fix: 6 critical/high bugs -- nesting, Figma crash, shade mapping, neutrals

Figma Plugin (code.js):
- Remove unused Inter SemiBold pre-load that crashed Create Visual Spec
- Wrap Bold font load in try/catch with fallback to Regular
- Use dynamic headingStyle variable for all section titles

Nesting Bug (app.py + color_classifier.py):
- _flat_key_to_nested: guard against navigating into DTCG leaf tokens
- Radius collision: return None for duplicates instead of .{px} suffix
- Color collision: skip duplicates instead of appending .N suffix

Palette Shade Assignment (color_classifier.py):
- Replace fixed-slot mapping with lightness-aware assignment
- Each color luminance maps to nearest shade (50-900) via interpolation
- Collision resolution nudges to nearest free shade slot

Neutral Detection (color_utils.py):
- Raise saturation threshold from 10% to 20%

Border Naming (color_classifier.py):
- Change border names from light/DEFAULT/dark to primary/secondary/muted

Type Scale Floor (app.py):
- Add MIN_FONT_SIZE 10px for desktop and mobile
- Prevents caption/overline from generating 6-8px unreadable sizes

All 113 tests pass.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

app.py

@@ -2847,10 +2847,11 @@ def _get_radius_token_name(value_str, seen_names: dict = None) -> str:
                 base_name = name
                 break
 
-    # Handle duplicates: if two radii map to same name, append px value
+    # Handle duplicates: if two radii map to same semantic name, skip the duplicate.
+    # Old behavior appended ".{px}" which created invalid nested DTCG structures.
     if seen_names is not None:
         if base_name in seen_names:
-            return f"{base_name}.{int(px)}"
+            return None  # Signal caller to skip this duplicate radius
         seen_names[base_name] = True
     return base_name
 
@@ -2911,13 +2912,22 @@ def _flat_key_to_nested(flat_key: str, value: dict, root: dict):
 
     Example: _flat_key_to_nested('color.brand.primary', token, {})
     Result: {'color': {'brand': {'primary': token}}}
+
+    Safety: If a path segment is already a DTCG leaf token ($type/$value),
+    the new token is SKIPPED to avoid creating invalid nested structures
+    like: {"$type":"color","$value":"#abc","2":{"$type":"color","$value":"#def"}}
     """
     parts = flat_key.split('.')
     current = root
     for part in parts[:-1]:
         if part not in current:
             current[part] = {}
-        current = current[part]
+        node = current[part]
+        # Guard: don't navigate into an existing leaf token
+        if isinstance(node, dict) and ('$type' in node or '$value' in node):
+            # This path would nest a child inside a DTCG leaf — skip silently
+            return
+        current = node
     current[parts[-1]] = value
 
 
@@ -3265,7 +3275,8 @@ def export_stage1_json(convention: str = "semantic"):
         seen_radius = {}
         for name, r in state.desktop_normalized.radius.items():
             token_name = _get_radius_token_name(r.value, seen_radius)
-            # Convert "radius.md" to nested: radius.md (keep as "radius" for consistency)
+            if token_name is None:
+                continue  # Duplicate radius — skip
             flat_key = token_name
             dtcg_token = _to_dtcg_token(r.value, "dimension", description="Extracted from site")
             _flat_key_to_nested(flat_key, dtcg_token, result)
@@ -3399,8 +3410,10 @@ def export_tokens_json(convention: str = "semantic"):
         return "body"
 
     # Desktop typography — W3C DTCG format
+    MIN_FONT_SIZE_DESKTOP = 10  # Floor: no text style below 10px
+    MIN_FONT_SIZE_MOBILE = 10   # Floor: same for mobile
     if ratio:
-        scales = [int(round(base_size * (ratio ** (8-i)) / 2) * 2) for i in range(13)]
+        scales = [max(MIN_FONT_SIZE_DESKTOP, int(round(base_size * (ratio ** (8-i)) / 2) * 2)) for i in range(13)]
         for i, token_name in enumerate(token_names):
             tier = _tier_from_token(token_name)
             flat_key = f"{token_name}.desktop"
@@ -3434,7 +3447,7 @@ def export_tokens_json(convention: str = "semantic"):
     # Mobile typography — W3C DTCG format
     if ratio:
         mobile_factor = 0.875
-        scales = [int(round(base_size * mobile_factor * (ratio ** (8-i)) / 2) * 2) for i in range(13)]
+        scales = [max(MIN_FONT_SIZE_MOBILE, int(round(base_size * mobile_factor * (ratio ** (8-i)) / 2) * 2)) for i in range(13)]
         for i, token_name in enumerate(token_names):
             tier = _tier_from_token(token_name)
             flat_key = f"{token_name}.mobile"
@@ -3522,7 +3535,8 @@ def export_tokens_json(convention: str = "semantic"):
         seen_radius = {}
         for name, r in state.desktop_normalized.radius.items():
             token_name = _get_radius_token_name(r.value, seen_radius)
-            # DTCG uses "dimension" for radii, not "borderRadius"
+            if token_name is None:
+                continue  # Duplicate radius — skip
             dtcg_token = _to_dtcg_token(r.value, "dimension")
             _flat_key_to_nested(token_name, dtcg_token, result)
             token_count += 1

core/color_classifier.py

@@ -46,7 +46,7 @@ ROLE_SHADE_NAMES = {
     "brand": ["primary", "secondary", "accent"],
     "text": ["primary", "secondary", "muted"],
     "bg": ["primary", "secondary", "tertiary"],
-    "border": ["light", "DEFAULT", "dark"],
+    "border": ["primary", "secondary", "muted"],
     "feedback": ["error", "warning", "success", "info"],
 }
 
@@ -581,13 +581,11 @@ def _assign_names(colors: list[dict], convention: str, log) -> list[ClassifiedCo
             else:
                 token_name = f"{prefix}{cat}{sep}{role}"
 
-            # Collision guard (should be rare for non-palette)
+            # Collision guard — skip duplicates instead of appending .N suffix
+            # (the .N suffix creates invalid nested DTCG when _flat_key_to_nested splits by ".")
             if token_name in used_names:
-                base_name = token_name
-                suffix = 2
-                while token_name in used_names:
-                    token_name = f"{base_name}{sep}{suffix}"
-                    suffix += 1
+                log(f"[SKIP] {c['hex']} → {token_name} collision, already taken — dropping")
+                continue
             used_names.add(token_name)
 
             evidence = _build_evidence(c)
@@ -626,11 +624,12 @@ def _assign_palette_names(
     log,
 ) -> list[ClassifiedColor]:
     """
-    Assign palette names by hue family with unique shade per color.
+    Assign palette names by hue family with lightness-aware shade mapping.
 
-    For N colors in a hue family, picks N evenly-spaced shade slots
-    sorted by lightness (lightest color → lightest shade).
-    No .2/.3 suffixes ever.
+    Each color gets a shade (50-900) based on its ACTUAL luminance, not a
+    fixed slot.  Lightest colors → lowest shade numbers (50/100), darkest → 800/900.
+    If two colors in the same hue map to the same shade, the less-frequent one
+    is nudged to the nearest free shade.  No .2/.3 suffixes ever.
     """
     # Group by hue family
     by_hue = {}
@@ -643,27 +642,43 @@ def _assign_palette_names(
     result = []
 
     for hue_fam, hue_colors in sorted(by_hue.items()):
-        n = len(hue_colors)
-
-        # Sort by luminance: lightest first → gets lightest shade slot
+        # Sort by luminance: lightest first
         hue_colors.sort(key=lambda x: -x["luminance"])
 
-        # Pick N evenly-spaced shade slots from the 10 available
-        if n == 1:
-            slots = ["500"]
-        elif n == 2:
-            slots = ["300", "700"]
-        elif n == 3:
-            slots = ["200", "500", "800"]
-        elif n == 4:
-            slots = ["100", "400", "600", "900"]
-        else:
-            # For n > 4 (shouldn't happen with cap=4, but safety)
-            step = max(1, len(_SHADE_SLOTS) // n)
-            slots = _SHADE_SLOTS[::step][:n]
-
-        for idx, c in enumerate(hue_colors):
-            role = slots[idx] if idx < len(slots) else str((idx + 1) * 100)
+        # Map each color's luminance to the nearest shade slot.
+        # Luminance 0.95+ → 50, 0.0 → 900.  Linear interpolation.
+        def _luminance_to_shade(lum: float) -> str:
+            # Clamp luminance to [0, 1]
+            lum = max(0.0, min(1.0, lum))
+            # Map: high luminance → low shade, low luminance → high shade
+            # 50 ← 0.95+, 100 ← ~0.85, 200 ← ~0.72, ..., 900 ← 0.0-0.05
+            shade_idx = int((1.0 - lum) * (len(_SHADE_SLOTS) - 1) + 0.5)
+            shade_idx = max(0, min(len(_SHADE_SLOTS) - 1, shade_idx))
+            return _SHADE_SLOTS[shade_idx]
+
+        # Assign shades, resolving collisions within the same hue family
+        used_shades_in_hue = set()
+        assignments = []  # list of (color_dict, shade_str)
+
+        for c in hue_colors:
+            shade = _luminance_to_shade(c["luminance"])
+            if shade in used_shades_in_hue:
+                # Nudge to nearest free shade
+                shade_int = _SHADE_SLOTS.index(shade)
+                found = False
+                for offset in range(1, len(_SHADE_SLOTS)):
+                    for direction in (+1, -1):
+                        cand = shade_int + offset * direction
+                        if 0 <= cand < len(_SHADE_SLOTS) and _SHADE_SLOTS[cand] not in used_shades_in_hue:
+                            shade = _SHADE_SLOTS[cand]
+                            found = True
+                            break
+                    if found:
+                        break
+            used_shades_in_hue.add(shade)
+            assignments.append((c, shade))
+
+        for c, role in assignments:
 
             if convention == "tailwind":
                 token_name = f"{hue_fam}{sep}{role}"

core/color_utils.py

@@ -340,7 +340,8 @@ def categorize_color(color: str) -> str:
     h, s, l = parsed.hsl
     
     # Neutrals (low saturation or extreme lightness)
-    if s < 10 or l < 5 or l > 95:
+    # s < 20 catches desaturated grays with a slight tint (e.g., #6f7597 S=16%)
+    if s < 20 or l < 5 or l > 95:
         return "neutral"
     
     # Categorize by hue

output_json/figma-plugin-extracted/figma-design-token-creator 5/src/code.js

@@ -791,17 +791,22 @@ figma.ui.onmessage = async function(msg) {
       var sectionGap = 80;
       var itemGap = 16;
 
-      // Load Inter font for labels
+      // Load Inter font for labels (with fallbacks for environments missing styles)
+      var headingStyle = 'Regular';
       await figma.loadFontAsync({ family: 'Inter', style: 'Regular' });
-      await figma.loadFontAsync({ family: 'Inter', style: 'Bold' });
-      await figma.loadFontAsync({ family: 'Inter', style: 'SemiBold' });
+      try {
+        await figma.loadFontAsync({ family: 'Inter', style: 'Bold' });
+        headingStyle = 'Bold';
+      } catch (e) {
+        console.warn('Inter Bold not available, using Regular for headings');
+      }
 
       // === COLORS SECTION ===
       if (tokens.colors.length > 0) {
         // Section title
         var colorTitle = figma.createText();
         colorTitle.characters = 'COLORS';
-        colorTitle.fontName = { family: 'Inter', style: 'Bold' };
+        colorTitle.fontName = { family: 'Inter', style: headingStyle };
         colorTitle.fontSize = 24;
         colorTitle.x = xOffset;
         colorTitle.y = yOffset;
@@ -860,7 +865,7 @@ figma.ui.onmessage = async function(msg) {
       if (tokens.typography.length > 0) {
         var typoTitle = figma.createText();
         typoTitle.characters = 'TYPOGRAPHY';
-        typoTitle.fontName = { family: 'Inter', style: 'Bold' };
+        typoTitle.fontName = { family: 'Inter', style: headingStyle };
         typoTitle.fontSize = 24;
         typoTitle.x = xOffset;
         typoTitle.y = yOffset;
@@ -916,7 +921,7 @@ figma.ui.onmessage = async function(msg) {
       if (tokens.spacing.length > 0) {
         var spacingTitle = figma.createText();
         spacingTitle.characters = 'SPACING';
-        spacingTitle.fontName = { family: 'Inter', style: 'Bold' };
+        spacingTitle.fontName = { family: 'Inter', style: headingStyle };
         spacingTitle.fontSize = 24;
         spacingTitle.x = xOffset;
         spacingTitle.y = yOffset;
@@ -956,7 +961,7 @@ figma.ui.onmessage = async function(msg) {
       if (tokens.borderRadius.length > 0) {
         var radiusTitle = figma.createText();
         radiusTitle.characters = 'BORDER RADIUS';
-        radiusTitle.fontName = { family: 'Inter', style: 'Bold' };
+        radiusTitle.fontName = { family: 'Inter', style: headingStyle };
         radiusTitle.fontSize = 24;
         radiusTitle.x = xOffset;
         radiusTitle.y = yOffset;
@@ -999,7 +1004,7 @@ figma.ui.onmessage = async function(msg) {
       if (tokens.shadows.length > 0) {
         var shadowTitle = figma.createText();
         shadowTitle.characters = 'SHADOWS';
-        shadowTitle.fontName = { family: 'Inter', style: 'Bold' };
+        shadowTitle.fontName = { family: 'Inter', style: headingStyle };
         shadowTitle.fontSize = 24;
         shadowTitle.x = xOffset;
         shadowTitle.y = yOffset;