cyclecad 0.2.2 → 0.2.3

package/app/js/material-library.js

@@ -0,0 +1,2115 @@
+/**
+ * material-library.js - PBR Material System + Physical Properties Database
+ *
+ * Comprehensive material library for cycleCAD with:
+ * - 50+ materials organized by category
+ * - Full physical properties (density, strength, thermal, electrical)
+ * - Manufacturing properties (machinability, weldability, processes)
+ * - Cost estimation and lead time
+ * - PBR material application (Three.js MeshStandardMaterial)
+ * - Surface finish variants with visual properties
+ * - Material comparison, search, and calculators
+ * - Integration with DFM analyzer and cost estimator
+ */
+
+import * as THREE from 'https://cdn.jsdelivr.net/npm/three@0.170.0/build/three.module.js';
+
+// ============================================================================
+// Material Database (50+ materials)
+// ============================================================================
+
+const MATERIAL_DATABASE = {
+  // METALS - Steels (5)
+  steel_1018: {
+    id: 'steel_1018',
+    name: 'Steel 1018 (Mild)',
+    category: 'metal',
+    subcategory: 'steel_carbon',
+    description: 'Low carbon steel, most common for CNC machining',
+
+    // Physical properties (kg/m³, MPa, %)
+    density: 7850,
+    tensileStrength: 440,
+    yieldStrength: 370,
+    elongation: 20,
+    hardness: { value: 95, scale: 'HB' },
+    youngsModulus: 205,
+    poissonsRatio: 0.285,
+    thermalConductivity: 51.9,
+    thermalExpansion: 12.2,
+    meltingPoint: 1475,
+    specificHeat: 486,
+    electricalResistivity: 155,
+
+    // Manufacturing
+    machinability: 1.0, // Reference material
+    weldability: 'excellent',
+    formability: 'good',
+    processes: ['cnc_mill', 'cnc_lathe', 'laser_cut', 'waterjet', 'sheet_metal', 'casting'],
+
+    // Cost and availability
+    costPerKg: 0.95,
+    availability: 'high',
+    leadTime: 'stock',
+
+    // PBR appearance
+    pbr: {
+      color: 0x8899aa,
+      metalness: 0.95,
+      roughness: 0.4,
+      envMapIntensity: 0.8,
+      clearcoat: 0.05,
+      clearcoatRoughness: 0.15
+    },
+
+    // Finish variants
+    finishes: [
+      { name: 'As-Machined', roughness: 0.45, metalness: 0.92 },
+      { name: 'Ground', roughness: 0.25, metalness: 0.95 },
+      { name: 'Polished', roughness: 0.1, metalness: 0.98 },
+      { name: 'Blackened', color: 0x1a1a1a, roughness: 0.6, metalness: 0.85 },
+      { name: 'Galvanized', color: 0xc8ccd0, roughness: 0.35, metalness: 0.93 }
+    ]
+  },
+
+  steel_4140: {
+    id: 'steel_4140',
+    name: 'Steel 4140 (Alloy)',
+    category: 'metal',
+    subcategory: 'steel_alloy',
+    description: 'Medium carbon alloy steel, high strength after heat treat',
+
+    density: 7850,
+    tensileStrength: 1000, // After heat treat
+    yieldStrength: 830,
+    elongation: 12,
+    hardness: { value: 32, scale: 'HRC' },
+    youngsModulus: 210,
+    poissonsRatio: 0.29,
+    thermalConductivity: 42.6,
+    thermalExpansion: 12.3,
+    meltingPoint: 1450,
+    specificHeat: 475,
+    electricalResistivity: 420,
+
+    machinability: 0.65,
+    weldability: 'good',
+    formability: 'moderate',
+    processes: ['cnc_mill', 'cnc_lathe', 'heat_treat', 'casting'],
+
+    costPerKg: 3.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0x7a8a9a,
+      metalness: 0.96,
+      roughness: 0.35,
+      envMapIntensity: 0.85,
+      clearcoat: 0.08,
+      clearcoatRoughness: 0.12
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.4, metalness: 0.94 },
+      { name: 'Ground', roughness: 0.2, metalness: 0.97 },
+      { name: 'Polished', roughness: 0.08, metalness: 0.99 },
+      { name: 'Oil-Hardened', color: 0x6a7a8a, roughness: 0.5, metalness: 0.90 }
+    ]
+  },
+
+  steel_316ss: {
+    id: 'steel_316ss',
+    name: 'Stainless Steel 316',
+    category: 'metal',
+    subcategory: 'steel_stainless',
+    description: 'Superior corrosion resistance, medical/marine grade',
+
+    density: 8000,
+    tensileStrength: 515,
+    yieldStrength: 205,
+    elongation: 40,
+    hardness: { value: 79, scale: 'HRB' },
+    youngsModulus: 193,
+    poissonsRatio: 0.27,
+    thermalConductivity: 16.3,
+    thermalExpansion: 16.0,
+    meltingPoint: 1400,
+    specificHeat: 500,
+    electricalResistivity: 740,
+
+    machinability: 0.36,
+    weldability: 'good',
+    formability: 'good',
+    processes: ['cnc_mill', 'cnc_lathe', 'laser_cut', 'waterjet', 'welding'],
+
+    costPerKg: 4.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xc0c0c0,
+      metalness: 0.98,
+      roughness: 0.25,
+      envMapIntensity: 0.9,
+      clearcoat: 0.12,
+      clearcoatRoughness: 0.08
+    },
+
+    finishes: [
+      { name: 'Brushed', roughness: 0.3, metalness: 0.97 },
+      { name: 'Polished', roughness: 0.08, metalness: 0.99 },
+      { name: 'Passivated', roughness: 0.2, metalness: 0.98 }
+    ]
+  },
+
+  steel_a36: {
+    id: 'steel_a36',
+    name: 'Steel A36 (Structural)',
+    category: 'metal',
+    subcategory: 'steel_structural',
+    description: 'Structural steel, beam and plate stock',
+
+    density: 7750,
+    tensileStrength: 400,
+    yieldStrength: 250,
+    elongation: 23,
+    hardness: { value: 119, scale: 'HB' },
+    youngsModulus: 200,
+    poissonsRatio: 0.26,
+    thermalConductivity: 50,
+    thermalExpansion: 12,
+    meltingPoint: 1480,
+    specificHeat: 490,
+    electricalResistivity: 160,
+
+    machinability: 0.92,
+    weldability: 'excellent',
+    formability: 'good',
+    processes: ['cnc_mill', 'cnc_lathe', 'welding', 'rolling', 'casting'],
+
+    costPerKg: 0.85,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0x8a8a8a,
+      metalness: 0.92,
+      roughness: 0.5,
+      envMapIntensity: 0.7,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Hot-Rolled', roughness: 0.55, metalness: 0.90 },
+      { name: 'Painted', color: 0x4a4a4a, roughness: 0.7, metalness: 0.1 }
+    ]
+  },
+
+  steel_ductile_iron: {
+    id: 'steel_ductile_iron',
+    name: 'Ductile Iron (Gray Cast)',
+    category: 'metal',
+    subcategory: 'cast_iron',
+    description: 'Cast iron with spheroidized graphite, strong and damping',
+
+    density: 7100,
+    tensileStrength: 450,
+    yieldStrength: 310,
+    elongation: 6,
+    hardness: { value: 150, scale: 'HB' },
+    youngsModulus: 170,
+    poissonsRatio: 0.27,
+    thermalConductivity: 38,
+    thermalExpansion: 11,
+    meltingPoint: 1150,
+    specificHeat: 460,
+    electricalResistivity: 1000,
+
+    machinability: 0.75,
+    weldability: 'difficult',
+    formability: 'none',
+    processes: ['casting', 'cnc_mill', 'cnc_lathe'],
+
+    costPerKg: 1.20,
+    availability: 'high',
+    leadTime: '4-6 weeks',
+
+    pbr: {
+      color: 0x5a5a5a,
+      metalness: 0.88,
+      roughness: 0.55,
+      envMapIntensity: 0.6,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'As-Cast', roughness: 0.65, metalness: 0.85 },
+      { name: 'Machined', roughness: 0.45, metalness: 0.90 }
+    ]
+  },
+
+  // METALS - Aluminum (3)
+  aluminum_6061: {
+    id: 'aluminum_6061',
+    name: 'Aluminum 6061-T6',
+    category: 'metal',
+    subcategory: 'aluminum',
+    description: 'Most versatile aluminum alloy, good corrosion resistance',
+
+    density: 2700,
+    tensileStrength: 310,
+    yieldStrength: 275,
+    elongation: 12,
+    hardness: { value: 95, scale: 'HB' },
+    youngsModulus: 69,
+    poissonsRatio: 0.33,
+    thermalConductivity: 167,
+    thermalExpansion: 23.6,
+    meltingPoint: 650,
+    specificHeat: 897,
+    electricalResistivity: 42,
+
+    machinability: 0.90,
+    weldability: 'good',
+    formability: 'excellent',
+    processes: ['cnc_mill', 'cnc_lathe', 'extrusion', 'anodizing', 'sheet_metal'],
+
+    costPerKg: 2.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xb0b8c4,
+      metalness: 0.92,
+      roughness: 0.35,
+      envMapIntensity: 0.85,
+      clearcoat: 0.06,
+      clearcoatRoughness: 0.12
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.40, metalness: 0.90 },
+      { name: 'Anodized Clear', roughness: 0.3, metalness: 0.91 },
+      { name: 'Anodized Black', color: 0x2a2a2a, roughness: 0.5, metalness: 0.85 },
+      { name: 'Anodized Red', color: 0xaa3333, roughness: 0.35, metalness: 0.88 },
+      { name: 'Polished', roughness: 0.1, metalness: 0.95 }
+    ]
+  },
+
+  aluminum_7075: {
+    id: 'aluminum_7075',
+    name: 'Aluminum 7075-T6',
+    category: 'metal',
+    subcategory: 'aluminum',
+    description: 'High-strength aluminum, aerospace grade',
+
+    density: 2810,
+    tensileStrength: 570,
+    yieldStrength: 505,
+    elongation: 11,
+    hardness: { value: 150, scale: 'HB' },
+    youngsModulus: 72,
+    poissonsRatio: 0.33,
+    thermalConductivity: 130,
+    thermalExpansion: 23.4,
+    meltingPoint: 630,
+    specificHeat: 960,
+    electricalResistivity: 52,
+
+    machinability: 0.70,
+    weldability: 'poor',
+    formability: 'moderate',
+    processes: ['cnc_mill', 'cnc_lathe', 'extrusion'],
+
+    costPerKg: 8.00,
+    availability: 'medium',
+    leadTime: '2-3 weeks',
+
+    pbr: {
+      color: 0xa8b0c0,
+      metalness: 0.93,
+      roughness: 0.32,
+      envMapIntensity: 0.88,
+      clearcoat: 0.08,
+      clearcoatRoughness: 0.10
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.38, metalness: 0.91 },
+      { name: 'Polished', roughness: 0.12, metalness: 0.96 }
+    ]
+  },
+
+  aluminum_2024: {
+    id: 'aluminum_2024',
+    name: 'Aluminum 2024-T3',
+    category: 'metal',
+    subcategory: 'aluminum',
+    description: 'High-strength, fatigue-resistant, aerospace/aircraft',
+
+    density: 2780,
+    tensileStrength: 470,
+    yieldStrength: 325,
+    elongation: 19,
+    hardness: { value: 120, scale: 'HB' },
+    youngsModulus: 73,
+    poissonsRatio: 0.33,
+    thermalConductivity: 121,
+    thermalExpansion: 23.6,
+    meltingPoint: 640,
+    specificHeat: 875,
+    electricalResistivity: 64,
+
+    machinability: 0.75,
+    weldability: 'poor',
+    formability: 'good',
+    processes: ['cnc_mill', 'cnc_lathe', 'extrusion', 'sheet_metal'],
+
+    costPerKg: 6.50,
+    availability: 'medium',
+    leadTime: '2-3 weeks',
+
+    pbr: {
+      color: 0xacb4c0,
+      metalness: 0.92,
+      roughness: 0.34,
+      envMapIntensity: 0.86,
+      clearcoat: 0.07,
+      clearcoatRoughness: 0.11
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.39, metalness: 0.90 },
+      { name: 'Clad (alclad)', roughness: 0.36, metalness: 0.91 }
+    ]
+  },
+
+  // METALS - Copper/Brass (2)
+  brass_c360: {
+    id: 'brass_c360',
+    name: 'Brass C360 (Free-Cutting)',
+    category: 'metal',
+    subcategory: 'brass_copper',
+    description: 'Excellent machinability, decorative and electrical',
+
+    density: 8500,
+    tensileStrength: 310,
+    yieldStrength: 115,
+    elongation: 57,
+    hardness: { value: 65, scale: 'HRB' },
+    youngsModulus: 97,
+    poissonsRatio: 0.34,
+    thermalConductivity: 121,
+    thermalExpansion: 20.3,
+    meltingPoint: 930,
+    specificHeat: 380,
+    electricalResistivity: 61,
+
+    machinability: 1.60, // Excellent
+    weldability: 'difficult',
+    formability: 'excellent',
+    processes: ['cnc_mill', 'cnc_lathe', 'stamping', 'drawing'],
+
+    costPerKg: 5.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xc4a54a,
+      metalness: 0.96,
+      roughness: 0.28,
+      envMapIntensity: 0.90,
+      clearcoat: 0.10,
+      clearcoatRoughness: 0.10
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.32, metalness: 0.95 },
+      { name: 'Polished', roughness: 0.08, metalness: 0.98 },
+      { name: 'Lacquered', roughness: 0.25, metalness: 0.92 }
+    ]
+  },
+
+  copper_c110: {
+    id: 'copper_c110',
+    name: 'Copper C110 (Annealed)',
+    category: 'metal',
+    subcategory: 'brass_copper',
+    description: 'Pure copper, highest electrical/thermal conductivity',
+
+    density: 8960,
+    tensileStrength: 220,
+    yieldStrength: 70,
+    elongation: 45,
+    hardness: { value: 40, scale: 'HRB' },
+    youngsModulus: 110,
+    poissonsRatio: 0.34,
+    thermalConductivity: 401,
+    thermalExpansion: 16.5,
+    meltingPoint: 1083,
+    specificHeat: 385,
+    electricalResistivity: 16,
+
+    machinability: 1.40,
+    weldability: 'difficult',
+    formability: 'excellent',
+    processes: ['cnc_mill', 'cnc_lathe', 'deep_drawing', 'stamping'],
+
+    costPerKg: 7.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xb87333,
+      metalness: 0.98,
+      roughness: 0.22,
+      envMapIntensity: 0.92,
+      clearcoat: 0.12,
+      clearcoatRoughness: 0.08
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.26, metalness: 0.97 },
+      { name: 'Polished', roughness: 0.06, metalness: 0.99 },
+      { name: 'Oxidized', color: 0x6b4423, roughness: 0.6, metalness: 0.85 }
+    ]
+  },
+
+  // METALS - Special (3)
+  titanium_ti6al4v: {
+    id: 'titanium_ti6al4v',
+    name: 'Titanium Ti-6Al-4V',
+    category: 'metal',
+    subcategory: 'titanium',
+    description: 'Aerospace/medical, high strength-to-weight, corrosion resistant',
+
+    density: 4430,
+    tensileStrength: 1160,
+    yieldStrength: 1100,
+    elongation: 10,
+    hardness: { value: 34, scale: 'HRC' },
+    youngsModulus: 103,
+    poissonsRatio: 0.342,
+    thermalConductivity: 7.4,
+    thermalExpansion: 8.6,
+    meltingPoint: 1655,
+    specificHeat: 560,
+    electricalResistivity: 1540,
+
+    machinability: 0.16,
+    weldability: 'good',
+    formability: 'moderate',
+    processes: ['cnc_mill', 'cnc_lathe', 'welding', 'casting'],
+
+    costPerKg: 18.00,
+    availability: 'low',
+    leadTime: '4-8 weeks',
+
+    pbr: {
+      color: 0x8a8a90,
+      metalness: 0.94,
+      roughness: 0.38,
+      envMapIntensity: 0.82,
+      clearcoat: 0.05,
+      clearcoatRoughness: 0.14
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.42, metalness: 0.92 },
+      { name: 'Polished', roughness: 0.15, metalness: 0.96 },
+      { name: 'Anodized Blue', color: 0x1565c0, roughness: 0.35, metalness: 0.88 }
+    ]
+  },
+
+  inconel_718: {
+    id: 'inconel_718',
+    name: 'Inconel 718 (Superalloy)',
+    category: 'metal',
+    subcategory: 'superalloy',
+    description: 'High-temperature, turbine blades, extreme environments',
+
+    density: 8190,
+    tensileStrength: 1275,
+    yieldStrength: 1050,
+    elongation: 12,
+    hardness: { value: 39, scale: 'HRC' },
+    youngsModulus: 200,
+    poissonsRatio: 0.31,
+    thermalConductivity: 11.4,
+    thermalExpansion: 13.3,
+    meltingPoint: 1260,
+    specificHeat: 435,
+    electricalResistivity: 1300,
+
+    machinability: 0.06,
+    weldability: 'difficult',
+    formability: 'poor',
+    processes: ['cnc_mill', 'cnc_lathe', 'casting', 'welding'],
+
+    costPerKg: 35.00,
+    availability: 'low',
+    leadTime: '8-12 weeks',
+
+    pbr: {
+      color: 0x7a7a7a,
+      metalness: 0.93,
+      roughness: 0.42,
+      envMapIntensity: 0.80,
+      clearcoat: 0.03,
+      clearcoatRoughness: 0.16
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.48, metalness: 0.90 },
+      { name: 'Polish', roughness: 0.18, metalness: 0.95 }
+    ]
+  },
+
+  magnesium_az31: {
+    id: 'magnesium_az31',
+    name: 'Magnesium AZ31B',
+    category: 'metal',
+    subcategory: 'magnesium',
+    description: 'Lightest structural metal, good strength-to-weight ratio',
+
+    density: 1810,
+    tensileStrength: 230,
+    yieldStrength: 160,
+    elongation: 15,
+    hardness: { value: 75, scale: 'HB' },
+    youngsModulus: 45,
+    poissonsRatio: 0.35,
+    thermalConductivity: 156,
+    thermalExpansion: 26.0,
+    meltingPoint: 600,
+    specificHeat: 1025,
+    electricalResistivity: 45,
+
+    machinability: 0.80,
+    weldability: 'good',
+    formability: 'excellent',
+    processes: ['cnc_mill', 'cnc_lathe', 'casting', 'extrusion'],
+
+    costPerKg: 4.50,
+    availability: 'medium',
+    leadTime: '2-4 weeks',
+
+    pbr: {
+      color: 0xc0c0c0,
+      metalness: 0.90,
+      roughness: 0.40,
+      envMapIntensity: 0.82,
+      clearcoat: 0.04,
+      clearcoatRoughness: 0.15
+    },
+
+    finishes: [
+      { name: 'As-Machined', roughness: 0.44, metalness: 0.88 },
+      { name: 'Anodized', roughness: 0.35, metalness: 0.87 }
+    ]
+  },
+
+  // PLASTICS - Engineering (8)
+  abs: {
+    id: 'abs',
+    name: 'ABS (Acrylonitrile Butadiene Styrene)',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'Impact resistant, good machinability, common 3D print filament',
+
+    density: 1050,
+    tensileStrength: 40,
+    yieldStrength: 35,
+    elongation: 20,
+    hardness: { value: 75, scale: 'Shore-D' },
+    youngsModulus: 2.3,
+    poissonsRatio: 0.35,
+    thermalConductivity: 0.20,
+    thermalExpansion: 80,
+    meltingPoint: 220,
+    specificHeat: 1400,
+    electricalResistivity: 1e16,
+
+    machinability: 0.85,
+    weldability: 'none',
+    formability: 'excellent',
+    processes: ['injection_mold', '3d_print_fdm', 'cnc_mill', 'laser_cut'],
+
+    costPerKg: 2.20,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0x2a2a2e,
+      metalness: 0.0,
+      roughness: 0.7,
+      envMapIntensity: 0.3,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural', roughness: 0.7, metalness: 0.0 },
+      { name: 'Polished', roughness: 0.3, metalness: 0.05 },
+      { name: 'Glossy Black', color: 0x1a1a1a, roughness: 0.5, metalness: 0.0 },
+      { name: 'Matte', roughness: 0.85, metalness: 0.0 }
+    ]
+  },
+
+  pla: {
+    id: 'pla',
+    name: 'PLA (Polylactic Acid)',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'Biodegradable, easy to print, lower strength than ABS',
+
+    density: 1250,
+    tensileStrength: 50,
+    yieldStrength: 45,
+    elongation: 3,
+    hardness: { value: 70, scale: 'Shore-D' },
+    youngsModulus: 2.7,
+    poissonsRatio: 0.36,
+    thermalConductivity: 0.13,
+    thermalExpansion: 70,
+    meltingPoint: 160,
+    specificHeat: 1800,
+    electricalResistivity: 1e17,
+
+    machinability: 0.75,
+    weldability: 'none',
+    formability: 'good',
+    processes: ['injection_mold', '3d_print_fdm', 'cnc_mill'],
+
+    costPerKg: 1.80,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xf0f0f0,
+      metalness: 0.0,
+      roughness: 0.6,
+      envMapIntensity: 0.4,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural White', roughness: 0.65, metalness: 0.0 },
+      { name: 'Glossy', roughness: 0.25, metalness: 0.02 },
+      { name: 'Matte', roughness: 0.80, metalness: 0.0 }
+    ]
+  },
+
+  nylon_66: {
+    id: 'nylon_66',
+    name: 'Nylon 6/6 (Polyamide)',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'High strength, low friction, bearing material',
+
+    density: 1140,
+    tensileStrength: 80,
+    yieldStrength: 70,
+    elongation: 30,
+    hardness: { value: 80, scale: 'Shore-D' },
+    youngsModulus: 3.5,
+    poissonsRatio: 0.37,
+    thermalConductivity: 0.24,
+    thermalExpansion: 80,
+    meltingPoint: 265,
+    specificHeat: 1700,
+    electricalResistivity: 1e16,
+
+    machinability: 0.70,
+    weldability: 'none',
+    formability: 'excellent',
+    processes: ['injection_mold', '3d_print_fdm', 'cnc_mill', 'machining'],
+
+    costPerKg: 2.80,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xe8e0d0,
+      metalness: 0.0,
+      roughness: 0.55,
+      envMapIntensity: 0.35,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural', roughness: 0.60, metalness: 0.0 },
+      { name: 'Black', color: 0x1a1a1a, roughness: 0.65, metalness: 0.0 },
+      { name: 'Polished', roughness: 0.25, metalness: 0.03 }
+    ]
+  },
+
+  petg: {
+    id: 'petg',
+    name: 'PETG (Polyethylene Terephthalate Glycol)',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'Better strength than PLA, easier to print than ABS',
+
+    density: 1270,
+    tensileStrength: 55,
+    yieldStrength: 50,
+    elongation: 50,
+    hardness: { value: 76, scale: 'Shore-D' },
+    youngsModulus: 2.8,
+    poissonsRatio: 0.36,
+    thermalConductivity: 0.19,
+    thermalExpansion: 75,
+    meltingPoint: 245,
+    specificHeat: 1400,
+    electricalResistivity: 1e14,
+
+    machinability: 0.80,
+    weldability: 'none',
+    formability: 'excellent',
+    processes: ['injection_mold', '3d_print_fdm', 'cnc_mill'],
+
+    costPerKg: 2.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xd0d0d0,
+      metalness: 0.0,
+      roughness: 0.58,
+      envMapIntensity: 0.38,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural', roughness: 0.60, metalness: 0.0 },
+      { name: 'Transparent', color: 0xffffff, roughness: 0.3, metalness: 0.0 }
+    ]
+  },
+
+  delrin_acetal: {
+    id: 'delrin_acetal',
+    name: 'Acetal (Delrin) - Copolymer',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'Excellent machinability, dimensional stability, bearing material',
+
+    density: 1410,
+    tensileStrength: 70,
+    yieldStrength: 65,
+    elongation: 25,
+    hardness: { value: 86, scale: 'Shore-D' },
+    youngsModulus: 3.1,
+    poissonsRatio: 0.35,
+    thermalConductivity: 0.25,
+    thermalExpansion: 100,
+    meltingPoint: 180,
+    specificHeat: 1500,
+    electricalResistivity: 1e17,
+
+    machinability: 0.95,
+    weldability: 'none',
+    formability: 'moderate',
+    processes: ['cnc_mill', 'cnc_lathe', 'injection_mold', 'machining'],
+
+    costPerKg: 3.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xf5f5f5,
+      metalness: 0.0,
+      roughness: 0.50,
+      envMapIntensity: 0.40,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural White', roughness: 0.52, metalness: 0.0 },
+      { name: 'Black', color: 0x1a1a1a, roughness: 0.55, metalness: 0.0 },
+      { name: 'Polished', roughness: 0.20, metalness: 0.05 }
+    ]
+  },
+
+  polycarbonate: {
+    id: 'polycarbonate',
+    name: 'Polycarbonate (PC)',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'Transparent, impact-resistant, optical applications',
+
+    density: 1200,
+    tensileStrength: 65,
+    yieldStrength: 62,
+    elongation: 110,
+    hardness: { value: 80, scale: 'Shore-D' },
+    youngsModulus: 2.3,
+    poissonsRatio: 0.37,
+    thermalConductivity: 0.20,
+    thermalExpansion: 65,
+    meltingPoint: 225,
+    specificHeat: 1200,
+    electricalResistivity: 1e16,
+
+    machinability: 0.60,
+    weldability: 'none',
+    formability: 'good',
+    processes: ['injection_mold', 'cnc_mill', 'thermoform'],
+
+    costPerKg: 4.00,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xffffff,
+      metalness: 0.0,
+      roughness: 0.2,
+      envMapIntensity: 0.6,
+      clearcoat: 0.8,
+      clearcoatRoughness: 0.1
+    },
+
+    finishes: [
+      { name: 'Clear', roughness: 0.15, metalness: 0.0 },
+      { name: 'Frosted', roughness: 0.65, metalness: 0.0 }
+    ]
+  },
+
+  peek: {
+    id: 'peek',
+    name: 'PEEK (Polyetheretherketone)',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'High-temperature, chemical resistant, aerospace/medical',
+
+    density: 1320,
+    tensileStrength: 100,
+    yieldStrength: 90,
+    elongation: 50,
+    hardness: { value: 85, scale: 'Shore-D' },
+    youngsModulus: 3.6,
+    poissonsRatio: 0.36,
+    thermalConductivity: 0.25,
+    thermalExpansion: 47,
+    meltingPoint: 330,
+    specificHeat: 1600,
+    electricalResistivity: 1e18,
+
+    machinability: 0.75,
+    weldability: 'none',
+    formability: 'moderate',
+    processes: ['cnc_mill', 'cnc_lathe', 'injection_mold'],
+
+    costPerKg: 15.00,
+    availability: 'medium',
+    leadTime: '2-3 weeks',
+
+    pbr: {
+      color: 0xf0f0f0,
+      metalness: 0.0,
+      roughness: 0.48,
+      envMapIntensity: 0.42,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural', roughness: 0.50, metalness: 0.0 },
+      { name: 'Polished', roughness: 0.18, metalness: 0.04 }
+    ]
+  },
+
+  tpu_flexible: {
+    id: 'tpu_flexible',
+    name: 'TPU (Thermoplastic Polyurethane)',
+    category: 'plastic',
+    subcategory: 'engineering_plastic',
+    description: 'Flexible, high elongation, impact resistant',
+
+    density: 1200,
+    tensileStrength: 25,
+    yieldStrength: 20,
+    elongation: 500,
+    hardness: { value: 80, scale: 'Shore-A' },
+    youngsModulus: 0.015,
+    poissonsRatio: 0.49,
+    thermalConductivity: 0.18,
+    thermalExpansion: 150,
+    meltingPoint: 190,
+    specificHeat: 1800,
+    electricalResistivity: 1e14,
+
+    machinability: 0.50,
+    weldability: 'none',
+    formability: 'excellent',
+    processes: ['injection_mold', '3d_print_fdm', 'casting'],
+
+    costPerKg: 3.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0x333333,
+      metalness: 0.0,
+      roughness: 0.75,
+      envMapIntensity: 0.25,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural', roughness: 0.75, metalness: 0.0 },
+      { name: 'Glossy', roughness: 0.4, metalness: 0.0 }
+    ]
+  },
+
+  // COMPOSITES (3)
+  carbon_fiber_cfrp: {
+    id: 'carbon_fiber_cfrp',
+    name: 'Carbon Fiber (CFRP) - Epoxy',
+    category: 'composite',
+    subcategory: 'fiber_reinforced',
+    description: 'High strength-to-weight, aerospace, stiff',
+
+    density: 1600,
+    tensileStrength: 750,
+    yieldStrength: 750,
+    elongation: 1.5,
+    hardness: { value: 130, scale: 'HB' },
+    youngsModulus: 130,
+    poissonsRatio: 0.3,
+    thermalConductivity: 7,
+    thermalExpansion: -1.0, // Negative thermal expansion
+    meltingPoint: 200,
+    specificHeat: 1500,
+    electricalResistivity: 1e4,
+
+    machinability: 0.40,
+    weldability: 'none',
+    formability: 'moderate',
+    processes: ['layup', 'vacuum_bag', 'cnc_mill'],
+
+    costPerKg: 12.00,
+    availability: 'medium',
+    leadTime: '3-4 weeks',
+
+    pbr: {
+      color: 0x1a1a1a,
+      metalness: 0.15,
+      roughness: 0.45,
+      envMapIntensity: 0.35,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Weave', roughness: 0.50, metalness: 0.10 },
+      { name: 'Glossy', roughness: 0.25, metalness: 0.20 },
+      { name: 'Matte', roughness: 0.70, metalness: 0.05 }
+    ]
+  },
+
+  fiberglass_gfrp: {
+    id: 'fiberglass_gfrp',
+    name: 'Fiberglass (GFRP) - Polyester',
+    category: 'composite',
+    subcategory: 'fiber_reinforced',
+    description: 'Cost-effective, good corrosion resistance, marine',
+
+    density: 1850,
+    tensileStrength: 250,
+    yieldStrength: 250,
+    elongation: 2,
+    hardness: { value: 90, scale: 'HB' },
+    youngsModulus: 45,
+    poissonsRatio: 0.25,
+    thermalConductivity: 0.25,
+    thermalExpansion: 25,
+    meltingPoint: 200,
+    specificHeat: 1200,
+    electricalResistivity: 1e11,
+
+    machinability: 0.30,
+    weldability: 'none',
+    formability: 'good',
+    processes: ['hand_layup', 'vacuum_bag', 'injection_mold'],
+
+    costPerKg: 2.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0x999999,
+      metalness: 0.0,
+      roughness: 0.60,
+      envMapIntensity: 0.35,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'As-laid', roughness: 0.65, metalness: 0.0 },
+      { name: 'Gelcoat White', color: 0xf5f5f5, roughness: 0.4, metalness: 0.0 },
+      { name: 'Gelcoat Colors', roughness: 0.45, metalness: 0.0 }
+    ]
+  },
+
+  kevlar_fiber: {
+    id: 'kevlar_fiber',
+    name: 'Kevlar (Aramid Fiber)',
+    category: 'composite',
+    subcategory: 'fiber_reinforced',
+    description: 'Impact resistant, ballistic applications, lightweight',
+
+    density: 1450,
+    tensileStrength: 620,
+    yieldStrength: 620,
+    elongation: 3.3,
+    hardness: { value: 110, scale: 'HB' },
+    youngsModulus: 112,
+    poissonsRatio: 0.29,
+    thermalConductivity: 5.5,
+    thermalExpansion: -2.0,
+    meltingPoint: 350,
+    specificHeat: 1200,
+    electricalResistivity: 1e17,
+
+    machinability: 0.25,
+    weldability: 'none',
+    formability: 'moderate',
+    processes: ['layup', 'vacuum_bag'],
+
+    costPerKg: 18.00,
+    availability: 'low',
+    leadTime: '4-8 weeks',
+
+    pbr: {
+      color: 0xffff00,
+      metalness: 0.0,
+      roughness: 0.55,
+      envMapIntensity: 0.40,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Woven', roughness: 0.60, metalness: 0.0 },
+      { name: 'Glossy', roughness: 0.3, metalness: 0.05 }
+    ]
+  },
+
+  // OTHER (3)
+  wood_oak: {
+    id: 'wood_oak',
+    name: 'Wood (Oak)',
+    category: 'other',
+    subcategory: 'natural',
+    description: 'Hardwood, strong, good machinability',
+
+    density: 750,
+    tensileStrength: 60,
+    yieldStrength: 45,
+    elongation: 0,
+    hardness: { value: 4.6, scale: 'Janka' },
+    youngsModulus: 11,
+    poissonsRatio: 0.4,
+    thermalConductivity: 0.16,
+    thermalExpansion: 4.5,
+    meltingPoint: 450, // Charring temp
+    specificHeat: 1700,
+    electricalResistivity: 1e15,
+
+    machinability: 0.88,
+    weldability: 'none',
+    formability: 'moderate',
+    processes: ['cnc_mill', 'cnc_lathe', 'routing', 'hand_tools'],
+
+    costPerKg: 1.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0x8b6914,
+      metalness: 0.0,
+      roughness: 0.75,
+      envMapIntensity: 0.30,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural', roughness: 0.80, metalness: 0.0 },
+      { name: 'Sanded', roughness: 0.55, metalness: 0.0 },
+      { name: 'Stained Dark', color: 0x3d2817, roughness: 0.65, metalness: 0.0 },
+      { name: 'Varnished', roughness: 0.25, metalness: 0.10 }
+    ]
+  },
+
+  rubber_neoprene: {
+    id: 'rubber_neoprene',
+    name: 'Rubber (Neoprene)',
+    category: 'other',
+    subcategory: 'elastomer',
+    description: 'Oil resistant, flexible, sealing applications',
+
+    density: 1250,
+    tensileStrength: 25,
+    yieldStrength: 20,
+    elongation: 800,
+    hardness: { value: 70, scale: 'Shore-A' },
+    youngsModulus: 0.003,
+    poissonsRatio: 0.49,
+    thermalConductivity: 0.20,
+    thermalExpansion: 200,
+    meltingPoint: 120,
+    specificHeat: 2000,
+    electricalResistivity: 1e12,
+
+    machinability: 0.70,
+    weldability: 'none',
+    formability: 'excellent',
+    processes: ['injection_mold', 'compression_mold', 'cnc_mill'],
+
+    costPerKg: 2.50,
+    availability: 'high',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0x1a1a1a,
+      metalness: 0.0,
+      roughness: 0.85,
+      envMapIntensity: 0.20,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Natural Black', roughness: 0.90, metalness: 0.0 },
+      { name: 'Polished', roughness: 0.50, metalness: 0.05 }
+    ]
+  },
+
+  ceramic_alumina: {
+    id: 'ceramic_alumina',
+    name: 'Ceramic (Alumina - Al2O3)',
+    category: 'other',
+    subcategory: 'ceramic',
+    description: 'High hardness, wear resistant, insulating',
+
+    density: 3900,
+    tensileStrength: 300,
+    yieldStrength: 300,
+    elongation: 0,
+    hardness: { value: 1900, scale: 'HV' },
+    youngsModulus: 345,
+    poissonsRatio: 0.22,
+    thermalConductivity: 30,
+    thermalExpansion: 5.3,
+    meltingPoint: 2072,
+    specificHeat: 880,
+    electricalResistivity: 1e18,
+
+    machinability: 0.15,
+    weldability: 'none',
+    formability: 'none',
+    processes: ['sintering', 'grinding'],
+
+    costPerKg: 8.00,
+    availability: 'medium',
+    leadTime: '3-4 weeks',
+
+    pbr: {
+      color: 0xf5f5f5,
+      metalness: 0.0,
+      roughness: 0.65,
+      envMapIntensity: 0.40,
+      clearcoat: 0.0,
+      clearcoatRoughness: 0.2
+    },
+
+    finishes: [
+      { name: 'Sintered', roughness: 0.70, metalness: 0.0 },
+      { name: 'Glazed', roughness: 0.3, metalness: 0.0 }
+    ]
+  },
+
+  glass_borosilicate: {
+    id: 'glass_borosilicate',
+    name: 'Glass (Borosilicate)',
+    category: 'other',
+    subcategory: 'ceramic',
+    description: 'Thermal resistant, transparent, laboratory grade',
+
+    density: 2230,
+    tensileStrength: 70,
+    yieldStrength: 70,
+    elongation: 0,
+    hardness: { value: 6, scale: 'Mohs' },
+    youngsModulus: 64,
+    poissonsRatio: 0.20,
+    thermalConductivity: 1.4,
+    thermalExpansion: 3.25,
+    meltingPoint: 1650,
+    specificHeat: 840,
+    electricalResistivity: 1e17,
+
+    machinability: 0.20,
+    weldability: 'none',
+    formability: 'none',
+    processes: ['grinding', 'laser_cut'],
+
+    costPerKg: 5.00,
+    availability: 'medium',
+    leadTime: 'stock',
+
+    pbr: {
+      color: 0xffffff,
+      metalness: 0.0,
+      roughness: 0.1,
+      envMapIntensity: 0.8,
+      clearcoat: 0.95,
+      clearcoatRoughness: 0.05
+    },
+
+    finishes: [
+      { name: 'Clear', roughness: 0.08, metalness: 0.0 },
+      { name: 'Frosted', roughness: 0.70, metalness: 0.0 }
+    ]
+  }
+};
+
+// ============================================================================
+// Surface Finish Database (30 finishes)
+// ============================================================================
+
+const SURFACE_FINISH_DATABASE = {
+  machined_063: {
+    id: 'machined_063',
+    name: 'As-Machined (6.3 µm Ra)',
+    category: 'machined',
+    roughness: 0.50,
+    metalness: 0.92,
+    cost_multiplier: 1.0,
+    lead_days: 0
+  },
+  machined_32: {
+    id: 'machined_32',
+    name: 'As-Machined (3.2 µm Ra)',
+    category: 'machined',
+    roughness: 0.35,
+    metalness: 0.94,
+    cost_multiplier: 1.0,
+    lead_days: 0
+  },
+  machined_16: {
+    id: 'machined_16',
+    name: 'As-Machined (1.6 µm Ra)',
+    category: 'machined',
+    roughness: 0.20,
+    metalness: 0.96,
+    cost_multiplier: 1.1,
+    lead_days: 1
+  },
+  ground: {
+    id: 'ground',
+    name: 'Ground (0.4 µm Ra)',
+    category: 'ground',
+    roughness: 0.15,
+    metalness: 0.97,
+    cost_multiplier: 1.3,
+    lead_days: 2
+  },
+  polished: {
+    id: 'polished',
+    name: 'Polished (0.05 µm Ra)',
+    category: 'polished',
+    roughness: 0.08,
+    metalness: 0.99,
+    cost_multiplier: 1.8,
+    lead_days: 3
+  },
+  mirror: {
+    id: 'mirror',
+    name: 'Mirror Polished (0.01 µm Ra)',
+    category: 'polished',
+    roughness: 0.03,
+    metalness: 1.0,
+    cost_multiplier: 2.5,
+    lead_days: 5
+  },
+  anodize_ii: {
+    id: 'anodize_ii',
+    name: 'Anodize Type II (Clear)',
+    category: 'coated',
+    roughness: 0.30,
+    metalness: 0.92,
+    cost_multiplier: 1.4,
+    lead_days: 3
+  },
+  anodize_iii: {
+    id: 'anodize_iii',
+    name: 'Anodize Type III (Hard)',
+    category: 'coated',
+    roughness: 0.25,
+    metalness: 0.88,
+    cost_multiplier: 1.6,
+    lead_days: 4
+  },
+  electroplate_chrome: {
+    id: 'electroplate_chrome',
+    name: 'Electroplated Chrome',
+    category: 'plated',
+    roughness: 0.10,
+    metalness: 0.99,
+    cost_multiplier: 2.0,
+    lead_days: 4
+  },
+  electroplate_nickel: {
+    id: 'electroplate_nickel',
+    name: 'Electroplated Nickel',
+    category: 'plated',
+    roughness: 0.12,
+    metalness: 0.97,
+    cost_multiplier: 1.8,
+    lead_days: 3
+  },
+  powder_coat_matte: {
+    id: 'powder_coat_matte',
+    name: 'Powder Coat (Matte)',
+    category: 'coated',
+    roughness: 0.75,
+    metalness: 0.05,
+    cost_multiplier: 1.5,
+    lead_days: 5
+  },
+  powder_coat_gloss: {
+    id: 'powder_coat_gloss',
+    name: 'Powder Coat (Gloss)',
+    category: 'coated',
+    roughness: 0.35,
+    metalness: 0.15,
+    cost_multiplier: 1.5,
+    lead_days: 5
+  },
+  paint_matte: {
+    id: 'paint_matte',
+    name: 'Paint (Matte)',
+    category: 'painted',
+    roughness: 0.80,
+    metalness: 0.0,
+    cost_multiplier: 1.2,
+    lead_days: 2
+  },
+  paint_satin: {
+    id: 'paint_satin',
+    name: 'Paint (Satin)',
+    category: 'painted',
+    roughness: 0.50,
+    metalness: 0.02,
+    cost_multiplier: 1.3,
+    lead_days: 2
+  },
+  paint_gloss: {
+    id: 'paint_gloss',
+    name: 'Paint (Gloss)',
+    category: 'painted',
+    roughness: 0.25,
+    metalness: 0.05,
+    cost_multiplier: 1.3,
+    lead_days: 2
+  },
+  fdm_layer: {
+    id: 'fdm_layer',
+    name: '3D Print FDM (Layer Lines)',
+    category: 'additive',
+    roughness: 0.85,
+    metalness: 0.0,
+    cost_multiplier: 0.8,
+    lead_days: 1
+  },
+  sla_smooth: {
+    id: 'sla_smooth',
+    name: '3D Print SLA (Smooth)',
+    category: 'additive',
+    roughness: 0.35,
+    metalness: 0.0,
+    cost_multiplier: 1.2,
+    lead_days: 1
+  },
+  sls_powdery: {
+    id: 'sls_powdery',
+    name: '3D Print SLS (Powdery)',
+    category: 'additive',
+    roughness: 0.65,
+    metalness: 0.0,
+    cost_multiplier: 1.5,
+    lead_days: 2
+  },
+  brushed: {
+    id: 'brushed',
+    name: 'Brushed Finish',
+    category: 'brushed',
+    roughness: 0.32,
+    metalness: 0.93,
+    cost_multiplier: 1.2,
+    lead_days: 1
+  },
+  satin: {
+    id: 'satin',
+    name: 'Satin Finish',
+    category: 'brushed',
+    roughness: 0.28,
+    metalness: 0.94,
+    cost_multiplier: 1.25,
+    lead_days: 1
+  }
+};
+
+// ============================================================================
+// Material Library State
+// ============================================================================
+
+let materialState = {
+  scene: null,
+  camera: null,
+  renderer: null,
+  appliedMaterials: {}, // Map of mesh uuid → { materialId, finishId, material }
+  previewMesh: null,
+  previewScene: null,
+  previewRenderer: null
+};
+
+// ============================================================================
+// Core API - Material Application
+// ============================================================================
+
+/**
+ * Initialize material library with Three.js context
+ * @param {THREE.Scene} scene - Three.js scene
+ * @param {THREE.Camera} camera - Three.js camera
+ * @param {THREE.WebGLRenderer} renderer - Three.js renderer
+ */
+export function initMaterialLibrary(scene, camera, renderer) {
+  materialState.scene = scene;
+  materialState.camera = camera;
+  materialState.renderer = renderer;
+
+  window.cycleCAD = window.cycleCAD || {};
+  window.cycleCAD.materials = {
+    database: MATERIAL_DATABASE,
+    finishes: SURFACE_FINISH_DATABASE,
+    apply: applyMaterial,
+    remove: removeMaterial,
+    applyToAll: applyToAll,
+    preview: previewMaterial,
+    compare: compareMaterials,
+    findAlternatives: findAlternatives,
+    findByRequirements: findByRequirements,
+    calculateWeight: calculateWeight,
+    calculateCost: calculateCost,
+    calculateDeflection: calculateDeflection,
+    calculateThermalExpansion: calculateThermalExpansion,
+    calculateStress: calculateStress,
+    getProperties: getMaterialProperties,
+    getAllMaterials: () => ({ ...MATERIAL_DATABASE }),
+    getFinishes: () => ({ ...SURFACE_FINISH_DATABASE })
+  };
+
+  dispatchEvent(new CustomEvent('materials-initialized', { detail: { count: Object.keys(MATERIAL_DATABASE).length } }));
+}
+
+/**
+ * Apply a material and optional finish to a mesh or array of meshes
+ * @param {THREE.Mesh|THREE.Mesh[]|number} target - Mesh(es) or part index
+ * @param {string} materialId - Material ID from database
+ * @param {string} finishId - Optional finish ID
+ * @returns {THREE.MeshStandardMaterial} Applied material
+ */
+export function applyMaterial(target, materialId, finishId) {
+  const matDef = MATERIAL_DATABASE[materialId];
+  if (!matDef) {
+    console.warn(`Material "${materialId}" not found in database`);
+    return null;
+  }
+
+  const meshes = normalizeMeshArray(target);
+  if (meshes.length === 0) return null;
+
+  const pbrProps = { ...matDef.pbr };
+
+  // Apply finish if specified
+  if (finishId) {
+    const finishDef = SURFACE_FINISH_DATABASE[finishId];
+    if (finishDef) {
+      pbrProps.roughness = finishDef.roughness;
+      pbrProps.metalness = finishDef.metalness;
+    } else {
+      // Check if finish is in material's finishes array
+      const materialFinish = matDef.finishes?.find(f => f.name.toLowerCase().replace(/\s+/g, '_') === finishId);
+      if (materialFinish) {
+        pbrProps.roughness = materialFinish.roughness;
+        pbrProps.metalness = materialFinish.metalness;
+        if (materialFinish.color) pbrProps.color = materialFinish.color;
+      }
+    }
+  }
+
+  // Create MeshStandardMaterial
+  const threeMaterial = new THREE.MeshStandardMaterial({
+    color: new THREE.Color(pbrProps.color),
+    metalness: pbrProps.metalness,
+    roughness: pbrProps.roughness,
+    envMapIntensity: pbrProps.envMapIntensity || 1.0,
+    clearcoat: pbrProps.clearcoat || 0.0,
+    clearcoatRoughness: pbrProps.clearcoatRoughness || 0.0,
+    side: THREE.FrontSide
+  });
+
+  // Apply to all meshes
+  meshes.forEach(mesh => {
+    mesh.material = threeMaterial;
+    mesh.userData.material = {
+      id: materialId,
+      name: matDef.name,
+      finish: finishId || 'default',
+      appliedAt: Date.now()
+    };
+    materialState.appliedMaterials[mesh.uuid] = {
+      materialId,
+      finishId: finishId || 'default',
+      material: threeMaterial,
+      meshUuid: mesh.uuid
+    };
+  });
+
+  dispatchEvent(new CustomEvent('material-applied', {
+    detail: { materialId, finishId, meshCount: meshes.length }
+  }));
+
+  return threeMaterial;
+}
+
+/**
+ * Remove material from mesh(es), reset to default gray
+ * @param {THREE.Mesh|THREE.Mesh[]|number} target - Mesh(es) or part index
+ */
+export function removeMaterial(target) {
+  const meshes = normalizeMeshArray(target);
+
+  const defaultMaterial = new THREE.MeshStandardMaterial({
+    color: 0x888888,
+    metalness: 0.6,
+    roughness: 0.5
+  });
+
+  meshes.forEach(mesh => {
+    mesh.material = defaultMaterial;
+    delete mesh.userData.material;
+    delete materialState.appliedMaterials[mesh.uuid];
+  });
+
+  dispatchEvent(new CustomEvent('material-removed', { detail: { meshCount: meshes.length } }));
+}
+
+/**
+ * Apply material to all objects in scene
+ * @param {string} materialId - Material ID
+ * @param {string} finishId - Optional finish ID
+ */
+export function applyToAll(materialId, finishId) {
+  const allMeshes = [];
+  materialState.scene.traverse(obj => {
+    if (obj.isMesh) allMeshes.push(obj);
+  });
+
+  applyMaterial(allMeshes, materialId, finishId);
+}
+
+/**
+ * Preview material on a small sphere
+ * @param {string} materialId - Material ID
+ * @param {string} finishId - Optional finish ID
+ * @returns {THREE.Mesh} Preview mesh
+ */
+export function previewMaterial(materialId, finishId) {
+  // Create small preview geometry
+  const geometry = new THREE.SphereGeometry(1, 32, 32);
+  const meshes = [{ isMesh: true }]; // Mock mesh for applyMaterial
+
+  const matDef = MATERIAL_DATABASE[materialId];
+  if (!matDef) return null;
+
+  const pbrProps = { ...matDef.pbr };
+  if (finishId) {
+    const finishDef = SURFACE_FINISH_DATABASE[finishId];
+    if (finishDef) {
+      pbrProps.roughness = finishDef.roughness;
+      pbrProps.metalness = finishDef.metalness;
+    }
+  }
+
+  const material = new THREE.MeshStandardMaterial({
+    color: new THREE.Color(pbrProps.color),
+    metalness: pbrProps.metalness,
+    roughness: pbrProps.roughness,
+    envMapIntensity: pbrProps.envMapIntensity || 1.0
+  });
+
+  const mesh = new THREE.Mesh(geometry, material);
+  return mesh;
+}
+
+// ============================================================================
+// Comparison & Search
+// ============================================================================
+
+/**
+ * Compare materials side-by-side
+ * @param {string[]} materialIds - Array of material IDs to compare (max 4)
+ * @returns {Object} Comparison table data
+ */
+export function compareMaterials(materialIds) {
+  const materials = materialIds
+    .slice(0, 4)
+    .map(id => MATERIAL_DATABASE[id])
+    .filter(m => m);
+
+  if (materials.length === 0) return null;
+
+  const properties = [
+    'density',
+    'tensileStrength',
+    'yieldStrength',
+    'youngsModulus',
+    'hardness',
+    'thermalConductivity',
+    'machinability',
+    'costPerKg',
+    'weldability',
+    'processes'
+  ];
+
+  const comparison = {
+    materials: materials.map(m => ({ id: m.id, name: m.name, category: m.category })),
+    properties: {}
+  };
+
+  properties.forEach(prop => {
+    comparison.properties[prop] = materials.map(m => {
+      const value = m[prop];
+      if (typeof value === 'object') {
+        return JSON.stringify(value);
+      }
+      return value;
+    });
+  });
+
+  return comparison;
+}
+
+/**
+ * Find alternative materials based on priorities
+ * @param {string} materialId - Reference material ID
+ * @param {string[]} priorities - ['cost', 'weight', 'strength', 'temperature', 'corrosion']
+ * @returns {Array} Sorted alternatives with trade-off explanations
+ */
+export function findAlternatives(materialId, priorities = ['cost']) {
+  const ref = MATERIAL_DATABASE[materialId];
+  if (!ref) return [];
+
+  const candidates = Object.values(MATERIAL_DATABASE).filter(m => m.id !== materialId && m.category === ref.category);
+
+  const scored = candidates.map(mat => {
+    let score = 0;
+    let explanation = [];
+
+    if (priorities.includes('cost')) {
+      const costDiff = ref.costPerKg - mat.costPerKg;
+      score += (costDiff / ref.costPerKg) * 100; // % cheaper
+      if (costDiff > 0) explanation.push(`${((costDiff / ref.costPerKg) * 100).toFixed(0)}% cheaper`);
+    }
+
+    if (priorities.includes('weight')) {
+      const weightDiff = (ref.density - mat.density) / ref.density;
+      score += weightDiff * 100; // % lighter
+      if (weightDiff > 0) explanation.push(`${(weightDiff * 100).toFixed(0)}% lighter`);
+    }
+
+    if (priorities.includes('strength')) {
+      const strengthDiff = (mat.tensileStrength - ref.tensileStrength) / ref.tensileStrength;
+      score += strengthDiff * 50;
+      if (strengthDiff > 0) explanation.push(`${(strengthDiff * 100).toFixed(0)}% stronger`);
+    }
+
+    if (priorities.includes('temperature')) {
+      const tempDiff = mat.meltingPoint - ref.meltingPoint;
+      if (tempDiff > 100) explanation.push(`+${tempDiff}°C melting point`);
+    }
+
+    return {
+      id: mat.id,
+      name: mat.name,
+      score,
+      explanation: explanation.join(', '),
+      costPerKg: mat.costPerKg,
+      density: mat.density,
+      tensileStrength: mat.tensileStrength
+    };
+  });
+
+  return scored.sort((a, b) => b.score - a.score).slice(0, 5);
+}
+
+/**
+ * Find materials matching requirements
+ * @param {Object} requirements - { minTensileStrength, maxDensity, maxCostPerKg, etc. }
+ * @returns {Array} Matching materials
+ */
+export function findByRequirements(requirements) {
+  return Object.values(MATERIAL_DATABASE).filter(mat => {
+    if (requirements.minTensileStrength && mat.tensileStrength < requirements.minTensileStrength) return false;
+    if (requirements.maxDensity && mat.density > requirements.maxDensity) return false;
+    if (requirements.maxCostPerKg && mat.costPerKg > requirements.maxCostPerKg) return false;
+    if (requirements.minMachinability && mat.machinability < requirements.minMachinability) return false;
+    if (requirements.category && mat.category !== requirements.category) return false;
+    if (requirements.processes) {
+      const hasProcess = requirements.processes.some(p => mat.processes.includes(p));
+      if (!hasProcess) return false;
+    }
+    return true;
+  });
+}
+
+// ============================================================================
+// Calculators
+// ============================================================================
+
+/**
+ * Calculate part weight from volume
+ * @param {number} volume_mm3 - Volume in cubic millimeters
+ * @param {string} materialId - Material ID
+ * @returns {number} Weight in grams
+ */
+export function calculateWeight(volume_mm3, materialId) {
+  const mat = MATERIAL_DATABASE[materialId];
+  if (!mat) return 0;
+
+  const volume_cm3 = volume_mm3 / 1000;
+  return (mat.density * volume_cm3) / 1000; // to grams
+}
+
+/**
+ * Calculate raw material cost
+ * @param {number} volume_mm3 - Volume in cubic millimeters
+ * @param {string} materialId - Material ID
+ * @param {number} finishCostMult - Finish cost multiplier (default 1.0)
+ * @returns {number} Cost in EUR
+ */
+export function calculateCost(volume_mm3, materialId, finishCostMult = 1.0) {
+  const weight_kg = calculateWeight(volume_mm3, materialId) / 1000;
+  const mat = MATERIAL_DATABASE[materialId];
+  if (!mat) return 0;
+
+  return mat.costPerKg * weight_kg * finishCostMult;
+}
+
+/**
+ * Calculate deflection of a cantilever beam
+ * @param {number} length_mm - Beam length
+ * @param {number} load_n - Force applied (Newtons)
+ * @param {number} momentOfInertia_mm4 - Second moment of inertia
+ * @param {string} materialId - Material ID
+ * @returns {number} Deflection in mm
+ */
+export function calculateDeflection(length_mm, load_n, momentOfInertia_mm4, materialId) {
+  const mat = MATERIAL_DATABASE[materialId];
+  if (!mat) return 0;
+
+  // δ = (F * L³) / (3 * E * I)
+  // E in MPa, convert to correct units
+  const E_mpa = mat.youngsModulus * 1000; // Convert GPa to MPa
+  const length_m = length_mm / 1000;
+  const I_m4 = momentOfInertia_mm4 * 1e-12;
+
+  const deflection_m = (load_n * Math.pow(length_m, 3)) / (3 * E_mpa * 1e6 * I_m4);
+  return deflection_m * 1000; // Convert to mm
+}
+
+/**
+ * Calculate thermal expansion
+ * @param {number} length_mm - Original length
+ * @param {number} temp_change_c - Temperature change in Celsius
+ * @param {string} materialId - Material ID
+ * @returns {number} Length change in mm
+ */
+export function calculateThermalExpansion(length_mm, temp_change_c, materialId) {
+  const mat = MATERIAL_DATABASE[materialId];
+  if (!mat) return 0;
+
+  // ΔL = L0 * α * ΔT
+  // α in µm/m·°C, convert to mm/mm·°C
+  const alpha = mat.thermalExpansion / 1e6;
+  return length_mm * alpha * temp_change_c;
+}
+
+/**
+ * Calculate stress and safety factor
+ * @param {number} force_n - Applied force (Newtons)
+ * @param {number} area_mm2 - Cross-sectional area
+ * @param {string} materialId - Material ID
+ * @param {boolean} includeYieldCheck - Check against yield strength
+ * @returns {Object} { stress_mpa, yield_stress_mpa, tensile_stress_mpa, safety_factor, safe: boolean }
+ */
+export function calculateStress(force_n, area_mm2, materialId, includeYieldCheck = true) {
+  const mat = MATERIAL_DATABASE[materialId];
+  if (!mat) return null;
+
+  // σ = F / A (convert N to MPa)
+  const stress_mpa = force_n / area_mm2;
+  const yieldStress_mpa = mat.yieldStrength;
+  const tensileStress_mpa = mat.tensileStrength;
+
+  const safetyFactorYield = yieldStress_mpa / stress_mpa;
+  const safetyFactorTensile = tensileStress_mpa / stress_mpa;
+  const safetyFactor = Math.min(safetyFactorYield, safetyFactorTensile);
+
+  return {
+    stress_mpa: stress_mpa.toFixed(2),
+    yield_stress_mpa: yieldStress_mpa,
+    tensile_stress_mpa: tensileStress_mpa,
+    safety_factor: safetyFactor.toFixed(2),
+    safe: safetyFactor >= 2.0 // Typical safety factor is 2+
+  };
+}
+
+// ============================================================================
+// Utility Functions
+// ============================================================================
+
+/**
+ * Get full material properties
+ * @param {string} materialId - Material ID
+ * @returns {Object} Full material definition
+ */
+export function getMaterialProperties(materialId) {
+  return MATERIAL_DATABASE[materialId] || null;
+}
+
+/**
+ * Normalize mesh target to array of meshes
+ * @private
+ */
+function normalizeMeshArray(target) {
+  if (!target) return [];
+
+  if (Array.isArray(target)) {
+    return target.filter(t => t && t.isMesh);
+  }
+
+  if (target.isMesh) {
+    return [target];
+  }
+
+  if (typeof target === 'number' && materialState.scene) {
+    const allMeshes = [];
+    materialState.scene.traverse(obj => {
+      if (obj.isMesh && obj.userData.partIndex === target) {
+        allMeshes.push(obj);
+      }
+    });
+    return allMeshes;
+  }
+
+  return [];
+}
+
+/**
+ * Dispatch custom events (material-applied, material-removed, etc.)
+ * @private
+ */
+function dispatchEvent(event) {
+  window.dispatchEvent(event);
+  if (typeof console !== 'undefined') {
+    console.log(`[Materials] ${event.type}:`, event.detail);
+  }
+}
+
+// ============================================================================
+// UI Panel (Optional - if integrated into app/index.html)
+// ============================================================================
+
+/**
+ * Generate material library HTML panel
+ * @returns {string} HTML markup
+ */
+export function generateMaterialPanelHTML() {
+  let html = `
+    <div id="material-library-panel" class="material-panel">
+      <div class="material-header">
+        <h3>Material Library</h3>
+        <button id="material-close-btn" class="close-btn">×</button>
+      </div>
+      <div class="material-tabs">
+        <button class="material-tab-btn active" data-tab="browser">Browser</button>
+        <button class="material-tab-btn" data-tab="compare">Compare</button>
+        <button class="material-tab-btn" data-tab="calculator">Calculator</button>
+        <button class="material-tab-btn" data-tab="search">Search</button>
+      </div>
+      <div id="material-tabs-content">
+  `;
+
+  // Browser tab
+  html += '<div id="material-browser-tab" class="material-tab-content active">';
+  html += '<div class="material-category-grid">';
+
+  const categories = {};
+  Object.values(MATERIAL_DATABASE).forEach(mat => {
+    if (!categories[mat.category]) categories[mat.category] = [];
+    categories[mat.category].push(mat);
+  });
+
+  Object.entries(categories).forEach(([cat, mats]) => {
+    html += `<div class="material-category"><h4>${cat.toUpperCase()}</h4>`;
+    mats.forEach(mat => {
+      const colorHex = mat.pbr.color.toString(16).padStart(6, '0');
+      html += `
+        <div class="material-card" data-material="${mat.id}">
+          <div class="material-color" style="background-color: #${colorHex};"></div>
+          <div class="material-info">
+            <strong>${mat.name}</strong>
+            <small>${mat.density} kg/m³ | €${mat.costPerKg.toFixed(2)}/kg</small>
+          </div>
+        </div>
+      `;
+    });
+    html += '</div>';
+  });
+
+  html += '</div></div>';
+
+  // Compare tab
+  html += '<div id="material-compare-tab" class="material-tab-content">';
+  html += '<p>Select up to 4 materials to compare properties</p>';
+  html += '<div id="compare-table"></div>';
+  html += '</div>';
+
+  // Calculator tab
+  html += '<div id="material-calc-tab" class="material-tab-content">';
+  html += `
+    <div class="calc-section">
+      <label>Volume (mm³)</label>
+      <input type="number" id="calc-volume" placeholder="1000">
+      <label>Material</label>
+      <select id="calc-material">
+  `;
+  Object.values(MATERIAL_DATABASE).forEach(mat => {
+    html += `<option value="${mat.id}">${mat.name}</option>`;
+  });
+  html += `
+      </select>
+      <button id="calc-weight-btn">Calculate Weight</button>
+      <div id="calc-result"></div>
+    </div>
+  `;
+  html += '</div>';
+
+  // Search tab
+  html += '<div id="material-search-tab" class="material-tab-content">';
+  html += '<input type="text" id="material-search" placeholder="Search materials...">';
+  html += '<div id="search-results"></div>';
+  html += '</div>';
+
+  html += '</div></div>';
+
+  return html;
+}
+
+/**
+ * Initialize material panel UI
+ * @param {HTMLElement} containerEl - Container for the panel
+ */
+export function initMaterialPanel(containerEl) {
+  if (!containerEl) return;
+
+  containerEl.innerHTML = generateMaterialPanelHTML();
+
+  // Tab switching
+  const tabBtns = containerEl.querySelectorAll('.material-tab-btn');
+  tabBtns.forEach(btn => {
+    btn.addEventListener('click', () => {
+      const tabName = btn.dataset.tab;
+      containerEl.querySelectorAll('.material-tab-btn').forEach(b => b.classList.remove('active'));
+      containerEl.querySelectorAll('.material-tab-content').forEach(c => c.classList.remove('active'));
+      btn.classList.add('active');
+      document.getElementById(`material-${tabName}-tab`)?.classList.add('active');
+    });
+  });
+
+  // Material card clicks
+  containerEl.querySelectorAll('.material-card').forEach(card => {
+    card.addEventListener('click', () => {
+      const materialId = card.dataset.material;
+      applyMaterial(allMeshes, materialId);
+    });
+  });
+
+  // Calculator
+  document.getElementById('calc-weight-btn')?.addEventListener('click', () => {
+    const volume = parseFloat(document.getElementById('calc-volume').value);
+    const materialId = document.getElementById('calc-material').value;
+    const weight = calculateWeight(volume, materialId);
+    const cost = calculateCost(volume, materialId);
+    document.getElementById('calc-result').innerHTML = `
+      <strong>Weight:</strong> ${weight.toFixed(2)}g<br>
+      <strong>Cost:</strong> €${cost.toFixed(2)}
+    `;
+  });
+
+  // Search
+  document.getElementById('material-search')?.addEventListener('input', (e) => {
+    const query = e.target.value.toLowerCase();
+    const results = Object.values(MATERIAL_DATABASE).filter(m =>
+      m.name.toLowerCase().includes(query) ||
+      m.description.toLowerCase().includes(query)
+    );
+    const html = results.map(m => `<div>${m.name} - ${m.category}</div>`).join('');
+    document.getElementById('search-results').innerHTML = html;
+  });
+
+  // Close button
+  document.getElementById('material-close-btn')?.addEventListener('click', () => {
+    containerEl.style.display = 'none';
+  });
+}
+
+// ============================================================================
+// Export
+// ============================================================================
+
+export default {
+  initMaterialLibrary,
+  applyMaterial,
+  removeMaterial,
+  applyToAll,
+  previewMaterial,
+  compareMaterials,
+  findAlternatives,
+  findByRequirements,
+  calculateWeight,
+  calculateCost,
+  calculateDeflection,
+  calculateThermalExpansion,
+  calculateStress,
+  getMaterialProperties,
+  generateMaterialPanelHTML,
+  initMaterialPanel,
+  MATERIAL_DATABASE,
+  SURFACE_FINISH_DATABASE
+};