From 3fd8dfe294111e0a93476326a109e5e855b8fd01 Mon Sep 17 00:00:00 2001
From: weeihan <whyap79@gmail.com>
Date: Tue, 28 Jul 2026 17:53:04 +0800
Subject: [PATCH] fix(pdf): sanitise non-WinAnsi chars, handle newlines in wrap

---
 lib/pdf/incident-report.ts | 40 +++++++++++++++++++++++++-------------
 1 file changed, 27 insertions(+), 13 deletions(-)

diff --git a/lib/pdf/incident-report.ts b/lib/pdf/incident-report.ts
index 2ba3c31..aa16433 100644
--- a/lib/pdf/incident-report.ts
+++ b/lib/pdf/incident-report.ts
@@ -48,6 +48,18 @@ export type IncidentReportData = {
 type EmbeddedFont = Awaited<ReturnType<PDFDocument['embedFont']>>
 type Page = ReturnType<PDFDocument['addPage']>
 
+// WinAnsi (Windows-1252) cannot encode chars outside its range.
+// Replace common typographic Unicode with ASCII equivalents, strip the rest.
+function sanitize(str: string): string {
+  return str
+    .replace(/[‘’]/g, "'")
+    .replace(/[“”]/g, '"')
+    .replace(/–|—/g, '-')
+    .replace(/…/g, '...')
+    .replace(/ /g, ' ')
+    .replace(/[^\x20-\xFF]/g, '?')
+}
+
 const MARGIN = 50
 const PAGE_WIDTH = 595
 const PAGE_HEIGHT = 842
@@ -81,20 +93,22 @@ function ensureSpace(state: State, needed: number): void {
 }
 
 function wrapText(text: string, maxWidth: number, font: EmbeddedFont, size: number): string[] {
-  const words = text.split(' ')
-  const lines: string[] = []
-  let current = ''
-  for (const word of words) {
-    const test = current ? `${current} ${word}` : word
-    if (font.widthOfTextAtSize(test, size) > maxWidth && current) {
-      lines.push(current)
-      current = word
-    } else {
-      current = test
+  const result: string[] = []
+  for (const paragraph of text.split('\n')) {
+    const words = paragraph.split(' ')
+    let current = ''
+    for (const word of words) {
+      const test = current ? `${current} ${word}` : word
+      if (font.widthOfTextAtSize(test, size) > maxWidth && current) {
+        result.push(current)
+        current = word
+      } else {
+        current = test
+      }
     }
+    if (current) result.push(current)
   }
-  if (current) lines.push(current)
-  return lines.length ? lines : ['']
+  return result.length ? result : ['']
 }
 
 function drawSection(state: State, title: string): void {
@@ -117,7 +131,7 @@ function drawSection(state: State, title: string): void {
 }
 
 function drawField(state: State, label: string, value: string | null): void {
-  const v = value ?? '—'
+  const v = sanitize(value ?? '—')
   const maxW = PAGE_WIDTH - MARGIN * 2 - 120
   const lines = wrapText(v, maxW, state.font, BODY_FONT_SIZE)
   ensureSpace(state, (lines.length + 1) * LINE_HEIGHT)