo)")

    # Also run smart plug, notifications, and maintenance as background tasks
    print_status = data.get("status", "completed")

    async def _background_smart_plug():
        """Handle smart plug automation in background."""
        try:
            logger.info(f"[AUTO-OFF-BG] Starting smart plug automation for printer {printer_id}")
            async with async_session() as db:
                await smart_plug_manager.on_print_complete(printer_id, print_status, db)
                logger.info("[AUTO-OFF-BG] Completed")
        except Exception as e:
            logger.warning(f"[AUTO-OFF-BG] Failed: {e}")

    async def _background_notifications():
        """Send print complete notifications in background."""
        try:
            logger.info(f"[NOTIFY-BG] Starting notifications for printer {printer_id}")
            async with async_session() as db:
                from backend.app.models.archive import PrintArchive
                from backend.app.models.printer import Printer

                result = await db.execute(select(Printer).where(Printer.id == printer_id))
                printer = result.scalar_one_or_none()
                printer_name = printer.name if printer else f"Printer {printer_id}"

                archive_data = None
                if archive_id:
                    archive_result = await db.execute(select(PrintArchive).where(PrintArchive.id == archive_id))
                    archive = archive_result.scalar_one_or_none()
                    if archive:
                        archive_data = {
                            "print_time_seconds": archive.print_time_seconds,
                            "actual_filament_grams": archive.filament_used_grams,
                            "failure_reason": archive.failure_reason,
                        }

                await notification_service.on_print_complete(
                    printer_id, printer_name, print_status, data, db, archive_data=archive_data
                )
                logger.info("[NOTIFY-BG] Completed")
        except Exception as e:
            logger.warning(f"[NOTIFY-BG] Failed: {e}")

    async def _background_maintenance_check():
        """Check for maintenance due in background."""
        if print_status != "completed":
            return
        try:
            logger.info(f"[MAINT-BG] Starting maintenance check for printer {printer_id}")
            async with async_session() as db:
                from backend.app.models.printer import Printer

                result = await db.execute(select(Printer).where(Printer.id == printer_id))
                printer = result.scalar_one_or_none()
                printer_name = printer.name if printer else f"Printer {printer_id}"

                await ensure_default_types(db)
                overview = await _get_printer_maintenance_internal(printer_id, db, commit=True)

                items_needing_attention = [
                    {"name": item.maintenance_type_name, "is_due": item.is_due, "is_warning": item.is_warning}
                    for item in overview.maintenance_items
                    if item.enabled and (item.is_due or item.is_warning)
                ]

                if items_needing_attention:
                    await notification_service.on_maintenance_due(printer_id, printer_name, items_needing_attention, db)
                    logger.info(f"[MAINT-BG] Sent notification: {len(items_needing_attention)} items need attention")
                else:
                    logger.info("[MAINT-BG] Completed (no items need attention)")
        except Exception as e:
            logger.warning(f"[MAINT-BG] Failed: {e}")

    asyncio.create_task(_background_smart_plug())
    asyncio.create_task(_background_notifications())
    asyncio.create_task(_background_maintenance_check())
    log_timing("All background tasks scheduled")

    # Auto-scan for timelapse if recording was active during the print
    if archive_id and data.get("timelapse_was_active") and data.get("status") == "completed":
        logger.info(f"[TIMELAPSE] Timelapse was active during print, scheduling auto-scan for archive {archive_id}")
        # Schedule timelapse scan as background task with retries
        # The printer needs time to encode the video after print completion
        asyncio.create_task(_scan_for_timelapse_with_retries(archive_id))
        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")
            )
            queue_item = result.scalar_one_or_none()
            if queue_item:
                status = data.get("status", "completed")
                queue_item.status = status
                queue_item.completed_at = datetime.now()
                await db.commit()
                logger.info(f"Updated queue item {queue_item.id} status to {status}")

                # 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(f"Auto-off requested for printer {printer_id}, waiting for cooldown...")

                        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(f"Powered off printer {pid} via smart plug '{p.name}'")
                                    else:
                                        logger.warning(f"Failed to power off printer {pid} via smart plug")

                        asyncio.create_task(cooldown_and_poweroff(printer_id, plug.id))
    except Exception as e:
        import logging

        logging.getLogger(__name__).warning(f"Queue item update failed: {e}")

    log_timing("Queue item update")
    logger.info(f"[CALLBACK] on_print_complete finished for printer {printer_id}, archive {archive_id}")


# AMS sensor history recording
_ams_history_task: asyncio.Task | None = None
AMS_HISTORY_INTERVAL = 300  # Record every 5 minutes
AMS_HISTORY_RETENTION_DAYS = 30  # Keep data for 30 days
_ams_cleanup_counter = 0  # Track recordings to trigger periodic cleanup
_ams_alarm_cooldown: dict[str, datetime] = {}  # Track alarm cooldowns (printer_id:ams_id:type -> last_alarm_time)
AMS_ALARM_COOLDOWN_MINUTES = 60  # Don't send same alarm more than once per hour


async def record_ams_history():
    """Background task to record AMS humidity and temperature data."""
    import logging

    logger = logging.getLogger(__name__)

    # Wait a short time for MQTT connections to establish on startup
    await asyncio.sleep(10)

    while True:
        try:
            from backend.app.models.ams_history import AMSSensorHistory
            from backend.app.models.printer import Printer
            from backend.app.models.settings import Settings

            async with async_session() as db:
                # Get all active printers
                result = await db.execute(select(Printer).where(Printer.is_active.is_(True)))
                printers = result.scalars().all()

                # Get alarm thresholds from settings
                humidity_threshold = 60.0  # Default: fair threshold
                temp_threshold = 35.0  # Default: fair threshold
                result = await db.execute(select(Settings).where(Settings.key == "ams_humidity_fair"))
                setting = result.scalar_one_or_none()
                if setting:
                    try:
                        humidity_threshold = float(setting.value)
                    except (ValueError, TypeError):
                        pass
                result = await db.execute(select(Settings).where(Settings.key == "ams_temp_fair"))
                setting = result.scalar_one_or_none()
                if setting:
                    try:
                        temp_threshold = float(setting.value)
                    except (ValueError, TypeError):
                        pass

                recorded_count = 0
                for printer in printers:
                    # Get current state from printer manager
                    state = printer_manager.get_status(printer.id)
                    if not state or not state.connected or not state.raw_data:
                        continue  # Skip disconnected printers - don't use stale data

                    raw_data = state.raw_data
                    if "ams" not in raw_data or not isinstance(raw_data["ams"], list):
                        continue

                    # Record data for each AMS unit
                    for ams_data in raw_data["ams"]:
                        ams_id = int(ams_data.get("id", 0))

                        # Get humidity (prefer humidity_raw)
                        humidity_raw = ams_data.get("humidity_raw")
                        humidity_idx = ams_data.get("humidity")
                        humidity = None
                        if humidity_raw is not None:
                            try:
                                humidity = float(humidity_raw)
                            except (ValueError, TypeError):
                                pass
                        if humidity is None and humidity_idx is not None:
                            try:
                                humidity = float(humidity_idx)
                            except (ValueError, TypeError):
                                pass

                        # Get temperature
                        temperature = None
                        temp_str = ams_data.get("temp")
                        if temp_str is not None:
                            try:
                                temperature = float(temp_str)
                            except (ValueError, TypeError):
                                pass

                        # Skip if no data
                        if humidity is None and temperature is None:
                            continue

                        # Record the data point
                        history = AMSSensorHistory(
                            printer_id=printer.id,
                            ams_id=ams_id,
                            humidity=humidity,
                            humidity_raw=float(humidity_raw) if humidity_raw else None,
                            temperature=temperature,
                        )
                        db.add(history)
                        recorded_count += 1

                        # Generate AMS label and determine if it's AMS-HT (A, B, C, D or HT-A for AMS-Lite/Hub)
                        is_ams_ht = ams_id >= 128
                        if is_ams_ht:
                            ams_label = f"HT-{chr(65 + (ams_id - 128))}"
                        else:
                            ams_label = f"AMS-{chr(65 + ams_id)}"

                        # Check humidity alarm (only if above threshold)
                        if humidity is not None and humidity > humidity_threshold:
                            cooldown_key = f"{printer.id}:{ams_id}:humidity"
                            last_alarm = _ams_alarm_cooldown.get(cooldown_key)
                            now = datetime.now()
                            if (
                                last_alarm is None
                                or (now - last_alarm).total_seconds() >= AMS_ALARM_COOLDOWN_MINUTES * 60
                            ):
                                _ams_alarm_cooldown[cooldown_key] = now
                                logger.info(
                                    f"Sending humidity alarm for {printer.name} {ams_label}: {humidity}% > {humidity_threshold}%"
                                )
                                try:
                                    # Call different notification method based on AMS type
                                    if is_ams_ht:
                                        await notification_service.on_ams_ht_humidity_high(
                                            printer.id, printer.name, ams_label, humidity, humidity_threshold, db
                                        )
                                    else:
                                        await notification_service.on_ams_humidity_high(
                                            printer.id, printer.name, ams_label, humidity, humidity_threshold, db
                                        )
                                except Exception as e:
                                    logger.warning(f"Failed to send humidity alarm: {e}")

                        # Check temperature alarm (only if above threshold)
                        if temperature is not None and temperature > temp_threshold:
                            cooldown_key = f"{printer.id}:{ams_id}:temperature"
                            last_alarm = _ams_alarm_cooldown.get(cooldown_key)
                            now = datetime.now()
                            if (
                                last_alarm is None
                                or (now - last_alarm).total_seconds() >= AMS_ALARM_COOLDOWN_MINUTES * 60
                            ):
                                _ams_alarm_cooldown[cooldown_key] = now
                                logger.info(
                                    f"Sending temperature alarm for {printer.name} {ams_label}: {temperature}°C > {temp_threshold}°C"
                                )
                                try:
                                    # Call different notification method based on AMS type
                                    if is_ams_ht:
                                        await notification_service.on_ams_ht_temperature_high(
                                            printer.id, printer.name, ams_label, temperature, temp_threshold, db
                                        )
                                    else:
                                        await notification_service.on_ams_temperature_high(
                                            printer.id, printer.name, ams_label, temperature, temp_threshold, db
                                        )
                                except Exception as e:
                                    logger.warning(f"Failed to send temperature alarm: {e}")

                await db.commit()
                if recorded_count > 0:
                    logger.info(f"Recorded {recorded_count} AMS sensor history entries")

                # Periodic cleanup of old data (every ~288 recordings = ~24 hours at 5min interval)
                global _ams_cleanup_counter
                _ams_cleanup_counter += 1
                if _ams_cleanup_counter >= 288:
                    _ams_cleanup_counter = 0
                    # Get retention days from settings
                    from backend.app.models.settings import Settings

                    result = await db.execute(select(Settings).where(Settings.key == "ams_history_retention_days"))
                    setting = result.scalar_one_or_none()
                    retention_days = int(setting.value) if setting else AMS_HISTORY_RETENTION_DAYS

                    cutoff = datetime.now() - timedelta(days=retention_days)
                    result = await db.execute(delete(AMSSensorHistory).where(AMSSensorHistory.recorded_at < cutoff))
                    await db.commit()
                    if result.rowcount > 0:
                        logger.info(
                            f"Cleaned up {result.rowcount} old AMS sensor history entries (older than {retention_days} days)"
                        )

            # Wait until next recording interval
            await asyncio.sleep(AMS_HISTORY_INTERVAL)

        except asyncio.CancelledError:
            break
        except Exception as e:
            logger.warning(f"AMS history recording failed: {e}")
            await asyncio.sleep(60)  # Wait a bit before retrying


def start_ams_history_recording():
    """Start the AMS history recording background task."""
    global _ams_history_task
    if _ams_history_task is None:
        _ams_history_task = asyncio.create_task(record_ams_history())
        logging.getLogger(__name__).info("AMS history recording started")


def stop_ams_history_recording():
    """Stop the AMS history recording background task."""
    global _ams_history_task
    if _ams_history_task:
        _ams_history_task.cancel()
        _ams_history_task = None
        logging.getLogger(__name__).info("AMS history recording stopped")


# Printer runtime tracking
_runtime_tracking_task: asyncio.Task | None = None
RUNTIME_TRACKING_INTERVAL = 30  # Update every 30 seconds


async def track_printer_runtime():
    """Background task to track printer active runtime (RUNNING/PAUSE states)."""
    import logging

    logger = logging.getLogger(__name__)

    # Wait for MQTT connections to establish on startup
    await asyncio.sleep(15)

    while True:
        try:
            from backend.app.models.printer import Printer

            async with async_session() as db:
                # Get all active printers
                result = await db.execute(select(Printer).where(Printer.is_active.is_(True)))
                printers = result.scalars().all()

                now = datetime.now()
                updated_count = 0

                needs_commit = False

                for printer in printers:
                    # Get current state from printer manager
                    state = printer_manager.get_status(printer.id)
                    if not state:
                        logger.debug(f"[{printer.name}] Runtime tracking: no state available")
                        continue
                    if not state.connected:
                        logger.debug(f"[{printer.name}] Runtime tracking: not connected")
                        continue

                    # Check if printer is in an active state (RUNNING or PAUSE)
                    if state.state in ("RUNNING", "PAUSE"):
                        # Calculate time since last update
                        if printer.last_runtime_update:
                            elapsed = (now - printer.last_runtime_update).total_seconds()
                            # Sanity check: don't add more than 2x the interval (handles server restarts)
                            if elapsed > 0 and elapsed < RUNTIME_TRACKING_INTERVAL * 2:
                                printer.runtime_seconds += int(elapsed)
                                updated_count += 1
                                needs_commit = True
                                logger.debug(
                                    f"[{printer.name}] Runtime tracking: added {int(elapsed)}s, "
                                    f"total={printer.runtime_seconds}s ({printer.runtime_seconds / 3600:.2f}h)"
                                )
                            else:
                                logger.warning(
                                    f"[{printer.name}] Runtime tracking: skipped elapsed={elapsed:.1f}s "
                                    f"(outside valid range 0-{RUNTIME_TRACKING_INTERVAL * 2}s)"
                                )
                        else:
                            # First time seeing printer active - need to commit to save timestamp
                            needs_commit = True
                            logger.debug(f"[{printer.name}] Runtime tracking: first active detection")

                        printer.last_runtime_update = now
                    else:
                        # Printer is idle/offline - clear last_runtime_update
                        if printer.last_runtime_update is not None:
                            logger.debug(
                                f"[{printer.name}] Runtime tracking: state={state.state}, clearing last_runtime_update"
                            )
                            printer.last_runtime_update = None
                            needs_commit = True

                if needs_commit:
                    await db.commit()
                    if updated_count > 0:
                        logger.debug(f"Updated runtime for {updated_count} printer(s)")

        except asyncio.CancelledError:
            logger.info("Runtime tracking cancelled")
            break
        except Exception as e:
            logger.warning(f"Runtime tracking failed: {e}")

        await asyncio.sleep(RUNTIME_TRACKING_INTERVAL)


def start_runtime_tracking():
    """Start the printer runtime tracking background task."""
    global _runtime_tracking_task
    if _runtime_tracking_task is None:
        _runtime_tracking_task = asyncio.create_task(track_printer_runtime())
        logging.getLogger(__name__).info("Printer runtime tracking started")


def stop_runtime_tracking():
    """Stop the printer runtime tracking background task."""
    global _runtime_tracking_task
    if _runtime_tracking_task:
        _runtime_tracking_task.cancel()
        _runtime_tracking_task = None
        logging.getLogger(__name__).info("Printer runtime tracking stopped")


@asynccontextmanager
async def lifespan(app: FastAPI):
    # Startup
    await init_db()

    # Restore debug logging state from previous session
    await init_debug_logging()

    # Set up printer manager callbacks
    loop = asyncio.get_event_loop()
    printer_manager.set_event_loop(loop)
    printer_manager.set_status_change_callback(on_printer_status_change)
    printer_manager.set_print_start_callback(on_print_start)
    printer_manager.set_print_complete_callback(on_print_complete)
    printer_manager.set_ams_change_callback(on_ams_change)

    # Connect to all active printers
    async with async_session() as db:
        await init_printer_connections(db)

    # Auto-connect to Spoolman if enabled
    async with async_session() as db:
        from backend.app.api.routes.settings import get_setting

        spoolman_enabled = await get_setting(db, "spoolman_enabled")
        spoolman_url = await get_setting(db, "spoolman_url")

        if spoolman_enabled and spoolman_enabled.lower() == "true" and spoolman_url:
            try:
                client = await init_spoolman_client(spoolman_url)
                if await client.health_check():
                    logging.info(f"Auto-connected to Spoolman at {spoolman_url}")
                else:
                    logging.warning(f"Spoolman at {spoolman_url} is not reachable")
            except Exception as e:
                logging.warning(f"Failed to auto-connect to Spoolman: {e}")

    # Start the print scheduler
    asyncio.create_task(print_scheduler.run())

    # Start the smart plug scheduler for time-based on/off
    smart_plug_manager.start_scheduler()

    # Resume any pending auto-offs that were interrupted by restart
    await smart_plug_manager.resume_pending_auto_offs()

    # Start the notification digest scheduler
    notification_service.start_digest_scheduler()

    # Start AMS history recording
    start_ams_history_recording()

    # Start printer runtime tracking
    start_runtime_tracking()

    # Start anonymous telemetry (opt-out via settings)
    asyncio.create_task(start_telemetry_loop(async_session))

    # Initialize virtual printer manager
    from backend.app.services.virtual_printer import virtual_printer_manager

    virtual_printer_manager.set_session_factory(async_session)

    # Auto-start virtual printer if enabled
    async with async_session() as db:
        from backend.app.api.routes.settings import get_setting

        vp_enabled = await get_setting(db, "virtual_printer_enabled")
        if vp_enabled and vp_enabled.lower() == "true":
            vp_access_code = await get_setting(db, "virtual_printer_access_code") or ""
            vp_mode = await get_setting(db, "virtual_printer_mode") or "immediate"
            vp_model = await get_setting(db, "virtual_printer_model") or ""

            if vp_access_code:
                try:
                    await virtual_printer_manager.configure(
                        enabled=True,
                        access_code=vp_access_code,
                        mode=vp_mode,
                        model=vp_model,
                    )
                    logging.info(f"Virtual printer started (model={vp_model or 'default'})")
                except Exception as e:
                    logging.warning(f"Failed to start virtual printer: {e}")

    yield

    # Shutdown
    print_scheduler.stop()
    smart_plug_manager.stop_scheduler()
    notification_service.stop_digest_scheduler()
    stop_ams_history_recording()
    stop_runtime_tracking()
    printer_manager.disconnect_all()
    await close_spoolman_client()

    # Stop virtual printer if running
    if virtual_printer_manager.is_enabled:
        await virtual_printer_manager.configure(enabled=False)


app = FastAPI(
    title=app_settings.app_name,
    description="Archive and manage Bambu Lab 3MF files",
    version=APP_VERSION,
    lifespan=lifespan,
)

# API routes
app.include_router(printers.router, prefix=app_settings.api_prefix)
app.include_router(archives.router, prefix=app_settings.api_prefix)
app.include_router(filaments.router, prefix=app_settings.api_prefix)
app.include_router(settings_routes.router, prefix=app_settings.api_prefix)
app.include_router(cloud.router, prefix=app_settings.api_prefix)
app.include_router(smart_plugs.router, prefix=app_settings.api_prefix)
app.include_router(print_queue.router, prefix=app_settings.api_prefix)
app.include_router(kprofiles.router, prefix=app_settings.api_prefix)
app.include_router(notifications.router, prefix=app_settings.api_prefix)
app.include_router(notification_templates.router, prefix=app_settings.api_prefix)
app.include_router(spoolman.router, prefix=app_settings.api_prefix)
app.include_router(updates.router, prefix=app_settings.api_prefix)
app.include_router(maintenance.router, prefix=app_settings.api_prefix)
app.include_router(camera.router, prefix=app_settings.api_prefix)
app.include_router(external_links.router, prefix=app_settings.api_prefix)
app.include_router(projects.router, prefix=app_settings.api_prefix)
app.include_router(api_keys.router, prefix=app_settings.api_prefix)
app.include_router(webhook.router, prefix=app_settings.api_prefix)
app.include_router(ams_history.router, prefix=app_settings.api_prefix)
app.include_router(system.router, prefix=app_settings.api_prefix)
app.include_router(support.router, prefix=app_settings.api_prefix)
app.include_router(websocket.router, prefix=app_settings.api_prefix)
app.include_router(discovery.router, prefix=app_settings.api_prefix)
app.include_router(pending_uploads.router, prefix=app_settings.api_prefix)
app.include_router(firmware.router, prefix=app_settings.api_prefix)


# Serve static files (React build)
if app_settings.static_dir.exists() and any(app_settings.static_dir.iterdir()):
    app.mount(
        "/assets",
        StaticFiles(directory=app_settings.static_dir / "assets"),
        name="assets",
    )
    if (app_settings.static_dir / "img").exists():
        app.mount(
            "/img",
            StaticFiles(directory=app_settings.static_dir / "img"),
            name="img",
        )
    if (app_settings.static_dir / "icons").exists():
        app.mount(
            "/icons",
            StaticFiles(directory=app_settings.static_dir / "icons"),
            name="icons",
        )


@app.get("/")
async def serve_frontend():
    """Serve the React frontend."""
    index_file = app_settings.static_dir / "index.html"
    if index_file.exists():
        return FileResponse(index_file)
    return {
        "message": "Bambuddy API",
        "docs": "/docs",
        "frontend": "Build and place React app in /static directory",
    }


@app.get("/health")
async def health_check():
    """Health check endpoint."""
    return {"status": "healthy"}


@app.get("/manifest.json")
async def serve_manifest():
    """Serve PWA manifest."""
    manifest_file = app_settings.static_dir / "manifest.json"
    if manifest_file.exists():
        return FileResponse(manifest_file, media_type="application/manifest+json")
    return {"error": "Manifest not found"}


@app.get("/sw.js")
async def serve_service_worker():
    """Serve service worker."""
    sw_file = app_settings.static_dir / "sw.js"
    if sw_file.exists():
        return FileResponse(sw_file, media_type="application/javascript")
    return {"error": "Service worker not found"}


# Catch-all route for React Router (must be last)
@app.get("/{full_path:path}")
async def serve_spa(full_path: str):
    """Serve React app for client-side routing."""
    # Don't intercept API routes
    if full_path.startswith("api/"):
        return {"error": "Not found"}

    index_file = app_settings.static_dir / "index.html"
    if index_file.exists():
        return FileResponse(index_file)

    return {"error": "Frontend not built"}