wp_mail not sending attachment

Question

You said in your OP that the absolute path was returned, but you are using the ‘baseurl’ value which gives you a URL to the file that you can browse to. That’s a URL, which is not the same as the path to the file in the file system.

This line is your issue:

$attachment = $upload_dir['baseurl'] . "/order-confirm/wardrobe- 
".$build_id.".pdf";

This gives you a URL like this:

http://yoursite.com/directory/order-confirm/wardrobe-something.pdf

You can’t attach a file to an email from a URL. You need the file path to the file on the server so you can attach it. Use the basedir value to build the file path instead.

$attachment = $upload_dir['basedir'] . "/order-confirm/wardrobe- 
".$build_id.".pdf";

The basedir result will give you something like the following:

/yourserver/somepath/directory/order-confirm/wardrobe-something.pdf

With the path to the file, you can attach it to your email.

Here’s your function revised to use basedir instead of baseurl (noted with a comment where I changed it):

add_action('wp_ajax_order_processing', 'order_processing');
function order_processing(){
    include 'mail-translations.php';

    require_once( ABSPATH . 'wp-admin/includes/file.php' );
    global $wp_filesystem;
    $upload_dir = wp_upload_dir();   
    $dir = trailingslashit( $upload_dir['basedir'] )  . 'order-confirm/';

    WP_Filesystem();
    $wp_filesystem->mkdir( $dir );

    $build_id=md5(uniqid(cvf_td_generate_random_code(), true));

    $message = "<p>Hello</p>";    

    $mpdf = new mPDF('utf-8', 'A4-P'); 
    $mpdf->debug = true;
    $mpdf->dpi = 150;
    $mpdf->img_dpi = 150;
    $mpdf->setAutoTopMargin = 'stretch'; 
    $mpdf->setAutoBottomMargin = 'stretch';

    $src = get_template_directory_uri() . '/images/rsz_bomann-logo-black.png';
    $mpdf->SetWatermarkImage($src);
    $mpdf->showWatermarkImage=true;
    $mpdf->SetHTMLHeader('');
    // PDF footer content                      
    $mpdf->SetHTMLFooter('');
    $mpdf->SetFont('helvetica');


    $mpdf->WriteHTML($message); // Writing html to pdf
    // FOR EMAIL

    $content = $mpdf->Output( $dir . "wardrobe-".$build_id.".pdf", 'F'); 
    $content = chunk_split(base64_encode($content));

    // Use 'basedir' instead of 'baseurl':
    $attachment = $upload_dir['basedir'] . "/order-confirm/wardrobe- 
    ".$build_id.".pdf";


    // Set Mail Headers
    $headers = "MIME-Version: 1.0" . "\r\n";
    $headers .= "Content-type: text/html; charset=" . get_bloginfo('charset') . 
    "" . "\r\n";

    $subject = __('Order Confirmation for Order No. ', 'skapnet');

    $order_mail = wp_mail("[email protected]", $subject, 'message' , 
    $headers, array($attachment));

    echo $order_mail;

}

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