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Scott Idem
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# PROJECT: Zebra ZC10L Hardware Test Day
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**Created:** 2026-03-12
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**Planned date:** ~week of 2026-03-16 (printer rented for one day)
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**Hardware:** Zebra ZC10L, 3.5" × 5.5" PVC card stock
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**Goal:** Validate real-world badge printing before Axonius (NYC, mid-April 2026)
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**Owner:** Scott Idem / One Sky IT
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---
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## Before the Printer Arrives — Pre-Test Checklist
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These must be done before the printer is on-site so you're not burning rental time on setup.
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- [ ] **Remove debug outlines** from `print/+page.svelte` print CSS.
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The lime/blue/red/orange/purple/cyan debug outlines are still in the file. Remove the
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entire `TEMPORARY DEBUG OUTLINES` block. Commit before the test day.
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- [ ] **Zebra ZC10L Linux driver** — install CUPS driver ahead of time.
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- Check Zebra's site for the Linux CUPS driver for ZC10L.
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- Install, configure in CUPS (`http://localhost:631`), do a test page print with a spare card.
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- Confirm the card feeds without jam and ink/dye-sub layer applies cleanly.
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- Driver may need the printer set to the correct card stock size (3.5" × 5.5").
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- [ ] **Wire `style_href`** — add `<link rel="stylesheet" href={...}>` to `<svelte:head>` in
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`print/+page.svelte` when `$lq__event_badge_template_obj?.style_href` is set.
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Without this, any client-specific external CSS won't load.
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See `documentation/MODULE__AE_Events_Badge_Templates.md` → "External CSS Approach".
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- [ ] **Confirm single-sided print (duplex=0)** — `duplex` backend field doesn't exist yet.
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For PVC cards, the badge back must NOT print. Verify this works by checking that
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`.badge_back` is hidden in `@media print` when the layout is `badge_3.5x5.5_pvc`.
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The PVC CSS (`badge_layout_zebra_zc10l_pvc.css`) may already handle this — confirm.
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If not, add a print rule: `[data-layout="badge_3.5x5.5_pvc"] .badge_back { display: none !important; }`
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- [ ] **Test event + template in dev DB** — create/confirm:
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- Event with `mod_badges_json` configured
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- PVC template: `layout: badge_3.5x5.5_pvc`, `duplex: 0` (once backend supports it),
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`header_path` set to a real image URL, `badge_type_list` JSON populated
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- Test badge records (see "Test Data Set" below)
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- [ ] **Test data set** — create badge records covering:
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- Short name: "Kim Lee"
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- Long name: "Bartholomew Vandenberghe-Christopoulos"
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- HTML in name: `<b>Dr.</b> Patricia Adams`
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- HTML in affiliations: `University of Minnesota<br>Dept. of Surgery`
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- Badge with no affiliations, no location
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- Badge with all 8 ticket codes set
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- Three different badge_type_codes (e.g. member, staff, guest) — to verify footer
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stripe color for each
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- [ ] **Browser setup on kiosk machine** — confirm Chrome and Firefox both installed.
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Test print dialog settings once driver is working:
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- Chrome: Margins → None (required), paper size set to 3.5×5.5 if available
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- Firefox: should just work — `@page { size: 3.5in 5.5in }` is honored
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---
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## Test Day Checklist
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### 1. Basic Print Path
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- [ ] Card feeds and prints without jam
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- [ ] Badge fills the card edge-to-edge (no white border, no clipping)
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- [ ] Content horizontally centered on the card
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- [ ] Content vertically centered on the card
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- [ ] No debug outlines visible (confirm cleanup commit applied)
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**Chrome:**
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- [ ] Print → Margins: **None** → correct output
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- [ ] Print → Margins: **Default** → bad (expected — documents the known issue)
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- [ ] Print → Margins: **Minimum** → correct output
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- [ ] "More settings" → paper size: does selecting 3.5×5.5 matter, or does Zebra driver override?
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**Firefox:**
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- [ ] Print → just works out of the box
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### 2. Single-Sided PVC
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- [ ] Only the front face prints — back does NOT print
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- [ ] No second card ejected or blank card printed for the back
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### 3. Visual Quality
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- [ ] Font sizes readable at 3.5×5.5 physical scale (name, title, affiliations, location)
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- [ ] Auto-scaling text (v2) — does it look natural, not crunched?
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- [ ] Header image renders correctly (colors, resolution, no pixelation)
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- [ ] Footer stripe color correct for each badge_type_code tested
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- [ ] HTML in name/affiliations renders correctly (bold, line break, etc.)
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- [ ] Badge with no affiliations — no awkward blank space
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### 4. Edge Cases — Badge Content
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- [ ] Long name auto-scales without overflow or clipping
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- [ ] HTML markup in name field: `<b>Dr.</b>` renders bold on the physical card
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- [ ] HTML line break in affiliations: two-line org renders cleanly
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- [ ] Badge with no location — layout doesn't break
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- [ ] Badge with all 8 ticket/option codes — back of badge (if applicable) lays out cleanly
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### 5. Print Tracking
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- [ ] `print_count` increments after printing via the **Print Badge** button
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- [ ] `print_first_datetime` set on first print
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- [ ] "Printed N×" amber chip appears in print page header after first print
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- [ ] Reprint via Re-print shortcut (trusted + edit mode) does NOT increment count
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- [ ] Second print via Print Badge button DOES increment count (to 2)
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### 6. QR Code
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- [ ] QR on printed card is scannable with a phone camera
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- [ ] QR scans to the correct badge ID (test with `/events/[id]/badges` search by QR scan)
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- [ ] QR on back (if `show_qr_back=1`) also scans correctly
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- [ ] If `show_qr_back=0` — no QR code visible on back
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### 7. Font Size Controls
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- [ ] Manual font size override (+ / − in controls panel) changes the badge render live
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- [ ] Change is visible on the physical printed card
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- [ ] Reset (↺) returns to auto-sizing
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- [ ] Auto-sizing produces a reasonable default for all test names without manual adjustment
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### 8. Edit Fields at Kiosk
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- [ ] Badge info editable before printing: change full_name_override, verify change appears on card
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- [ ] Save change → re-print → new value printed
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- [ ] Cancel reverts to saved value
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- [ ] Badge type dropdown changes footer stripe color on the rendered badge
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---
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## Known Limitations on Test Day
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These are not bugs — just gaps that won't be addressed during the test day:
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- **`style_href` external CSS**: Must be wired before test day (see pre-checklist). If not
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done, client-specific CSS from the template won't load — fall back to default styles.
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- **`duplex` backend field**: Not yet in the backend schema. Single-sided behavior depends
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on the PVC CSS hiding `.badge_back` in print. Verify manually.
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- **Per-template print margins (`print_margin_cfg`)**: UI doesn't exist yet. If the card
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needs a physical offset for the Zebra's feed, apply a manual CSS tweak to the PVC layout
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CSS file and revert after testing.
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- **Kiosk attendee editing (TASK 4.0)**: Edit panel is currently trusted_access only.
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Attendee self-edit at kiosk isn't finished — staff will need to do all edits on test day.
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- **`@page { size }` in Chrome**: Chrome ignores the CSS page size for Save as PDF.
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For physical Zebra printing the driver controls paper size — this is fine.
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---
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## Known Print Dialog Behavior (for reference)
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| Browser | Save to PDF | Physical Printer |
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| Firefox | Paper size locked to CSS `@page { size }` ✅ | Can select paper size in dialog |
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| Chrome | Paper size = system default (letter/A4) ❌ | Can select paper size under "More settings" |
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| Chrome Margin Setting | Result |
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|---|---|
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| Default | ❌ Inserts URL/date/page chrome, offsets badge centering |
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| None | ✅ Badge centered correctly |
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| Minimum | ✅ Badge centered correctly |
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---
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## Things to Note / Capture During Testing
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Use this section to log observations on the day:
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```
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DATE: ___________
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Driver version: ___________
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Card stock type: ___________
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CUPS printer name: ___________
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Observations:
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-
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-
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-
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Font size adjustments needed:
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Name default: was __px, adjusted to __px
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Title default: was __px, adjusted to __px
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Affiliations: was __px, adjusted to __px
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Location: was __px, adjusted to __px
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Physical offset needed (crop/margin): ___________
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Bugs found:
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-
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-
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```
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---
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## Follow-Up After Test Day
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- [ ] Update font size defaults in `ae_comp__badge_print_controls.svelte` based on observations
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- [ ] Note any physical margin/offset needed into `cfg_json: { print_margin: {...} }` once that UI exists
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- [ ] Document driver version and CUPS config that worked in this file
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- [ ] Commit any fixes, re-run `npx svelte-check`, commit clean
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