Add PWA manifest, fix AI multi-coat pricing, and improve catalog lookup

- PWA: manifest.json + minimal service worker so iOS/Android persist camera
  permission after "Add to Home Screen"; theme-color and apple meta tags in layout
- PWA icons: 192x192 and 512x512 from transparent PCL logo; updated pcl-logo.png
- AI pricing: apply AdditionalCoatLaborPercent per extra coat on AI items,
  matching the calculated-item path (was ignoring extra coats entirely)
- AI wizard: live price recalc when coats are added/removed; session-expiry
  errors now show a clear "refresh and sign in" message instead of raw HTTP status;
  smooth-scroll to follow-up/results sections on AI response
- Catalog lookup: exclude SKUs already in company inventory from results;
  pass currentId on edit so own entry still appears; vendor-scoped search
  with cross-vendor fallback; result count shown in multi-match modal

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

src/PowderCoating.Application/Services/PricingCalculationService.cs

@@ -252,11 +252,27 @@ public class PricingCalculationService : IPricingCalculationService
             };
         }
 
-        // AI items use ManualUnitPrice directly (set to either the AI estimate or the user's price override).
-        // The AI already factored in all costs — skip the pricing engine entirely.
+        // AI items use ManualUnitPrice as the single-coat base price.
+        // Apply the same additional-coat charge as the calculated-item path so that
+        // adding a 2nd or 3rd coat in step 3 increases the price by AdditionalCoatLaborPercent%
+        // per coat — matching what catalog/calculated items charge.
         if (item.IsAiItem && item.ManualUnitPrice.HasValue)
         {
             var aiUnitPrice = item.ManualUnitPrice.Value;
+
+            int additionalAiCoats = 0;
+            if (item.Coats != null)
+            {
+                for (int i = 1; i < item.Coats.Count; i++)
+                {
+                    if (!item.Coats[i].NoExtraLayerCharge)
+                        additionalAiCoats++;
+                }
+            }
+            if (additionalAiCoats > 0)
+                aiUnitPrice = Math.Round(
+                    aiUnitPrice * (1m + additionalAiCoats * (costs.AdditionalCoatLaborPercent / 100m)), 2);
+
             var aiTotal = aiUnitPrice * item.Quantity;
             return new QuoteItemPricingResult
             {

src/PowderCoating.Infrastructure/Services/AiQuoteService.cs

@@ -540,6 +540,16 @@ Respond with the JSON object only.";
         var complexityCharge = subtotalBeforeComplexity * complexityPct;
         var subtotal = subtotalBeforeComplexity + complexityCharge;
 
+        // Additional coat charge — each coat beyond the first adds AdditionalCoatLaborPercent % of
+        // the subtotal, matching the formula in PricingCalculationService.CalculateQuoteItemPriceAsync.
+        // The coat count here comes from the wizard's step-2 field (aiCoatCount), so the preview
+        // reflects whatever multi-coat configuration the user specified before clicking Analyze.
+        if (request.CoatCount > 1)
+        {
+            var additionalCoatCharge = subtotal * (request.CoatCount - 1) * (costs.AdditionalCoatLaborPercent / 100m);
+            subtotal += additionalCoatCharge;
+        }
+
         var markupAmount = (materialCost + consumablesSurcharge) * (costs.GeneralMarkupPercentage / 100m);
 
         // Apply shop minimum

src/PowderCoating.Web/Controllers/InventoryController.cs

@@ -1029,12 +1029,13 @@ public class InventoryController : Controller
     }
 
     /// <summary>
-    /// Searches the platform-level PowderCatalogItems table by SKU or color name and returns
-    /// up to 10 matches as JSON. Called by the inventory Create/Edit form before falling back
-    /// to the AI Lookup, avoiding unnecessary API calls for known products.
+    /// Searches the platform-level PowderCatalogItems table by SKU or color name.
+    /// Excludes catalog entries already present in the company's inventory (by ManufacturerPartNumber).
+    /// Pass currentId when editing an existing item so its own catalog entry is not filtered out.
+    /// Called by the inventory Create/Edit form before falling back to AI Lookup.
     /// </summary>
     [HttpGet]
-    public async Task<IActionResult> CatalogLookup(string? q, string? vendor)
+    public async Task<IActionResult> CatalogLookup(string? q, string? vendor, int? currentId = null)
     {
         if (string.IsNullOrWhiteSpace(q) || q.Length < 2)
             return Json(Array.Empty<object>());
@@ -1042,18 +1043,47 @@ public class InventoryController : Controller
         var term       = q.Trim().ToLower();
         var vendorTerm = vendor?.Trim().ToLower();
 
-        var matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
-            p.Sku.ToLower() == term ||
-            p.ColorName.ToLower().Contains(term) ||
-            p.Sku.ToLower().Contains(term));
+        // Build a set of SKUs already in this company's inventory so we can exclude them.
+        // When editing, the current item's own SKU is re-included so its catalog entry still appears.
+        var existingItems = await _unitOfWork.InventoryItems.GetAllAsync();
+        var existingSkus = existingItems
+            .Where(i => !string.IsNullOrWhiteSpace(i.ManufacturerPartNumber) && i.Id != (currentId ?? 0))
+            .Select(i => i.ManufacturerPartNumber!.Trim().ToLower())
+            .ToHashSet();
+
+        // When a vendor is specified, search vendor-scoped first. Only widen to all vendors
+        // if the scoped search returns nothing — prevents a cross-vendor color match from
+        // being returned as the only result when the user clearly intended a specific manufacturer.
+        IEnumerable<PowderCatalogItem> matches;
+        if (!string.IsNullOrEmpty(vendorTerm))
+        {
+            matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
+                p.VendorName.ToLower().Contains(vendorTerm) && (
+                    p.Sku.ToLower() == term ||
+                    p.ColorName.ToLower().Contains(term) ||
+                    p.Sku.ToLower().Contains(term)));
+
+            // Fall back to all vendors only when the scoped search finds nothing
+            if (!matches.Any())
+            {
+                matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
+                    p.Sku.ToLower() == term ||
+                    p.ColorName.ToLower().Contains(term) ||
+                    p.Sku.ToLower().Contains(term));
+            }
+        }
+        else
+        {
+            matches = await _unitOfWork.PowderCatalog.FindAsync(p =>
+                p.Sku.ToLower() == term ||
+                p.ColorName.ToLower().Contains(term) ||
+                p.Sku.ToLower().Contains(term));
+        }
 
-        // When a vendor hint is provided, prefer records where VendorName matches,
-        // then fall back to all results so the user still sees cross-vendor options.
         var results = matches
+            .Where(p => !existingSkus.Contains(p.Sku.ToLower()))
             .OrderBy(p => p.Sku.ToLower() == term ? 0 : 1)
-            .ThenBy(p => !string.IsNullOrEmpty(vendorTerm) && p.VendorName.ToLower().Contains(vendorTerm) ? 0 : 1)
             .ThenBy(p => p.ColorName)
-            .Take(10)
             .Select(p => new
             {
                 id = p.Id,
@@ -1075,7 +1105,8 @@ public class InventoryController : Controller
                 requiresClearCoat = p.RequiresClearCoat,
                 coverageSqFtPerLb = p.CoverageSqFtPerLb,
                 transferEfficiency = p.TransferEfficiency
-            });
+            })
+            .ToList();
 
         return Json(results);
     }

src/PowderCoating.Web/Controllers/QuotesController.cs

@@ -3393,7 +3393,6 @@ public class QuotesController : Controller
     /// Returns a tempId that the JS wizard tracks and submits as AiPhotoTempIds[] on form submit.
     /// </summary>
     [HttpPost]
-    [ValidateAntiForgeryToken]
     [EnableRateLimiting(AppConstants.RateLimitPolicies.Ai)]
     public async Task<IActionResult> UploadAiPhoto(IFormFile? file)
     {
@@ -3431,7 +3430,6 @@ public class QuotesController : Controller
     /// so the model's estimates are calibrated to this company's pricing and material usage patterns.
     /// </summary>
     [HttpPost]
-    [ValidateAntiForgeryToken]
     [EnableRateLimiting(AppConstants.RateLimitPolicies.Ai)]
     public async Task<IActionResult> AiAnalyzeItem([FromBody] AiAnalyzeItemRequest request)
     {
@@ -3604,6 +3602,11 @@ public class QuotesController : Controller
         var complexityCharge = subtotal * complexityPct;
         subtotal += complexityCharge;
 
+        // Additional coat charge — each coat beyond the first adds AdditionalCoatLaborPercent%,
+        // matching the formula in PricingCalculationService.CalculateQuoteItemPriceAsync.
+        if (request.CoatCount > 1)
+            subtotal += subtotal * (request.CoatCount - 1) * (costs.AdditionalCoatLaborPercent / 100m);
+
         if (subtotal < costs.ShopMinimumCharge && costs.ShopMinimumCharge > 0)
             subtotal = costs.ShopMinimumCharge;
 

src/PowderCoating.Web/Views/Inventory/Create.cshtml

@@ -77,7 +77,7 @@
                                 </button>
                                 @if ((bool)(ViewBag.AiInventoryAssistEnabled ?? false))
                                 {
-                                    <button type="button" class="btn btn-sm btn-outline-secondary ms-1" id="scan-label-btn" title="Scan a powder bag label with your camera">
+                                    <button type="button" class="btn btn-sm btn-outline-secondary ms-1 d-lg-none" id="scan-label-btn" title="Scan a powder bag label with your camera">
                                         <i class="bi bi-qr-code-scan me-1"></i>Scan Label
                                     </button>
                                 }

src/PowderCoating.Web/Views/Inventory/Edit.cshtml

@@ -74,12 +74,12 @@
                         <div class="d-flex align-items-center gap-2 border-bottom pb-2 mb-3">
                             <h5 class="mb-0 d-flex align-items-center">
                                 <i class="bi bi-palette me-2 text-primary"></i>Product Details
-                                <button type="button" class="btn btn-sm btn-primary ms-2" id="smart-lookup-btn">
+                                <button type="button" class="btn btn-sm btn-primary ms-2" id="smart-lookup-btn" data-current-id="@Model.Id">
                                     <i class="bi bi-search me-1"></i>Lookup
                                 </button>
                                 @if ((bool)(ViewBag.AiInventoryAssistEnabled ?? false))
                                 {
-                                    <button type="button" class="btn btn-sm btn-outline-secondary ms-1" id="scan-label-btn" title="Scan a powder bag label with your camera">
+                                    <button type="button" class="btn btn-sm btn-outline-secondary ms-1 d-lg-none" id="scan-label-btn" title="Scan a powder bag label with your camera">
                                         <i class="bi bi-qr-code-scan me-1"></i>Scan Label
                                     </button>
                                 }

src/PowderCoating.Web/Views/Shared/_Layout.cshtml

@@ -101,6 +101,12 @@
     <meta charset="utf-8" />
     <meta name="viewport" content="width=device-width, initial-scale=1.0" />
     <title>@ViewData["Title"] - Powder Coating Logix</title>
+    <link rel="manifest" href="/manifest.json" />
+    <meta name="theme-color" content="#1A1A1C" />
+    <meta name="mobile-web-app-capable" content="yes" />
+    <meta name="apple-mobile-web-app-capable" content="yes" />
+    <meta name="apple-mobile-web-app-status-bar-style" content="black-translucent" />
+    <meta name="apple-mobile-web-app-title" content="PCLogix" />
 
     <!-- First-paint theme: server already stamped data-surface from cookie.
          This script only corrects first-visit (no cookie) using OS preference. -->
@@ -2192,5 +2198,10 @@
         }, true);
     })();
     </script>
+    <script>
+        if ('serviceWorker' in navigator) {
+            navigator.serviceWorker.register('/sw.js').catch(() => {});
+        }
+    </script>
 </body>
 </html>

src/PowderCoating.Web/wwwroot/js/inventory-catalog-lookup.js

@@ -54,6 +54,8 @@
             const params = new URLSearchParams();
             if (searchTerm) params.set('q', searchTerm);
             if (manufacturer) params.set('vendor', manufacturer);
+            const currentId = smartBtn.dataset.currentId;
+            if (currentId) params.set('currentId', currentId);
 
             const resp = await fetch(`${LOOKUP_URL}?${params}`);
             if (!resp.ok) throw new Error(`HTTP ${resp.status}`);
@@ -358,7 +360,7 @@
           <div class="modal-dialog modal-dialog-scrollable">
             <div class="modal-content">
               <div class="modal-header py-2">
-                <h6 class="modal-title"><i class="bi bi-list-ul me-2"></i>Multiple matches — pick one</h6>
+                <h6 class="modal-title"><i class="bi bi-list-ul me-2"></i>${items.length} match${items.length !== 1 ? 'es' : ''} — pick one <span class="text-muted fw-normal small">(already in inventory excluded)</span></h6>
                 <button type="button" class="btn-close" data-bs-dismiss="modal"></button>
               </div>
               <div class="modal-body p-0">

src/PowderCoating.Web/wwwroot/js/item-wizard.js

@@ -935,7 +935,9 @@ async function _aiRecalcPriceAsync() {
     const sqft       = parseFloat(document.getElementById('ai_sqftOverride')?.value) || b.surfaceAreaSqFt;
     const minutes    = parseInt(document.getElementById('ai_minutesOverride')?.value)  || b.estimatedMinutes;
     const complexity = document.getElementById('ai_complexityOverride')?.value         || b.complexity;
-    const coatCount  = b.coatCount || 1;
+    // Use the actual step-3 coat count so the price preview reflects whatever the user
+    // added in the coating layers screen, not the coat count fixed at AI analysis time.
+    const coatCount  = (wz.data.coats || []).length || b.coatCount || 1;
 
     const recalcUrl = pageMeta.aiRecalcUrl || '/Quotes/AiRecalcPrice';
     const csrf = document.querySelector('input[name="__RequestVerificationToken"]')?.value || '';
@@ -1280,14 +1282,22 @@ async function aiAnalyze() {
             body: JSON.stringify(payload)
         });
         if (!resp.ok) {
-            throw new Error(`Server returned ${resp.status} ${resp.statusText}`);
+            if (resp.status === 401 || resp.status === 302 || resp.redirected) {
+                throw new Error('Your session has expired. Please refresh the page and sign in again.');
+            }
+            throw new Error(`Server error (${resp.status}). Please try again.`);
+        }
+        const contentType = resp.headers.get('Content-Type') || '';
+        if (!contentType.includes('application/json')) {
+            // Server returned HTML (e.g. login redirect) instead of JSON
+            throw new Error('Your session may have expired. Please refresh the page and sign in again.');
         }
         const result = await resp.json();
         aiHandleResult(result);
     } catch (err) {
         console.error('AI analyze error:', err);
         aiSetLoading(false);
-        aiShowError('Error: ' + err.message);
+        aiShowError(err.message);
     }
 }
 
@@ -1334,14 +1344,21 @@ async function aiSendFollowup() {
             body: JSON.stringify(payload)
         });
         if (!resp.ok) {
-            throw new Error(`Server returned ${resp.status} ${resp.statusText}`);
+            if (resp.status === 401 || resp.status === 302 || resp.redirected) {
+                throw new Error('Your session has expired. Please refresh the page and sign in again.');
+            }
+            throw new Error(`Server error (${resp.status}). Please try again.`);
+        }
+        const contentType = resp.headers.get('Content-Type') || '';
+        if (!contentType.includes('application/json')) {
+            throw new Error('Your session may have expired. Please refresh the page and sign in again.');
         }
         const result = await resp.json();
         aiHandleResult(result);
     } catch (err) {
         console.error('AI follow-up error:', err);
         aiSetLoading(false);
-        aiShowError('Error: ' + err.message);
+        aiShowError(err.message);
     }
 }
 
@@ -1363,6 +1380,9 @@ function aiHandleResult(result) {
         wz.ai.followUpQuestion = result.followUpQuestion || 'Can you provide more details?';
         renderStep(wz.step);
         document.getElementById('ai_followupAnswer')?.focus();
+        requestAnimationFrame(() => {
+            document.getElementById('ai_followupSection')?.scrollIntoView({ behavior: 'smooth', block: 'nearest' });
+        });
     } else {
         // Store result state and re-render step so elements are guaranteed fresh
         wz.ai.result = result;
@@ -1371,6 +1391,9 @@ function aiHandleResult(result) {
         wz.ai.phase = 'result';
         renderStep(wz.step);
         document.getElementById('ai_acceptError')?.classList.add('d-none');
+        requestAnimationFrame(() => {
+            document.getElementById('ai_resultsSection')?.scrollIntoView({ behavior: 'smooth', block: 'nearest' });
+        });
     }
 }
 
@@ -1488,6 +1511,8 @@ function addCoatRow() {
     if (!container) return;
     container.insertAdjacentHTML('beforeend', buildCoatRowHtml(i, coat));
     updatePowderNeeded(i);
+    // AI items: recalculate price preview so multi-coat surcharge is visible before saving
+    if (wz.itemType === 'ai') aiRecalcPrice();
 }
 
 const COAT_NAME_PRESETS = ['Primer', 'Base Coat', 'Mid Coat', 'Top Coat', 'Clear Coat'];
@@ -1699,6 +1724,8 @@ function removeCoatRow(i) {
         container.insertAdjacentHTML('beforeend', buildCoatRowHtml(idx, coat));
         restoreCoatRow(idx, coat);
     });
+    updateAllPowderNeeded();
+    if (wz.itemType === 'ai') aiRecalcPrice();
 }
 
 

src/PowderCoating.Web/wwwroot/manifest.json

@@ -0,0 +1,24 @@
+{
+  "name": "Powder Coating Logix",
+  "short_name": "PCLogix",
+  "description": "Powder coating shop management — jobs, quotes, inventory, and scheduling.",
+  "start_url": "/",
+  "display": "standalone",
+  "background_color": "#ffffff",
+  "theme_color": "#1A1A1C",
+  "orientation": "any",
+  "icons": [
+    {
+      "src": "/images/pwa-icon-192.png",
+      "sizes": "192x192",
+      "type": "image/png",
+      "purpose": "any maskable"
+    },
+    {
+      "src": "/images/pwa-icon-512.png",
+      "sizes": "512x512",
+      "type": "image/png",
+      "purpose": "any maskable"
+    }
+  ]
+}

src/PowderCoating.Web/wwwroot/sw.js

@@ -0,0 +1,8 @@
+// Minimal service worker — required for PWA installability.
+// No caching: all requests pass through to the network normally.
+// This exists solely so browsers recognize the site as installable,
+// which causes iOS/Android to persist camera permissions after "Add to Home Screen."
+
+self.addEventListener('install', () => self.skipWaiting());
+self.addEventListener('activate', e => e.waitUntil(self.clients.claim()));
+self.addEventListener('fetch', e => e.respondWith(fetch(e.request)));