Copy the hoodie eye pair onto the Worker head and lift every hat except the firefighter helmet

tools/blender_assets.py

@@ -1510,7 +1510,7 @@ QUATERNIUS_SOURCES = {
                                     "above": "hair", "below": "cloth"},
                   # The bar, the oversized eyes and the hard hat are replaced by
                   # `_transplant_worker_head()`; those materials are gone by here.
-                  "Eyebrows": "hair",
+                  "Eyebrows": "keep",
                   "Brows": "keep",
                   "Eye": "keep", "Moustache": "keep"},
         "donor_head": True,
@@ -1534,24 +1534,59 @@ QUATERNIUS_SOURCES = {
 WORKER_HEAD_DONOR = {
     "source": "Casual_Hoodie.glb",
     # donor material -> contract slot name.
-    "parts": {"Eyebrows": "Brows", "Hair": "hair"},
+    "parts": {"Eyebrows": "Brows", "Eye": "Eye", "Hair": "hair"},
     # The three upstream heads carry the same-sized eye quads (x +-0.057), but the
     # Worker's face is flatter, so unchecked they sit proud of the skin and merge
     # into one dark bar -- the "unibrow" the owner saw. Set them back into the
     # socket so the skin crops their edges, and lift the brows clear of them.
-    "offset": {"Brows": (0.0, 0.0, 0.020)},
+    # Brows lift clear of the eye line; the eyes are pushed 4 mm forward so they
+    # clear the Worker's flatter face instead of sinking into it.
+    "offset": {"Brows": (0.0, 0.0, 0.020), "Eye": (0.0, -0.004, 0.0)},
     # Our material -> the height below which its faces go away. `Eyebrows` is the
     # bar *and* the forehead shell, so only the bar is cut: removing the whole
     # material opened the skull and the interior rendered as a black band across
     # the brows. `Eye` goes entirely (its quads read as one dark mass).
-    # `Eye` is deliberately *not* removed: this head has open sockets and the eye
-    # quads are the only thing filling them, so deleting them showed the inside of
-    # the head as a black band. They stay; the donor brows sit above them.
-    "remove": {"Eyebrows": 1.715, "Worker_Yellow": 1.60},
+    # The Worker's own eye quads sit inside the head and never show (the owner
+    # reported the Worker roles as eyeless), so they are replaced by the hoodie's
+    # pair, which is the same geometry the other eight characters use.
+    "remove": {"Eyebrows": 1.715, "Worker_Yellow": 1.60, "Eye": None},
     "bone": "Head",
 }
 
 
+def _purge_unused_materials(obj):
+    """Drop material slots no face uses, so a donor can take the freed name.
+
+    `IDMaterials.pop()` repoints the polygons that used the slot, which corrupted
+    the mesh the first time this was tried; rebuilding the list from the per-face
+    names is explicit and leaves no dangling index.
+    """
+    names = []
+    for poly in obj.data.polygons:
+        material = obj.data.materials[poly.material_index]
+        names.append(material.name if material else "")
+    kept, index_of = [], {}
+    for name in names:
+        if name in index_of:
+            continue
+        source = bpy.data.materials.get(name)
+        if source is None:
+            continue
+        index_of[name] = len(kept)
+        kept.append(source)
+    if len(kept) == len(obj.data.materials):
+        return
+    obj.data.materials.clear()
+    for material in kept:
+        obj.data.materials.append(material)
+    for poly, name in zip(obj.data.polygons, names):
+        poly.material_index = index_of.get(name, 0)
+    # A removed slot leaves its datablock behind with zero users, which still owns
+    # the name and forces the donor's material to `Eye.001`.
+    for material in [m for m in bpy.data.materials if m.users == 0]:
+        bpy.data.materials.remove(material)
+
+
 def _base_name(name):
     """Strip Blender's `.001` duplicate suffix."""
     head, sep, tail = name.rpartition(".")
@@ -1588,6 +1623,8 @@ def _transplant_worker_head(obj):
         bm.to_mesh(obj.data)
         bm.free()
         print(f"  removed {len(doomed)} Worker head faces")
+    _purge_unused_materials(obj)
+
     donor_path = QUATERNIUS_SRC / spec["source"]
     if not donor_path.is_file():
         print(f"  head donor {donor_path.name} missing, Worker head left bare")
@@ -1632,7 +1669,7 @@ def _transplant_worker_head(obj):
             kept.append(m)
         for slot_name, rule in spec.get("narrow", {}).items():
             local = [i for i, m in enumerate(candidate.data.materials)
-                     if m is not None and m.name == slot_name]
+                     if m is not None and _base_name(m.name) == slot_name]
             if not local:
                 continue
             bm = bmesh.new()
@@ -1649,7 +1686,7 @@ def _transplant_worker_head(obj):
 
         for slot_name, offset in spec.get("offset", {}).items():
             local = [i for i, m in enumerate(candidate.data.materials)
-                     if m is not None and m.name == slot_name]
+                     if m is not None and _base_name(m.name) == slot_name]
             if not local:
                 continue
             bm = bmesh.new()
@@ -1684,6 +1721,17 @@ def _transplant_worker_head(obj):
     donor.select_set(True)
     bpy.context.view_layer.objects.active = obj
     bpy.ops.object.join()
+    # The join can leave `Eye.001` next to a zero-user `Eye`; the contract slot
+    # names must be exact because the runtime tints by name.
+    slot_names = {m.name for m in obj.data.materials if m is not None}
+    for material in obj.data.materials:
+        if material is None:
+            continue
+        base = _base_name(material.name)
+        if base != material.name and base not in slot_names:
+            slot_names.discard(material.name)
+            material.name = base
+            slot_names.add(base)
     group = obj.vertex_groups.get(spec["bone"]) or obj.vertex_groups.new(name=spec["bone"])
     group.add([v.index for v in obj.data.vertices if not v.groups], 1.0, "REPLACE")
     print(f"  transplanted {', '.join(sorted(spec['parts'].values()))} "