fix(badges): detect and surface PATCH failure in handle_print_badge

update_ae_obj__event_badge returns false on API failure without throwing,
so the old code always treated a failed PATCH as success — badge printed,
count not saved, page navigated away silently.

Now: check the return value explicitly. On failure — still fire window.print()
(physical print must never be blocked) and still navigate back, but show a
visible red error state ('Printed — count NOT saved (see staff)') and hold
for 4s so a kiosk operator can see it before the loop resets.

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

src/routes/events/[event_id]/(badges)/badges/[badge_id]/ae_comp__badge_print_controls.svelte

@@ -226,13 +226,31 @@ async function handle_print_badge() {
     if (is_first_print) data_to_update.print_first_datetime = now;
 
     try {
-        await events_func.update_ae_obj__event_badge({
+        const result = await events_func.update_ae_obj__event_badge({
             api_cfg: $ae_api,
             event_id,
             event_badge_id: $lq__event_badge_obj.event_badge_id,
             data_kv: data_to_update,
             log_lvl
         });
+
+        // update_ae_obj__event_badge returns false/null on API failure without throwing.
+        // A falsy result means the PATCH failed (e.g. 400/401/500) — the DB was NOT updated.
+        // We still print the physical badge (never block the physical print), but show a
+        // visible error so staff can catch a runaway "already printed" situation and fix
+        // the count manually via the Admin print count field in the Staff section.
+        if (!result) {
+            console.error('Badge print controls: PATCH returned falsy — DB count not updated.');
+            print_status = 'error';
+            // Still fire the physical print — the attendee must get their badge.
+            if (browser) window.print();
+            // Hold the error state long enough for a kiosk operator to notice before
+            // the loop returns to search for the next attendee.
+            await new Promise<void>((r) => setTimeout(r, 4000));
+            if (browser) window.location.href = `/events/${event_id}/badges`;
+            return;
+        }
+
         print_status = 'done';
         // Trigger browser print dialog after count is recorded
         if (browser) window.print();
@@ -243,9 +261,9 @@ async function handle_print_badge() {
     } catch (err) {
         console.error('Badge print controls: print error:', err);
         print_status = 'error';
-        setTimeout(() => {
-            print_status = 'idle';
-        }, 3000);
+        if (browser) window.print();
+        await new Promise<void>((r) => setTimeout(r, 4000));
+        if (browser) window.location.href = `/events/${event_id}/badges`;
     }
 }
 
@@ -924,7 +942,7 @@ let allow_tracking_open = $derived(
                 {:else if print_status === 'done'}
                     <Check size="14" /> Printed!
                 {:else if print_status === 'error'}
-                    Error — try again
+                    Printed — count NOT saved (see staff)
                 {:else}
                     <Printer size="14" />
                     {is_printed ? `Reprint (${print_count}×)` : 'Print Badge'}