Sketchup-Booth-Designer/docs/BILL_OF_MATERIALS.md

# Bill of Materials Guide

## Overview

The Expolinc Booth Designer generates a structured bill of materials (BOM) for every booth design. The BOM includes all Expolinc system components, connectors, accessories, weights, and transport recommendations.

## BOM Structure

### Component Types

| Type | Examples |
|---|---|
| `classic_frame_wall` | Classic Frame walls of various sizes |
| `light_frame_wall` | Light Frame backlit walls |
| `connector_90` | 90° corner connectors |
| `connector_180` | Inline connectors |
| `connector_t` | T-connectors |
| `support_feet` | Double-sided support feet (pair) |
| `storage_room` | Storage room enclosure |
| `door` | Hinged or sliding door |
| `shelf` | Shelf unit |
| `seg_graphic` | SEG fabric graphic panel |
| `led_driver` | LED driver/power supply |
| `transport_case` | Shipping/storage case |

### BOM Output Formats

| Format | Description | Use Case |
|---|---|---|
| **JSON** | Structured data, machine-readable | Integration with ordering systems |
| **CSV** | Table format | Spreadsheet import, purchasing |
| **FreeCAD Spreadsheet** | Live spreadsheet in document | In-document reference |
| **Summary** | Human-readable text | Quick overview for AI response |

## JSON Output Example

```json
{
  "project": "Booth_Island_6x4",
  "date": "2026-05-30",
  "layout": "island",
  "dimensions": {
    "width_mm": 6000,
    "depth_mm": 4000,
    "height_mm": 2500
  },
  "components": [
    {
      "part_number": "CF-4950-2500",
      "name": "Classic Frame Wall 4950×2500mm",
      "system": "classic_frame",
      "category": "wall",
      "quantity": 2,
      "width_mm": 4950,
      "height_mm": 2500,
      "weight_kg": 25.0,
      "total_weight_kg": 50.0,
      "seg_area_m2": 12.375,
      "finish": "silver",
      "notes": "Main walls front and back"
    },
    {
      "part_number": "CF-950-2500",
      "name": "Classic Frame Wall 950×2500mm",
      "system": "classic_frame",
      "category": "wall",
      "quantity": 2,
      "width_mm": 950,
      "height_mm": 2500,
      "weight_kg": 10.5,
      "total_weight_kg": 21.0,
      "seg_area_m2": 2.375,
      "finish": "silver",
      "notes": "Side wall extensions"
    },
    {
      "part_number": "LF-4950-2500",
      "name": "Light Frame Wall 4950×2500mm",
      "system": "light_frame",
      "category": "wall",
      "quantity": 2,
      "width_mm": 4950,
      "height_mm": 2500,
      "weight_kg": 27.5,
      "total_weight_kg": 55.0,
      "led_temperature_K": 4000,
      "led_brightness_lm": 1500,
      "notes": "Backlit feature walls"
    },
    {
      "part_number": "CN-90-STD",
      "name": "90° Corner Connector",
      "system": "connector",
      "category": "connector",
      "quantity": 4,
      "weight_kg": 1.5,
      "total_weight_kg": 6.0,
      "finish": "silver"
    },
    {
      "part_number": "SF-DBL",
      "name": "Support Feet (double-sided, pair)",
      "system": "accessory",
      "category": "feet",
      "quantity": 8,
      "weight_kg": 0.8,
      "total_weight_kg": 6.4
    },
    {
      "part_number": "SR-1950-1000-2500",
      "name": "Storage Room 1950×1000×2500mm",
      "system": "accessory",
      "category": "storage",
      "quantity": 1,
      "width_mm": 1950,
      "depth_mm": 1000,
      "height_mm": 2500,
      "weight_kg": 35.0,
      "total_weight_kg": 35.0,
      "has_door": true,
      "door_type": "hinged",
      "has_shelving": false
    }
  ],
  "totals": {
    "component_count": 19,
    "total_weight_kg": 173.4,
    "seg_area_m2": 29.5,
    "connector_count": {
      "90_degree": 4,
      "180_inline": 0,
      "T": 0
    },
    "light_frame_walls": 2,
    "storage_rooms": 1,
    "doors": 1,
    "transport_cases": [
      {
        "type": "Standard Case XL",
        "dimensions_mm": "1200×800×500",
        "quantity": 3,
        "notes": "For walls and connectors"
      },
      {
        "type": "Travel Set (soft bag)",
        "quantity": 1,
        "notes": "For accessories and small parts"
      }
    ],
    "estimated_setup_time_minutes": 60,
    "estimated_crew": 2
  }
}
```

## CSV Output Example

```csv
part_number,name,system,category,qty,width_mm,height_mm,weight_kg,total_kg,notes
CF-4950-2500,Classic Frame Wall 4950x2500mm,classic_frame,wall,2,4950,2500,25.0,50.0,Main walls
CF-950-2500,Classic Frame Wall 950x2500mm,classic_frame,wall,2,950,2500,10.5,21.0,Side extensions
LF-4950-2500,Light Frame Wall 4950x2500mm,light_frame,wall,2,4950,2500,27.5,55.0,Backlit
CN-90-STD,90° Corner Connector,connector,connector,4,,,1.5,6.0,
SF-DBL,Support Feet (pair),accessory,feet,8,,,0.8,6.4,
SR-1950-1000-2500,Storage Room,accessory,storage,1,1950,2500,35.0,35.0,
```

## FreeCAD Spreadsheet BOM

When `expolinc_export_bom` is called with `format="spreadsheet"`, a FreeCAD Spreadsheet object is created in the active document:

| Cell | Content |
|---|---|
| `A1` | **Booth BOM** (title) |
| `A3` | **Component** |
| `B3` | **System** |
| `C3` | **Qty** |
| `D3` | **Width (mm)** |
| `E3` | **Height (mm)** |
| `F3` | **Unit Weight (kg)** |
| `G3` | **Total Weight (kg)** |
| `H3` | **Area (m²)** |
| `A4..H{n}` | Component data |
| Last row | **Totals** with SUM formulas |

## Weight Reference Tables

### Classic Frame Weights

| Width × Height | Weight (kg) |
|---|---|
| 500 × 2500 mm | 8.3 |
| 950 × 2500 mm | 10.5 |
| 1950 × 2500 mm | 14.5 |
| 2950 × 2500 mm | 16.5 |
| 3950 × 2500 mm | 20.4 |
| 4950 × 2500 mm | 25.0 |
| 500 × 3000 mm | 9.5 |
| 950 × 3000 mm | 12.0 |
| 1950 × 3000 mm | 18.3 |
| 2950 × 3000 mm | 23.3 |
| 3950 × 3000 mm | 26.3 |
| 4950 × 3000 mm | 28.5 |

### Light Frame Additional Weight

Light Frame walls add the following over the base Classic Frame weight: +2.5 kg (LED frame + diffuser + LED strip + driver).

### Connector Weights

| Connector | Weight (kg) |
|---|---|
| 90° corner connector | 1.5 |
| 180° inline connector | 1.2 |
| T-connector | 1.8 |
| Support feet (pair) | 0.8 |

### Accessory Weights

| Accessory | Weight (kg) |
|---|---|
| Storage room (1950×1000×2500mm) | 35.0 |
| Door (hinged, 900×2200mm) | 8.0 |
| Door (sliding, 900×2200mm) | 10.0 |
| Shelf unit (950×400mm, 3 levels) | 6.0 |

## Transport Case Selection

The BOM generator automatically recommends transport cases based on component sizes and quantities.

| Case Type | Capacity | Suitable For |
|---|---|---|
| **Basic Box** (cardboard) | Single wall up to 1950mm | One-time use, small walls |
| **Travel Set** (soft bag with wheels) | 1–2 walls + accessories | Frequent travel, medium booths |
| **Standard Case XL** (hard case) | Multiple walls + connectors | Large booths, frequent use |

**Recommendation logic:**
- Total weight < 50 kg → 1× Travel Set
- Total weight 50–100 kg → 1× Standard Case XL
- Total weight > 100 kg → Multiple Standard Case XL cases (calculated by volume)

## Using the BOM for Ordering

The generated BOM can be sent directly to Expolinc or an authorized distributor for component ordering. Each component includes:

- Expolinc part number (based on type and dimensions)
- Quantity required
- Finish specification
- Notes on configuration

To generate an order-ready BOM:

```
User: "Export the bill of materials as CSV for ordering"
Assistant: → expolinc_export_bom(format="csv", filepath="booth_bom_2026-05-30.csv")
```