FIX_VOLO_ECARD_ISSUE

app/Controllers/EmployeeRestController.php

@@ -7727,14 +7727,16 @@ class EmployeeRestController extends AdminController
 
                 $benefits = [];
                 if (!empty($termsArray['enrollment_display_key']) && is_array($termsArray['enrollment_display_key'])) {
-                    $benefits = $termsArray['enrollment_display_key'];
+                    $benefits = $this->normalizePolicyTermsKeys($termsArray['enrollment_display_key']);
                 } else {
-                    $benefits = $this->policyTermsFiter($termsRaw, $ticketMeta['policy_group']);
+                    $benefits = $this->normalizePolicyTermsKeys(
+                        $this->policyTermsFiter($termsRaw, $ticketMeta['policy_group']) ?: []
+                    );
                 }
 
                 $policyTerms = [];
                 if (!empty($termsArray['enrollment_display_key']) && is_array($termsArray['enrollment_display_key'])) {
-                    $policyTerms = $termsArray['enrollment_display_key'];
+                    $policyTerms = $this->normalizePolicyTermsKeys($termsArray['enrollment_display_key']);
                 }
 
                 $familyFloaters = $this->extractFamilyFloaters($termsArray);
@@ -8027,6 +8029,36 @@ class EmployeeRestController extends AdminController
         return number_format((float) $amount, 0, '.', ',');
     }
 
+    /**
+     * Normalize enrollment_display_key terms:
+     * - "Room Rent Limit" => room_rent_limit
+     * - whitespace-only values => ""
+     */
+    private function normalizePolicyTermsKeys(array $terms): array
+    {
+        $normalized = [];
+
+        foreach ($terms as $key => $value) {
+            $snakeKey = strtolower(trim((string) $key));
+            $snakeKey = preg_replace('/[^a-z0-9]+/', '_', $snakeKey);
+            $snakeKey = trim($snakeKey, '_');
+
+            if (is_string($value)) {
+                $value = trim($value);
+            } elseif (is_array($value)) {
+                $value = $this->normalizePolicyTermsKeys($value);
+            }
+
+            if ($snakeKey === '') {
+                continue;
+            }
+
+            $normalized[$snakeKey] = $value;
+        }
+
+        return $normalized;
+    }
+
     private function buildPremiumDetails(array $coveredMembers, int $policyTypeId): array
     {
         $siValue      = 0;

app/Controllers/VoloApiController.php

@@ -906,7 +906,7 @@ class VoloApiController extends BaseController
     }
 
     /**
-     * E-card PDF — returns a data URL the app can open, or null on failure.
+     * E-card PDF — saves base64 PDF to public/tmp and returns a downloadable URL, or null on failure.
      *
      * @param string|null $voloEmployeeId Volo/TPA employee or member id stored in employee_polices.tpa_id
      */
@@ -919,13 +919,15 @@ class VoloApiController extends BaseController
         }
 
         $entityId = $this->resolveEntityId((string) $policy_no);
+        log_message('error', 'VOLO - Ecard | entity id: ' . $entityId . ' | policy_no: ' . $policy_no . ' | voloEmployeeId: ' . $voloEmployeeId);
         if ($entityId === null) {
             log_message('error', 'VOLO - Ecard | entity id not resolved | policy: ' . ($policy_no ?? ''));
 
             return null;
         }
 
-        $res = $this->getEcardPdfRequest((string) $voloEmployeeId, $entityId);
+        $res = $this->getEcardPdfRequest((string) $emp_code, $entityId);
+        log_message('error', 'VOLO - Ecard | res: ' . json_encode($res));
         if (empty($res['status']) || !is_array($res['data'])) {
             log_message('error', 'VOLO - Ecard FAILED | ' . json_encode($res));
 
@@ -939,6 +941,38 @@ class VoloApiController extends BaseController
             return null;
         }
 
-        return 'data:application/pdf;base64,' . $body;
+        // Strip data-URI prefix if the API already included it.
+        if (stripos($body, 'base64,') !== false) {
+            $body = substr($body, strpos($body, 'base64,') + 7);
+        }
+
+        $pdfBinary = base64_decode($body, true);
+        if ($pdfBinary === false || $pdfBinary === '') {
+            log_message('error', 'VOLO - Ecard FAILED | base64 decode failed | emp_code: ' . ($emp_code ?? ''));
+
+            return null;
+        }
+
+        $dir = FCPATH . 'tmp/';
+        if (!is_dir($dir) && !mkdir($dir, 0775, true) && !is_dir($dir)) {
+            log_message('error', 'VOLO - Ecard FAILED | cannot create dir: ' . $dir);
+
+            return null;
+        }
+
+        $safeEmp = preg_replace('/[^A-Za-z0-9_-]/', '_', (string) $emp_code) ?: 'emp';
+        $fileName = 'volo_ecard_' . $safeEmp . '_' . time() . '_' . bin2hex(random_bytes(4)) . '.pdf';
+        $filePath = $dir . $fileName;
+
+        if (file_put_contents($filePath, $pdfBinary) === false) {
+            log_message('error', 'VOLO - Ecard FAILED | cannot write file: ' . $filePath);
+
+            return null;
+        }
+
+        $downloadUrl = base_url('public/tmp/' . $fileName);
+        log_message('error', 'VOLO - Ecard SUCCESS | url: ' . $downloadUrl);
+
+        return $downloadUrl;
     }
 }