fix(warehouse): correct label extension, surface print errors, revert…

[thesleepyniko]

… status on carrier failure

• Use .png extension for Chit Chats PNG labels (was hardcoded .pdf, breaking PDF readers)
• Wrap QZ Tray qz.print() calls in try/catch and surface failures via labelErrors[orderId]
• Revert warehouseOrder.status back to APPROVED if carrier throws after the SHIPPED claim, so retries don't hit "already shipped" 409

[vercel]

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Project	Deployment	Actions	Updated (UTC)
resolution	Ready	Preview, Comment	May 19, 2026 10:28pm

[Copilot]

Pull request overview

This PR improves warehouse label/packing-slip handling by fixing Chit Chats label download filenames, surfacing QZ Tray print failures in the UI, and making /api/fulfillment/get-label resilient to carrier failures by rolling back an order’s status when shipment creation fails after the “SHIPPED” claim.

Changes:

• Generate label download filenames with a .png extension when the label is a PNG data URL.
• Wrap QZ Tray qz.print() calls in try/catch and report failures via labelErrors[orderId].
• Add a try/catch around post-claim shipment creation so failures revert warehouseOrder.status from SHIPPED back to APPROVED to allow retries.

Reviewed changes

Copilot reviewed 2 out of 2 changed files in this pull request and generated 2 comments.

File	Description
resolution-frontend/src/routes/app/warehouse/fulfillment/+page.svelte	Adds label filename inference for PNG/PDF and surfaces QZ print errors per order.
resolution-frontend/src/routes/api/fulfillment/get-label/+server.ts	Rolls back status to APPROVED on post-claim carrier failures to avoid “already shipped” retry dead-ends.

Comments suppressed due to low confidence (2)

resolution-frontend/src/routes/app/warehouse/fulfillment/+page.svelte:112

• printAll now records print failures in labelErrors, but it never clears a previous error when the user retries printing. This can leave a stale error displayed even after a subsequent successful print. Consider resetting labelErrors[orderId] at the start of printAll (and/or clearing it after successful label + slip printing).

	async function printAll(orderId: string, result: { labelUrl: string | null; packingSlipBase64: string }) {
		if (!qz || qzStatus !== 'connected') return;
		const settings = getQZSettings();
		if (!settings.printer) { alert('No printer selected. Go to Settings to configure.'); return; }
		const config = () => qz.configs.create(settings.printer, {

resolution-frontend/src/routes/api/fulfillment/get-label/+server.ts:160

• The try { block introduced here isn't indented, which makes it harder to visually see what is covered by the rollback catch. Re-indent the code inside the try to match the surrounding style.

	try {
	// Total weight always comes from items. Dimensions come from the packaging
	// record chosen at estimate time so the carrier request matches the quote.
	// Fall back to item-derived dims for legacy orders without packaging info.
	const MAX_HEIGHT_IN = 48;

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