feat(billing): 80mm thermal invoice layout (ADD-P001)

GET billing/invoices/:id/document?format=thermal renders a dedicated 80mm
receipt template (72mm printable, 4mm margins each side), not a CSS variant
of the A4 layout — the A4 CSS is absolutely-positioned/fixed-px, tuned for a
210mm page, and doesn't reflow at thermal width. No seal (not a thermal
convention, renders badly on 1-bit thermal heads); line items stack
(description, then qty x rate = amount) instead of a table, since a real
table leaves ~10-14 chars for description at this width.

PdfRenderService gains a thermal render path: full 80mm-width viewport,
content height measured via page.evaluate after settle (continuous-roll
receipts have no fixed page length), and a noFallback option — a Chromium
failure throws a clear error instead of silently degrading to the generic
A4/no-QR fallback, which would hand back a different document than what was
asked for. The frontend surfaces that as a toast pointing at the existing A4
download.

format is strictly validated (a4|thermal only, BadRequestException
otherwise), not silently coerced.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>

apps/edr-freight-api/src/modules/billing/billing.controller.ts

@@ -1,4 +1,5 @@
 import {
+  BadRequestException,
   Body,
   Controller,
   Get,
@@ -113,9 +114,19 @@ export class BillingController {
 
   @Get("invoices/:id/document")
   @BookingStaff(FREIGHT_PERMS.invoices.export)
-  @ApiOperation({ summary: "Download the sealed invoice PDF" })
-  async document(@Param("id", ParseUUIDPipe) id: string, @Res() res: Response) {
-    const { filename, buffer } = await this.billingService.document(id);
+  @ApiOperation({
+    summary:
+      'Download the sealed invoice PDF. ?format=a4 (default) or ?format=thermal for the 80mm thermal layout (ADD-P001).',
+  })
+  async document(
+    @Param("id", ParseUUIDPipe) id: string,
+    @Query("format") format: string | undefined,
+    @Res() res: Response,
+  ) {
+    if (format !== undefined && format !== "a4" && format !== "thermal") {
+      throw new BadRequestException(`Unsupported format "${format}" — use "a4" or "thermal".`);
+    }
+    const { filename, buffer } = await this.billingService.document(id, format === "thermal" ? "thermal" : "a4");
     sendPdf(res, filename, buffer);
   }
 

apps/edr-freight-api/src/modules/billing/billing.service.spec.ts

@@ -927,6 +927,7 @@ describe("BillingService.document", () => {
 
   const build = (invoice: Record<string, unknown>) => {
     const render = jest.fn().mockResolvedValue({ filename: "x.pdf", buffer: Buffer.from("") });
+    const renderThermal = jest.fn().mockResolvedValue({ filename: "x-thermal.pdf", buffer: Buffer.from("") });
     const service = new BillingService(
       {} as never,
       { findById: jest.fn().mockResolvedValue(invoice) } as never,
@@ -934,7 +935,7 @@ describe("BillingService.document", () => {
       {} as never,
       {} as never,
       {} as never,
-      { render } as never,
+      { render, renderThermal } as never,
       {} as never,
       {
         get: (key: string) =>
@@ -943,7 +944,7 @@ describe("BillingService.document", () => {
             : undefined,
       } as never, // config
     );
-    return { service, render };
+    return { service, render, renderThermal };
   };
 
   it("adds no EIMS IRN row and no QR for an unregistered invoice", async () => {
@@ -1000,4 +1001,24 @@ describe("BillingService.document", () => {
     expect(model.summary).toContainEqual({ label: "EIMS IRN", value: "IRN-123" });
     expect(model.qrImageUrl).toBe("data:image/png;base64,signed-payload");
   });
+
+  it("calls render (not renderThermal) for the default format", async () => {
+    const { service, render, renderThermal } = build(invoiceRow());
+    jest.spyOn(service as never, "toDocumentModel").mockResolvedValue({} as never);
+
+    await service.document("inv-1");
+
+    expect(render).toHaveBeenCalledTimes(1);
+    expect(renderThermal).not.toHaveBeenCalled();
+  });
+
+  it("calls renderThermal (not render) for format 'thermal'", async () => {
+    const { service, render, renderThermal } = build(invoiceRow());
+    jest.spyOn(service as never, "toDocumentModel").mockResolvedValue({} as never);
+
+    await service.document("inv-1", "thermal");
+
+    expect(renderThermal).toHaveBeenCalledTimes(1);
+    expect(render).not.toHaveBeenCalled();
+  });
 });

apps/edr-freight-api/src/modules/billing/billing.service.ts

@@ -411,12 +411,20 @@ export class BillingService {
 
   // ── Documents (central PDF) ──────────────────────────────────────────────────
 
-  /** Sealed PDF invoice for any source, rendered by the shared document service. */
-  async document(id: string): Promise<{ filename: string; buffer: Buffer }> {
+  /**
+   * Sealed PDF invoice for any source, rendered by the shared document service. `format`
+   * validation (rejecting anything but `"a4"`/`"thermal"`) is the controller's job — an input
+   * boundary check, not a business rule.
+   */
+  async document(
+    id: string,
+    format: "a4" | "thermal" = "a4",
+  ): Promise<{ filename: string; buffer: Buffer }> {
     const invoice = await this.findById(id);
-    return this.invoiceDocuments.render(
-      await this.toDocumentModel(invoice, "INVOICE"),
-    );
+    const model = await this.toDocumentModel(invoice, "INVOICE");
+    return format === "thermal"
+      ? this.invoiceDocuments.renderThermal(model)
+      : this.invoiceDocuments.render(model);
   }
 
   /** Sealed PDF receipt; available once any payment has been recorded. */

apps/edr-freight-api/src/modules/billing/documents/invoice-document.service.spec.ts

@@ -44,3 +44,46 @@ describe("InvoiceDocumentService.buildHtml — EIMS QR", () => {
     );
   });
 });
+
+describe("InvoiceDocumentService.buildThermalHtml", () => {
+  const service = new InvoiceDocumentService({} as never, {} as never, {} as never);
+
+  it("renders no seal markup at all — dropped for thermal, not shrunk", () => {
+    const html = service.buildThermalHtml(model());
+    expect(html).not.toContain('class="seal"');
+    expect(html).not.toContain("seal-image");
+  });
+
+  it("renders the QR image when qrImageUrl is set, centered rather than absolutely positioned", () => {
+    const html = service.buildThermalHtml(model({ qrImageUrl: "data:image/png;base64,QR" }));
+    expect(html).toContain('class="qr"');
+    expect(html).toContain('src="data:image/png;base64,QR"');
+    expect(html).not.toContain("position: absolute");
+  });
+
+  it("wraps a long IRN summary value rather than truncating it", () => {
+    const irn = "9fe9bbbece6ab76c112b617534e6aac7aa8b819d5be79f4d3d088ed2e887b2e0";
+    const html = service.buildThermalHtml(model({ summary: [{ label: "EIMS IRN", value: irn }] }));
+    expect(html).toContain(irn);
+    expect(html).toContain("overflow-wrap: anywhere");
+  });
+
+  it("renders a line item as stacked description + qty x rate = amount, not a table row", () => {
+    const html = service.buildThermalHtml(
+      model({
+        lines: [{ description: "40ft container rail freight", quantity: 12, unitRate: 245683.95, amount: 2948207.4 }],
+      }),
+    );
+    expect(html).not.toContain("<table");
+    expect(html).not.toContain("<td");
+    expect(html).toContain("40ft container rail freight");
+    expect(html).toContain("12 x");
+    expect(html).toContain("2,948,207.4 Birr (ETB)");
+  });
+
+  it("uses fluid, full-width layout — no fixed-px A4 geometry", () => {
+    const html = service.buildThermalHtml(model());
+    expect(html).not.toContain("width: 330px");
+    expect(html).not.toContain("right: 160px");
+  });
+});

apps/edr-freight-api/src/modules/billing/documents/invoice-document.service.ts

@@ -27,6 +27,27 @@ export type InvoiceDocumentKind = "INVOICE" | "RECEIPT";
  */
 export const pngDataUrl = (base64: string): string => `data:image/png;base64,${base64}`;
 
+// ── Shared HTML-builder helpers (buildHtml + buildThermalHtml) ──────────────────────────────────
+// `buildFallbackPdf`'s own currency/money/date closures are a deliberately different, already-
+// established convention (bare "ETB" vs "Birr (ETB)") for the vector renderer — not touched here.
+
+function esc(value: unknown): string {
+  return String(value ?? "-")
+    .replace(/&/g, "&")
+    .replace(/</g, "&lt;")
+    .replace(/>/g, "&gt;")
+    .replace(/"/g, "&quot;")
+    .replace(/'/g, "&#39;");
+}
+
+function money(amount: unknown, currency: string): string {
+  return `${Number(amount ?? 0).toLocaleString()} ${currency === "ETB" ? "Birr (ETB)" : currency}`;
+}
+
+function formatDate(value: unknown): string {
+  return value ? new Date(value as string | Date).toLocaleDateString("en-GB") : "-";
+}
+
 /** One billed line on the document (charge type / fee type agnostic). */
 export interface InvoiceDocumentLine {
   description: string | null;
@@ -129,6 +150,117 @@ export class InvoiceDocumentService {
     };
   }
 
+  /**
+   * 80mm thermal invoice (ADD-P001) — physical page is the 80mm roll width; content stays within
+   * `THERMAL_MARGIN_MM` of each edge via `PdfRenderService`'s margin, not a narrower page, since
+   * thermal print mechanisms have a dead zone at the roll edge they can't reach either way.
+   *
+   * A genuinely different template from `buildHtml`, not a CSS variant of it: the A4 layout is
+   * absolutely-positioned and fixed-px (`.seal{right:28px}`, `.qr{right:160px}`,
+   * `.totals{width:330px}`), tuned for a 210mm page — none of it reflows at 72mm printable width.
+   * No seal here at all (a decorative wet-ink-style stamp is an A4/laser convention; no real POS
+   * thermal receipt carries one, and thermal heads render rotated circles badly) and line items
+   * are stacked (description, then `qty x rate = amount` below it) rather than a table — a real
+   * multi-column table leaves ~10-14 chars for description at this width, truncating almost every
+   * line, which stacking avoids entirely. No Chromium-less fallback — see `renderThermal`.
+   */
+  async renderThermal(model: InvoiceDocumentModel): Promise<{ filename: string; buffer: Buffer }> {
+    const logoImageUrl =
+      model.logoImageUrl !== undefined ? model.logoImageUrl : await this.logoSettings.getLogoImageUrl();
+    // Seal deliberately dropped — never fetched, so no stampSettings call either.
+    const resolvedModel: InvoiceDocumentModel = { ...model, logoImageUrl, stampImageUrl: null };
+
+    const html = this.buildThermalHtml(resolvedModel);
+    return {
+      filename: `${this.safeFilename(model.documentNumber)}-thermal.pdf`,
+      buffer: await this.pdf.htmlToPdfBuffer(html, {
+        label: `${model.title} thermal invoice`,
+        thermal: true,
+        // A generic A4-shaped, QR-less fallback is not an acceptable stand-in for "the thermal
+        // printer output" — fail loudly instead; the caller has the A4 download to fall back to.
+        noFallback: true,
+      }),
+    };
+  }
+
+  buildThermalHtml(model: InvoiceDocumentModel): string {
+    const heading = `${model.title} ${model.kind === "RECEIPT" ? "Receipt" : "Invoice"}`;
+    const logoInner = logoMarkup(model.logoImageUrl, "thermal-logo");
+
+    const summaryRows = model.summary
+      .map(
+        (row) =>
+          `<div class="row"><span class="label">${esc(row.label)}</span><span class="value">${esc(row.value)}</span></div>`,
+      )
+      .join("");
+
+    const itemBlocks = model.lines
+      .map((item) => {
+        const currency = item.currency ?? model.currency;
+        return `<div class="item">
+        <div class="item-desc">${esc(item.description)}</div>
+        <div class="item-calc">${esc(item.quantity ?? 0)} x ${esc(money(item.unitRate, currency))} = <strong>${esc(money(item.amount, currency))}</strong></div>
+      </div>`;
+      })
+      .join("");
+
+    const totalRows = model.totals
+      .map(
+        (total) =>
+          `<div class="total-row${total.grand ? " grand" : ""}"><span>${esc(total.label)}</span><strong>${esc(money(total.amount, model.currency))}</strong></div>`,
+      )
+      .join("");
+
+    const qrMarkup = model.qrImageUrl
+      ? `<div class="qr"><img src="${esc(model.qrImageUrl)}" alt="EIMS verification QR" /><div class="qr-caption">Scan to verify (MoR EIMS)</div></div>`
+      : "";
+
+    return `<!doctype html>
+<html>
+<head>
+  <meta charset="utf-8" />
+  <title>${esc(heading)}</title>
+  <style>
+    body { font-family: Arial, sans-serif; font-size: 9px; color: #0f172a; margin: 0; }
+    .doc { width: 100%; box-sizing: border-box; }
+    .thermal-logo { display: block; max-height: 28px; max-width: 100%; object-fit: contain; margin: 0 auto 4px; }
+    .brand { text-align: center; font-size: 9px; text-transform: uppercase; letter-spacing: .05em; }
+    .title { text-align: center; font-size: 13px; font-weight: 800; margin: 2px 0; }
+    .meta { text-align: center; font-size: 8px; color: #475569; margin-bottom: 4px; }
+    .rule { border-top: 1px dashed #334155; margin: 6px 0; }
+    .row { display: flex; justify-content: space-between; gap: 6px; font-family: monospace; font-size: 8.5px; padding: 1px 0; }
+    .row .label { color: #64748b; white-space: nowrap; }
+    .row .value { text-align: right; overflow-wrap: anywhere; }
+    .item { margin: 4px 0; }
+    .item-desc { font-size: 9px; overflow-wrap: anywhere; }
+    .item-calc { text-align: right; font-family: monospace; font-size: 8.5px; }
+    .total-row { display: flex; justify-content: space-between; font-size: 9px; padding: 2px 0; }
+    .total-row.grand { font-size: 11px; font-weight: 800; border-top: 1px solid #0f172a; margin-top: 3px; padding-top: 4px; }
+    .qr { text-align: center; margin: 8px 0; }
+    .qr img { width: 150px; height: 150px; }
+    .qr-caption { font-size: 7px; color: #64748b; margin-top: 2px; }
+    .footer { text-align: center; font-size: 7px; color: #94a3b8; margin-top: 8px; }
+  </style>
+</head>
+<body>
+  <div class="doc">
+    ${logoInner}
+    <div class="brand">Ethio-Djibouti Railway S.C.</div>
+    <div class="title">${esc(heading)}</div>
+    <div class="meta">${esc(model.documentNumber)} &middot; ${esc(formatDate(model.issuedAt))}</div>
+    <div class="rule"></div>
+    ${summaryRows}
+    <div class="rule"></div>
+    ${itemBlocks}
+    <div class="rule"></div>
+    ${totalRows}
+    ${qrMarkup}
+    <div class="footer">Thank you</div>
+  </div>
+</body>
+</html>`;
+  }
+
   /**
    * Vector-drawn styled invoice/receipt used when headless Chromium is
    * unavailable. Mirrors the HTML layout closely enough to pass as the same
@@ -250,18 +382,7 @@ export class InvoiceDocumentService {
   }
 
   buildHtml(model: InvoiceDocumentModel): string {
-    const esc = (value: unknown) =>
-      String(value ?? "-")
-        .replace(/&/g, "&amp;")
-        .replace(/</g, "&lt;")
-        .replace(/>/g, "&gt;")
-        .replace(/"/g, "&quot;")
-        .replace(/'/g, "&#39;");
-    const money = (amount: unknown, currency = model.currency) =>
-      `${Number(amount ?? 0).toLocaleString()} ${currency === "ETB" ? "Birr (ETB)" : currency}`;
-    const date = (value: unknown) =>
-      value ? new Date(value as string | Date).toLocaleDateString("en-GB") : "-";
-
+    const date = formatDate;
     const showCategory = Boolean(model.categoryHeader);
     const sealText =
       model.sealText ?? (model.kind === "RECEIPT" || model.status === "PAID" ? "EDR PAID" : "EDR");
@@ -292,7 +413,7 @@ export class InvoiceDocumentService {
     const totalRows = model.totals
       .map(
         (total) =>
-          `<div class="total-row${total.grand ? " grand" : ""}"><span>${esc(total.label)}</span><strong>${esc(money(total.amount))}</strong></div>`,
+          `<div class="total-row${total.grand ? " grand" : ""}"><span>${esc(total.label)}</span><strong>${esc(money(total.amount, model.currency))}</strong></div>`,
       )
       .join("");
 

apps/edr-freight-api/src/modules/billing/documents/pdf-render.service.ts

@@ -15,15 +15,43 @@ const PDF_PRINT_STYLES = `
   }
 </style>`;
 
+/**
+ * Physical roll width. Content stays within `THERMAL_MARGIN_MM` of each edge — every mainstream
+ * ESC/POS thermal head (Epson TM-T88, Star, Bixolon) has a dead zone near the edge of an 80mm roll
+ * it physically can't reach, so the page itself must stay 80mm (matching the roll the printer
+ * driver expects) with the safe area carved out by margin, not by shrinking the page.
+ */
+const THERMAL_PAGE_WIDTH_MM = 80;
+const THERMAL_MARGIN_MM = 4;
+/** Extra length past the measured content, so the cut isn't flush against the last line. */
+const THERMAL_FEED_MM = 6;
+/** Guard against a runaway line-item list producing an absurd page. */
+const THERMAL_MAX_HEIGHT_MM = 1500;
+
 export interface PdfRenderOptions {
   /** Label used in logs to identify the document kind. */
   label?: string;
   /** Landscape A4 instead of the default portrait — wide tables need it. */
   landscape?: boolean;
+  /**
+   * Render as an 80mm continuous thermal receipt instead of a fixed A4 page: content width is
+   * measured and the page height grows to fit it, rather than a fixed page with the format's
+   * `format: "A4"`.
+   */
+  thermal?: boolean;
+  /**
+   * Refuse to degrade to a fallback PDF on failure — throw instead. For a thermal request, a
+   * generic A4-shaped, QR-less fallback is not an acceptable stand-in for "the thermal printer
+   * output" (it silently hands back a different document shape than what was asked for); the
+   * caller has an existing A4 download to point the user at instead. Ignored when `fallback` is
+   * also supplied — an explicit fallback always wins.
+   */
+  noFallback?: boolean;
   /**
    * Degraded renderer used when Chromium is unavailable. Receives the
    * print-prepared HTML and must return a valid PDF buffer (≥ 2KB, `%PDF-`
-   * header). When omitted, a generic single-page fallback is produced.
+   * header). When omitted (and `noFallback` is not set), a generic single-page fallback is
+   * produced.
    */
   fallback?: (preparedHtml: string) => Buffer;
 }
@@ -54,17 +82,31 @@ export class PdfRenderService {
       const browser = await puppeteer.default.launch(launchOptions);
       try {
         const page = await browser.newPage();
-        await page.setViewport({ width: 794, height: 1123, deviceScaleFactor: 1 });
+        const thermal = opts.thermal ?? false;
+        const viewportWidth = thermal ? Math.round((THERMAL_PAGE_WIDTH_MM / 25.4) * 96) : 794;
+        await page.setViewport({ width: viewportWidth, height: 1123, deviceScaleFactor: 1 });
         await page.setContent(preparedHtml, { waitUntil: "load", timeout: 60_000 });
         await page.emulateMediaType("print");
         await new Promise((resolve) => setTimeout(resolve, 250));
 
-        const pdf = await page.pdf({
-          format: "A4",
-          landscape: opts.landscape ?? false,
-          printBackground: true,
-          margin: { top: "16mm", bottom: "18mm", left: "14mm", right: "14mm" },
-        });
+        const pdf = thermal
+          ? await page.pdf({
+              width: `${THERMAL_PAGE_WIDTH_MM}mm`,
+              height: `${await this.thermalContentHeightMm(page)}mm`,
+              printBackground: true,
+              margin: {
+                top: `${THERMAL_MARGIN_MM}mm`,
+                bottom: `${THERMAL_MARGIN_MM + THERMAL_FEED_MM}mm`,
+                left: `${THERMAL_MARGIN_MM}mm`,
+                right: `${THERMAL_MARGIN_MM}mm`,
+              },
+            })
+          : await page.pdf({
+              format: "A4",
+              landscape: opts.landscape ?? false,
+              printBackground: true,
+              margin: { top: "16mm", bottom: "18mm", left: "14mm", right: "14mm" },
+            });
 
         const buffer = Buffer.from(pdf);
         if (!this.isValidPdf(buffer)) {
@@ -79,6 +121,15 @@ export class PdfRenderService {
       }
     } catch (error) {
       this.logger.error(`${label} PDF failed (executable=${executablePath ?? "default"}): ${error}`);
+      if (!opts.fallback && opts.noFallback) {
+        // A generic A4-shaped, QR-less fallback is not an acceptable stand-in for "the thermal
+        // printer output" — it silently hands back a different document than what was asked for.
+        // Fail loudly instead; the caller already has a working A4 download to fall back to.
+        throw new InternalServerErrorException(
+          `${label} could not be generated — thermal rendering requires Chromium. ` +
+            "Ensure Chromium is installed or set PUPPETEER_EXECUTABLE_PATH, or download the A4 PDF instead.",
+        );
+      }
       const fallback = (opts.fallback ?? ((h) => this.genericFallbackPdf(h)))(preparedHtml);
       if (this.isValidPdf(fallback)) {
         this.logger.warn(
@@ -92,6 +143,20 @@ export class PdfRenderService {
     }
   }
 
+  /**
+   * Thermal receipts are continuous-roll — there is no fixed page height. Measures the rendered
+   * content's actual height and adds feed clearance, so the PDF page is exactly as long as the
+   * receipt, not a fixed A4-length page with blank space at the bottom.
+   */
+  private async thermalContentHeightMm(page: import("puppeteer").Page): Promise<number> {
+    // String form, not a typed closure: this project's tsconfig has no `dom` lib, so `document`
+    // isn't a known global to type-check against — the string is evaluated in the page's own
+    // browser context regardless, same as the closure form would be.
+    const scrollPx = (await page.evaluate("document.documentElement.scrollHeight")) as number;
+    const contentMm = (scrollPx / 96) * 25.4 + THERMAL_MARGIN_MM * 2 + THERMAL_FEED_MM;
+    return Math.min(THERMAL_MAX_HEIGHT_MM, contentMm);
+  }
+
   private injectPdfPrintStyles(html: string): string {
     if (html.includes("edr-pdf-print-fix")) return html;
     if (html.includes("</head>")) {

apps/edr-freight-web/backoffice/src/pages/invoices/InvoiceDetailPage.tsx

@@ -8,16 +8,18 @@ import {
   Grid,
   Group,
   Loader,
+  Menu,
   SimpleGrid,
   Stack,
   Table,
   Text,
 } from "@mantine/core";
 import { useQuery } from "@tanstack/react-query";
-import { ArrowLeft, Building2, Download, FileText } from "lucide-react";
+import { ArrowLeft, Building2, Download, FileText, Printer } from "lucide-react";
 import { useAuth } from "@/auth/useAuth";
 import { FREIGHT_PERMS, hasPermission } from "@/lib/permissions";
 import { EimsFilingCard } from "@/components/invoices/EimsFilingCard";
+import { useToast } from "@/hooks/use-toast";
 import { useState } from "react";
 import { useNavigate, useParams } from "react-router-dom";
 
@@ -145,6 +147,7 @@ export default function InvoiceDetailPage() {
   const canExport = hasPermission(user, FREIGHT_PERMS.invoices.export);
   const { id } = useParams<{ id: string }>();
   const navigate = useNavigate();
+  const { toast } = useToast();
   const [downloading, setDownloading] = useState(false);
 
   const { data: invoice, isLoading } = useQuery(
@@ -154,12 +157,27 @@ export default function InvoiceDetailPage() {
     }),
   );
 
-  const downloadDocument = async () => {
+  const downloadDocument = async (format?: "a4" | "thermal") => {
     if (!id) return;
     setDownloading(true);
     try {
-      const { data } = await invoicesService.downloadDocument(id);
-      openPdfBlob(data, `${invoice?.invoiceNumber ?? "invoice"}.pdf`);
+      const { data } = await invoicesService.downloadDocument(id, format);
+      const suffix = format === "thermal" ? "-thermal" : "";
+      openPdfBlob(data, `${invoice?.invoiceNumber ?? "invoice"}${suffix}.pdf`);
+    } catch (error) {
+      // Thermal rendering deliberately fails loudly rather than silently returning an A4-shaped,
+      // QR-less document (see PdfRenderService's `noFallback`) — surface that here rather than
+      // let it become a silent unhandled rejection with just a spinner stopping.
+      toast({
+        title: format === "thermal" ? "Could not generate the thermal invoice" : "Could not download the invoice",
+        description:
+          format === "thermal"
+            ? "Thermal rendering requires Chromium on the server. The A4 PDF is still available."
+            : error instanceof Error
+              ? error.message
+              : undefined,
+        variant: "destructive",
+      });
     } finally {
       setDownloading(false);
     }
@@ -202,17 +220,34 @@ export default function InvoiceDetailPage() {
         subtitle={humanize(invoice.source)}
         meta={<InvoiceStatusBadge status={invoice.status} />}
         action={
-          <ActionIcon
-            variant="default"
-            size="lg"
-            radius="md"
-            aria-label="Download invoice"
-            disabled={!canExport}
-            loading={downloading}
-            onClick={() => void downloadDocument()}
-          >
-            <Download size={16} />
-          </ActionIcon>
+          <Menu position="bottom-end" withinPortal>
+            <Menu.Target>
+              <ActionIcon
+                variant="default"
+                size="lg"
+                radius="md"
+                aria-label="Download invoice"
+                disabled={!canExport}
+                loading={downloading}
+              >
+                <Download size={16} />
+              </ActionIcon>
+            </Menu.Target>
+            <Menu.Dropdown>
+              <Menu.Item
+                leftSection={<Download size={14} />}
+                onClick={() => void downloadDocument("a4")}
+              >
+                Download PDF (A4)
+              </Menu.Item>
+              <Menu.Item
+                leftSection={<Printer size={14} />}
+                onClick={() => void downloadDocument("thermal")}
+              >
+                Download thermal invoice (80mm)
+              </Menu.Item>
+            </Menu.Dropdown>
+          </Menu>
         }
       />
 

apps/edr-freight-web/backoffice/src/services/invoices.service.ts

@@ -29,9 +29,11 @@ export const invoicesService = {
       .then((r) => r.data);
   },
 
-  downloadDocument(id: string) {
+  /** `format` omitted or "a4" → standard A4 PDF; "thermal" → 80mm thermal layout (ADD-P001). */
+  downloadDocument(id: string, format?: "a4" | "thermal") {
     return apiClient.get<Blob>(URL_CONSTANTS.BILLING.INVOICE_DOCUMENT(id), {
       responseType: "blob",
+      params: format ? { format } : undefined,
     });
   },