add drift script

Reviewed-on: #21

.gitignore

@@ -10,6 +10,7 @@ __pycache__/
 /build/dist/
 /build/lib/
 /build/pyinstaller_work/
+/build/release/reports/
 /build/*.spec
 /dist/
 /dist_obfuscated/
@@ -23,6 +24,7 @@ __pycache__/
 # Local tools / editor state
 /.cursor/
 /.vscode/
+/_perf/
 
 # Local data / models
 /models/
@@ -42,3 +44,6 @@ __pycache__/
 # Legacy / scratch folders
 /old_orisys/
 /tools/calibration/
+
+# Scratch output of examples/ (multi_stream.py's default --out-dir)
+/outputs/

MANIFEST.in

@@ -2,6 +2,8 @@
 include pyproject.toml
 include setup.py
 include README.md
+# Build-time input for the PyPI long description (read from the checkout).
+include docs/pypi_readme.md
 recursive-include config *.json
 recursive-include sensors *
 recursive-include build/common *.py

build/README.md

@@ -12,6 +12,7 @@ build/
   README.md
   common/                 shared helpers (paths, pyproject, verify)
   wheel/                  SDK .whl (Nuitka + manylinux Docker)
+  release/                local release gate (preflight / audit)
   gui/
     common/               shared PyInstaller driver
     ory_finger/           ORY-FINGER dashboard
@@ -38,9 +39,58 @@ Direct module paths (same behavior):
 ```bash
 python build/wheel/build.py
 build\wheel\win.bat
-.\build\wheel\docker\run.ps1
+.\build\wheel\docker\run.ps1 -SkipImageBuild   # reuse the image when only sources changed
 ```
 
+The image bakes in per-ABI build tooling and a per-ABI wheelhouse of the runtime
+deps, so the entrypoint no longer re-resolves them over the network. See
+`docs/publishing.md` §6 for build-time details, why `-SkipImageBuild` matters,
+and what to change before attempting to parallelize the per-ABI builds.
+
+### Release gate
+
+Local only: never publishes, and makes no network call unless `--check-pypi` is
+passed. See `docs/publishing.md` for the full flow.
+
+```bash
+python build/run.py release preflight --version <version>
+python build/run.py release preflight --all-wheel-pythons --check-pypi
+python build/run.py release audit SDK\<version>\orisys-<version>-cp312-cp312-win_amd64.whl
+```
+
+`preflight` runs: repo state → version consistency → version-string scan →
+duplicate guard (fails only when the version is already released: a local git
+tag, or PyPI with `--check-pypi`) → pytest → bundle precheck → per-wheel static
+content/metadata assertions → isolated runtime verification in one venv per wheel
+(imports + bundled assets + real frames, no camera). A populated `SDK/<version>/`
+is the expected input, so build first:
+
+```bash
+python build/run.py wheel-win
+python build/run.py release preflight --all-wheel-pythons --check-pypi
+```
+
+Reports land in `build/release/reports/<version>/`.
+
+### Publish
+
+Both default to a dry run; `--apply` is required for anything irreversible.
+
+```bash
+python build/run.py release auth                                   # credential status
+python build/run.py release auth --set-token pypi                 # hidden prompt, writes ~/.pypirc
+python build/run.py release github --version <version>            # preview
+python build/run.py release github --version <version> --apply    # sync + tag + push + Release
+python build/run.py release pypi   --version <version> --apply                  # TestPyPI only
+python build/run.py release pypi   --version <version> --confirm-pypi --apply   # + PyPI
+python build/run.py release pypi   --version <version> --pypi-only --apply      # skip TestPyPI
+```
+
+Both refuse to act unless `release preflight` passed on a clean commit with no
+waived options, and every wheel still hashes to what that report recorded.
+Tokens are only ever read from a hidden prompt or stdin, never from argv.
+See `docs/publishing.md` §3.
+
 ### GUI
 
 ```bash
@@ -53,13 +103,16 @@ python build/run.py gui box     # scaffold / NotImplemented
 
 ```bash
 python build/run.py verify path\to\orisys.whl
+python build/run.py verify path\to\orisys.whl --contents --assets --runtime
 python build/run.py verify --gui-dist --product ory_finger
 ```
 
 ## Outputs
 
 - Wheels: `SDK/<version>/`, `dist/repaired/`
+- Preflight reports: `build/release/reports/<version>/`
 - Finger GUI: `dist/OrisysDashboard/`
 - Future mini/box: `dist/OryMini/`, `dist/OryBox/`
 
-Generated work files under `build/nuitka/` and `build/pyinstaller_work/` are gitignored.
+Generated work files under `build/nuitka/`, `build/release/reports/` and
+`build/pyinstaller_work/` are gitignored.

build/common/verify/__init__.py

@@ -1,6 +1,21 @@
 """Post-build smoke tests for wheels and product GUI folders."""
 
 from common.verify.gui import GUI_PRODUCTS, verify_gui_dist
-from common.verify.wheel import verify_built_wheel
+from common.verify.wheel import (
+    verify_built_wheel,
+    verify_wheel,
+    verify_wheel_assets,
+    verify_wheel_runtime,
+)
+from common.verify.wheel_contents import WheelCheckResult, inspect_wheel
 
-__all__ = ["GUI_PRODUCTS", "verify_built_wheel", "verify_gui_dist"]
+__all__ = [
+    "GUI_PRODUCTS",
+    "WheelCheckResult",
+    "inspect_wheel",
+    "verify_built_wheel",
+    "verify_gui_dist",
+    "verify_wheel",
+    "verify_wheel_assets",
+    "verify_wheel_runtime",
+]

build/common/verify/cli.py

@@ -3,9 +3,24 @@
 from __future__ import annotations
 
 import argparse
+import sys
 from pathlib import Path
 
-from common.verify import GUI_PRODUCTS, verify_built_wheel, verify_gui_dist
+_BUILD_ROOT = Path(__file__).resolve().parents[2]
+if str(_BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(_BUILD_ROOT))
+
+from common.paths import REPO_ROOT  # noqa: E402
+from common.verify import (  # noqa: E402
+    GUI_PRODUCTS,
+    inspect_wheel,
+    verify_built_wheel,
+    verify_gui_dist,
+    verify_wheel,
+    verify_wheel_assets,
+    verify_wheel_runtime,
+)
+from common.verify.wheel import DEFAULT_RUNTIME_CONFIG, default_verification_video  # noqa: E402
 
 
 def main(argv: list[str] | None = None) -> int:
@@ -18,6 +33,31 @@ def main(argv: list[str] | None = None) -> int:
         help="GUI product profile (default: ory_finger)",
     )
     parser.add_argument("--dist-dir", type=Path, default=None, help="Override GUI dist folder")
+    parser.add_argument(
+        "--contents",
+        action="store_true",
+        help="Run static metadata/content assertions on the wheel",
+    )
+    parser.add_argument(
+        "--assets",
+        action="store_true",
+        help="Install the wheel in a temp venv and assert bundled assets load",
+    )
+    parser.add_argument(
+        "--runtime",
+        action="store_true",
+        help="Install the wheel and process real frames (no camera required)",
+    )
+    parser.add_argument("--expected-version", default=None, help="Assert the wheel version")
+    parser.add_argument(
+        "--strict-bundle",
+        action="store_true",
+        help="Treat bundled-file drift from the source tree as a failure",
+    )
+    parser.add_argument("--video", type=Path, default=None, help="Clip for --runtime")
+    parser.add_argument("--config", default=DEFAULT_RUNTIME_CONFIG, help="Config for --runtime")
+    parser.add_argument("--frames", type=int, default=40, help="Frames for --runtime")
+    parser.add_argument("--offline", action="store_true", help="Reuse parent-env dependencies")
     parser.add_argument("wheel", nargs="?", type=Path, help="Wheel path for import smoke test")
     args = parser.parse_args(argv)
 
@@ -26,6 +66,70 @@ def main(argv: list[str] | None = None) -> int:
         return 0
     if args.wheel is None:
         parser.error("Provide a wheel path or pass --gui-dist")
+
+    exit_code = 0
+
+    if args.contents:
+        result = inspect_wheel(
+            args.wheel,
+            expected_version=args.expected_version,
+            repo_root=REPO_ROOT,
+            strict_bundle=args.strict_bundle,
+        )
+        print(result.render())
+        if not result.ok:
+            exit_code = 1
+
+    if args.assets and args.runtime:
+        video = args.video or default_verification_video(REPO_ROOT)
+        if video is None:
+            print("[FAIL] runtime: no clip found; pass --video or set ORISYS_VERIFY_VIDEO")
+            return 1
+        try:
+            record = verify_wheel(
+                args.wheel,
+                video=video,
+                config_name=args.config,
+                frames=args.frames,
+                offline=args.offline,
+            )
+            print(f"[ok  ] {record['imports']}")
+            print(f"[ok  ] {record['assets']}")
+            print(f"[ok  ] runtime: frames={record['frames']} flow={record['flow_shape']}")
+        except Exception as exc:
+            print(f"[FAIL] isolated verification: {type(exc).__name__}: {exc}")
+            exit_code = 1
+        return exit_code
+
+    if args.assets:
+        try:
+            print(verify_wheel_assets(args.wheel))
+        except Exception as exc:
+            print(f"[FAIL] bundled assets: {type(exc).__name__}: {exc}")
+            exit_code = 1
+
+    if args.runtime:
+        video = args.video or default_verification_video(REPO_ROOT)
+        if video is None:
+            print("[FAIL] runtime: no clip found; pass --video or set ORISYS_VERIFY_VIDEO")
+            return 1
+        try:
+            info = verify_wheel_runtime(
+                args.wheel,
+                video=video,
+                config_name=args.config,
+                frames=args.frames,
+                offline=args.offline,
+            )
+            print(f"[ok  ] runtime: {info}")
+        except Exception as exc:
+            print(f"[FAIL] runtime: {type(exc).__name__}: {exc}")
+            exit_code = 1
+
+    if args.contents or args.assets or args.runtime:
+        return exit_code
+
+    # Default behaviour is unchanged: import smoke test in an isolated venv.
     verify_built_wheel(args.wheel)
     return 0
 

build/common/verify/wheel.py

@@ -1,11 +1,26 @@
-"""Isolated venv smoke tests for packaged orisys wheels."""
+"""Isolated venv smoke tests for packaged orisys wheels.
+
+Three levels of confidence, all in a throwaway virtualenv so the active
+environment is never touched:
+
+* :func:`verify_built_wheel` - the public API imports (fast, original check);
+* :func:`verify_wheel_assets` - bundled configs/sensors resolve and load via
+  ``importlib.resources``;
+* :func:`verify_wheel_runtime` - the compiled wheel actually processes real
+  frames through the public pipeline with no camera attached.
+
+Every level can be bootstrapped from another interpreter so each supported
+CPython ABI can be verified against its own wheel.
+"""
 
 from __future__ import annotations
 
+import os
 import subprocess
 import sys
 import tempfile
 import venv
+from contextlib import contextmanager
 from pathlib import Path
 
 # Public SDK surface that must import from a released wheel.
@@ -38,6 +53,167 @@ assert Stitcher is not None
 print(f"orisys {orisys.__version__} public API imports OK")
 """
 
+# Bundled data that must be resolvable and loadable from inside site-packages.
+# The wheel ships the compiled package, so these paths only exist if the bundle
+# step actually ran for this build.
+_ASSET_SCRIPT = r"""
+import sys
+from importlib.metadata import distribution
+from pathlib import Path
+
+import numpy as np
+import orisys
+
+# Locate bundled data through the installed distribution, NOT through
+# orisys.__file__ / importlib.resources. Nuitka compiles the package into one
+# extension module whose __init__ installs nuitka_module_loader, which reports a
+# synthetic __file__ (e.g. ...\site-packages\orisys\orisys\__init__.py) and a
+# synthetic __path__ ending in '\not_existing'. Neither points at the real data
+# directory, so importlib.resources silently finds nothing in a Nuitka wheel.
+dist = distribution("orisys")
+dist_root = Path(dist.locate_file("")).resolve()
+package_root = Path(dist.locate_file("orisys")).resolve()
+
+_diagnosis = (
+    f"orisys distribution resolved to {dist_root} (sys.prefix={sys.prefix!r}, "
+    f"sys.executable={sys.executable!r}), outside the verification venv. A stale "
+    "orisys in the parent environment is visible through --system-site-packages; "
+    "run `pip uninstall -y orisys` there, or re-run without --offline."
+)
+assert str(Path(sys.prefix).resolve()) in str(dist_root), _diagnosis
+assert package_root.is_dir(), f"package directory not found: {package_root}"
+
+required = [
+    "configs/box.json",
+    "configs/finger.json",
+    "sensors/box/force_calibration.json",
+    "sensors/box/sensor.json",
+    "sensors/finger/manifest.json",
+    "sensors/finger/sensor.json",
+    "sensors/mini/sensor.json",
+    "sensors/finger/assets/30fps-0703/mesh.npz",
+    "sensors/finger/assets/30fps-0703/camera_intrinsics.npz",
+    "sensors/finger/assets/30fps-0703/world_to_cam.npy",
+    "sensors/finger/assets/visualization/mesh.npz",
+    "sensors/finger/assets/visualization/world_to_cam.npy",
+]
+
+missing = [name for name in required if not (package_root / name).is_file()]
+assert not missing, (
+    f"bundled assets missing from the wheel: {missing}\n"
+    f"package root: {package_root}\ninstalled tree: "
+    f"{sorted(p.name for p in package_root.iterdir()) if package_root.is_dir() else '<missing>'}"
+)
+
+for name in required:
+    path = package_root / name
+    if name.endswith(".npz"):
+        data = np.load(str(path))
+        assert len(data.files) > 0, f"{name} is an empty npz"
+    elif name.endswith(".npy"):
+        arr = np.load(str(path))
+        assert arr.size > 0, f"{name} is an empty npy"
+
+configs = orisys.list_config()
+assert configs, "orisys.list_config() returned nothing"
+
+print(f"bundled assets OK ({len(required)} files, {len(configs)} configs) "
+      f"from {package_root}")
+"""
+
+# End-to-end pipeline run against a video file: no camera, no GUI, no imshow.
+_RUNTIME_SCRIPT = r"""
+import json
+import os
+import sys
+from importlib.metadata import distribution
+from pathlib import Path
+
+import numpy as np
+
+os.environ.setdefault("OPENCV_VIDEOIO_MSMF_ENABLE_HW_TRANSFORMS", "0")
+
+import orisys
+
+# Provenance via the installed distribution: a Nuitka-compiled package reports a
+# synthetic orisys.__file__ (see the asset check) and a stale orisys visible
+# through --system-site-packages would otherwise satisfy this check.
+dist = distribution("orisys")
+dist_root = Path(dist.locate_file("")).resolve()
+assert str(Path(sys.prefix).resolve()) in str(dist_root), (
+    f"the installed orisys came from {dist_root}, outside the verification venv "
+    f"{sys.prefix!r}; run `pip uninstall -y orisys` in the parent environment or "
+    "re-run without --offline."
+)
+
+video, config_name, frames = sys.argv[1], sys.argv[2], int(sys.argv[3])
+
+sensor = orisys.Sensor(
+    vid_src=video,
+    config_name=config_name,
+    backend="cpu",
+    verbose=False,
+)
+processed = 0
+try:
+    for _ in range(frames):
+        img = sensor.get_img()
+        assert img is not None, "get_img returned None"
+        assert isinstance(img, np.ndarray) and img.ndim in (2, 3)
+
+        sensor.compute_deformation(check_motion=False)
+        flow, vnormal, vshear = sensor.read_info(
+            sensor.info.VRAW, sensor.info.VNORMAL, sensor.info.VSHEAR
+        )
+        for name, array in (("flow", flow), ("vnormal", vnormal), ("vshear", vshear)):
+            assert np.isfinite(array).all(), f"{name} contains NaN/Inf"
+
+        contact = sensor.compute_contact()
+        assert isinstance(contact, dict) and "centroid_found" in contact
+
+        fnormal, fsx, fsy = sensor.read_info(
+            sensor.info.FNORMAL, sensor.info.FSHEARX, sensor.info.FSHEARY
+        )
+        assert np.isfinite([fnormal, fsx, fsy]).all(), "force output contains NaN/Inf"
+        processed += 1
+finally:
+    sensor.disconnect()
+
+assert processed == frames, f"only processed {processed}/{frames} frames"
+print(json.dumps({
+    "version": orisys.__version__,
+    "frames": processed,
+    "flow_shape": list(flow.shape),
+    "video": video,
+    "config": config_name,
+    "package_root": str(Path(dist.locate_file("orisys")).resolve()),
+}))
+"""
+
+
+# Default runtime-verification inputs. Overridable by CLI flags or environment.
+DEFAULT_RUNTIME_CONFIG = os.getenv("ORISYS_VERIFY_CONFIG", "box")
+# Clips tracked in the repository. ``data/sample/s1.mp4`` is the sanctioned
+# verification input; the larger 720p clip is deliberately not listed, so a
+# missing s1.mp4 fails loudly instead of silently verifying against it.
+DEFAULT_VIDEO_CANDIDATES = (
+    Path("data") / "sample" / "s1.mp4",
+)
+
+
+def default_verification_video(repo_root: Path) -> Path | None:
+    """Resolve the clip used for the end-to-end runtime check, if any."""
+    env_video = os.getenv("ORISYS_VERIFY_VIDEO")
+    repo_root = Path(repo_root)
+    if env_video:
+        candidate = Path(env_video)
+        return candidate if candidate.is_absolute() else repo_root / candidate
+    for relative in DEFAULT_VIDEO_CANDIDATES:
+        candidate = repo_root / relative
+        if candidate.is_file():
+            return candidate
+    return None
+
 
 def _venv_python(venv_dir: Path) -> Path:
     if sys.platform == "win32":
@@ -45,18 +221,226 @@ def _venv_python(venv_dir: Path) -> Path:
     return venv_dir / "bin" / "python"
 
 
-def verify_built_wheel(wheel_path: Path) -> None:
-    """Install the wheel in a temporary venv and smoke-test public imports."""
-    wheel_path = wheel_path.resolve()
-    with tempfile.TemporaryDirectory(prefix="orisys-wheel-verify-") as tmp:
-        venv_dir = Path(tmp) / "venv"
-        venv.create(venv_dir, with_pip=True)
-        python = _venv_python(venv_dir)
+def _hermetic_env() -> dict:
+    """Environment for the verification venv with PYTHONPATH removed.
 
-        subprocess.check_call(
-            [python, "-m", "pip", "install", "-q", "--upgrade", "pip"],
+    An inherited PYTHONPATH=src would let the checkout satisfy the checks
+    instead of the installed wheel, which is precisely the failure mode the
+    provenance assertions in the scripts exist to catch.
+    """
+    return {key: value for key, value in os.environ.items() if key != "PYTHONPATH"}
+
+
+def _create_venv(
+    venv_dir: Path,
+    *,
+    python_executable: Path | None = None,
+    system_site_packages: bool = False,
+) -> Path:
+    """Create a throwaway venv, optionally from a different interpreter."""
+    if python_executable is None:
+        venv.create(venv_dir, with_pip=True, system_site_packages=system_site_packages)
+    else:
+        command = [str(python_executable), "-m", "venv"]
+        if system_site_packages:
+            command.append("--system-site-packages")
+        command.append(str(venv_dir))
+        subprocess.check_call(command, env=_hermetic_env())
+    return _venv_python(venv_dir)
+
+
+def _install_wheel(
+    python: Path, wheel_path: Path, *, offline: bool = False, env: dict | None = None
+) -> None:
+    """Install the wheel under test, guaranteeing it lands in the venv.
+
+    ``--force-reinstall --no-deps`` is not optional: pip reports a same-version
+    requirement as "already satisfied" and skips the file, which is fatal here
+    because ``--offline`` also exposes the parent environment's site-packages.
+    Without it the venv check can silently validate a *different* orisys than
+    the one passed in (the scripts additionally assert provenance).
+    """
+    if offline:
+        # Dependencies come from the parent environment via --system-site-packages.
+        commands = [
+            [
+                str(python),
+                "-m",
+                "pip",
+                "install",
+                "-q",
+                "--no-index",
+                "--no-deps",
+                "--force-reinstall",
+                str(wheel_path),
+            ]
+        ]
+    else:
+        commands = [
+            [str(python), "-m", "pip", "install", "-q", "--upgrade", "pip"],
+            [str(python), "-m", "pip", "install", "-q", str(wheel_path)],
+            [
+                str(python),
+                "-m",
+                "pip",
+                "install",
+                "-q",
+                "--force-reinstall",
+                "--no-deps",
+                str(wheel_path),
+            ],
+        ]
+
+    for command in commands:
+        subprocess.check_call(command, stdout=subprocess.DEVNULL, env=env)
+
+
+class WheelVerificationError(RuntimeError):
+    """A verification step failed inside the throwaway venv.
+
+    Carries the child's stdout/stderr so the real traceback is visible instead of
+    a bare non-zero exit code.
+    """
+
+
+def _run_script(
+    python: Path, script: str, args: list[str] | None = None, *, env: dict
+) -> str:
+    """Run a verification script in an already-prepared venv."""
+    completed = subprocess.run(
+        [str(python), "-c", script, *(args or [])],
+        capture_output=True,
+        text=True,
+        env=env,
+        check=False,
+    )
+    if completed.returncode != 0:
+        command = " ".join(str(part) for part in (args or []))
+        raise WheelVerificationError(
+            f"verification script failed in the venv (exit {completed.returncode}"
+            + (f", args: {command}" if command else "")
+            + ").\n--- stdout ---\n"
+            + (completed.stdout.strip() or "<empty>")
+            + "\n--- stderr ---\n"
+            + (completed.stderr.strip() or "<empty>")
         )
-        subprocess.check_call(
-            [python, "-m", "pip", "install", "-q", str(wheel_path)],
+    return completed.stdout.strip()
+
+
+@contextmanager
+def _installed_venv(
+    wheel_path: Path,
+    *,
+    python_executable: Path | None = None,
+    offline: bool = False,
+    prefix: str = "orisys-wheel-verify-",
+):
+    """Create a venv with the wheel installed, for one or more checks.
+
+    Creating a venv and installing the runtime dependencies is by far the most
+    expensive part of verification (tens of seconds plus a large download when
+    not using ``--offline``), so callers that run several checks must share one
+    venv instead of building one per check.
+    """
+    wheel_path = wheel_path.resolve()
+    env = _hermetic_env()
+    with tempfile.TemporaryDirectory(prefix=prefix) as tmp:
+        venv_dir = Path(tmp) / "venv"
+        interpreter = python_executable or Path(sys.executable)
+        print(
+            f"  [{wheel_path.name}] creating venv from {interpreter.name}"
+            + ("" if offline else " and installing dependencies (first run downloads packages)")
+            + " ...",
+            flush=True,
         )
-        subprocess.check_call([python, "-c", _SMOKE_IMPORT_SCRIPT])
+        python = _create_venv(
+            venv_dir,
+            python_executable=python_executable,
+            system_site_packages=offline,
+        )
+        _install_wheel(python, wheel_path, offline=offline, env=env)
+        yield python, env
+
+
+def verify_built_wheel(wheel_path: Path, *, python_executable: Path | None = None) -> None:
+    """Install the wheel in a temporary venv and smoke-test public imports."""
+    with _installed_venv(wheel_path, python_executable=python_executable) as (python, env):
+        _run_script(python, _SMOKE_IMPORT_SCRIPT, env=env)
+
+
+def verify_wheel_assets(wheel_path: Path, *, python_executable: Path | None = None) -> str:
+    """Assert the wheel carries loadable bundled configs and sensor assets."""
+    with _installed_venv(wheel_path, python_executable=python_executable) as (python, env):
+        return _run_script(python, _ASSET_SCRIPT, env=env)
+
+
+def verify_wheel_runtime(
+    wheel_path: Path,
+    *,
+    video: Path,
+    config_name: str,
+    frames: int = 40,
+    python_executable: Path | None = None,
+    offline: bool = False,
+) -> dict:
+    """Run real frames through the installed wheel with no camera attached.
+
+    This is the only check that proves the compiled extension plus the bundled
+    sensor assets actually produce finite flow/force output end to end.
+    """
+    with _installed_venv(
+        wheel_path, python_executable=python_executable, offline=offline
+    ) as (python, env):
+        return _runtime_check(python, env, video=video, config_name=config_name, frames=frames)
+
+
+def _runtime_check(
+    python: Path, env: dict, *, video: Path, config_name: str, frames: int
+) -> dict:
+    video = Path(video).resolve()
+    if not video.is_file():
+        raise FileNotFoundError(f"verification video not found: {video}")
+    if frames < 1:
+        raise ValueError("frames must be >= 1")
+
+    print(f"  processing {frames} frame(s) with config {config_name!r} ...", flush=True)
+    output = _run_script(
+        python, _RUNTIME_SCRIPT, [str(video), config_name, str(frames)], env=env
+    )
+    import json
+
+    return json.loads(output.splitlines()[-1])
+
+
+def verify_wheel(
+    wheel_path: Path,
+    *,
+    video: Path | None = None,
+    config_name: str = DEFAULT_RUNTIME_CONFIG,
+    frames: int = 40,
+    python_executable: Path | None = None,
+    offline: bool = False,
+    check_assets: bool = True,
+) -> dict:
+    """Run every isolated-check level for one wheel inside a single venv.
+
+    Use this instead of calling the individual ``verify_wheel_*`` helpers: it
+    pays the venv/dependency cost once and returns the runtime record plus the
+    asset and import summaries.
+    """
+    with _installed_venv(
+        wheel_path, python_executable=python_executable, offline=offline
+    ) as (python, env):
+        imports = _run_script(python, _SMOKE_IMPORT_SCRIPT, env=env)
+        record: dict = {"wheel": Path(wheel_path).name, "imports": imports}
+        if check_assets:
+            record["assets"] = _run_script(python, _ASSET_SCRIPT, env=env)
+        else:
+            record["assets"] = "asset check skipped (--no-assets)"
+        if video is not None:
+            record.update(
+                _runtime_check(
+                    python, env, video=video, config_name=config_name, frames=frames
+                )
+            )
+        return record

build/common/verify/wheel_contents.py

@@ -0,0 +1,501 @@
+"""Static content and metadata validation for built orisys wheels.
+
+Everything here is pure standard library: the wheel is opened as a zip and
+inspected in place. No installation, no network, no hardware.
+
+The checks encode the guarantees a Nuitka-compiled release must satisfy:
+
+* the filename, ``METADATA`` and ``RECORD`` agree on name/version/tags;
+* PyPI-visible metadata (``Requires-Python``, classifiers, project URLs,
+  license) is present instead of silently dropped by the hand-written
+  ``setup.py`` template in :mod:`wheel.package`;
+* no Python sources ship inside ``orisys/`` (IP containment) while the compiled
+  extension is present;
+* every file declared by ``[[tool.orisys.bundle.items]]`` is present and
+  byte-identical to the source tree;
+* no caches, build leftovers or scratch directories leak in.
+"""
+
+from __future__ import annotations
+
+import base64
+import hashlib
+import re
+import sys
+import zipfile
+from dataclasses import dataclass, field
+from email.parser import Parser
+from pathlib import Path
+
+_BUILD_ROOT = Path(__file__).resolve().parents[1]
+if str(_BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(_BUILD_ROOT))
+
+from common.paths import REPO_ROOT  # noqa: E402
+from common.pyproject_utils import bundle_items, extras_require, install_requires, project_metadata  # noqa: E402
+from wheel.layout import resolve_bundle_source_files  # noqa: E402
+from wheel.package import is_compliant_manylinux_wheel  # noqa: E402
+
+# PyPI's default per-project file limit is 100 MB; keep headroom.
+MAX_WHEEL_BYTES = 90 * 1024 * 1024
+
+_FILENAME_RE = re.compile(
+    r"^(?P<name>[^-]+)-(?P<version>[^-]+)-(?P<python>[^-]+)-(?P<abi>[^-]+)-(?P<platform>.+)\.whl$"
+)
+_COMPILED_EXT_RE = re.compile(r"^orisys/__init__\..+\.(?:pyd|so)$")
+_FORBIDDEN_PREFIXES = (
+    "test/",
+    "tests/",
+    "data/",
+    "build/",
+    "dist/",
+    "sdk/",
+    ".git",
+)
+_FORBIDDEN_SUFFIXES = (".pyc", ".pyo", ".c", ".pdb", ".map", ".spec")
+
+
+@dataclass(frozen=True)
+class Check:
+    name: str
+    ok: bool
+    detail: str = ""
+
+    def render(self) -> str:
+        return f"[{'ok' if self.ok else 'FAIL'}] {self.name}: {self.detail}"
+
+
+@dataclass
+class WheelCheckResult:
+    wheel: Path
+    version: str | None = None
+    name: str | None = None
+    platform_tag: str | None = None
+    entry_count: int = 0
+    uncompressed_bytes: int = 0
+    file_bytes: int = 0
+    checks: list[Check] = field(default_factory=list)
+    warnings: list[str] = field(default_factory=list)
+
+    @property
+    def ok(self) -> bool:
+        return all(check.ok for check in self.checks)
+
+    @property
+    def failures(self) -> list[Check]:
+        return [check for check in self.checks if not check.ok]
+
+    def add(self, name: str, ok: bool, detail: str = "") -> bool:
+        self.checks.append(Check(name=name, ok=ok, detail=detail))
+        return ok
+
+    def warn(self, message: str) -> None:
+        self.warnings.append(message)
+
+    def render(self) -> str:
+        lines = [
+            f"wheel: {self.wheel.name}",
+            f"  version={self.version} platform={self.platform_tag} "
+            f"entries={self.entry_count} file_size={self.file_bytes} "
+            f"uncompressed={self.uncompressed_bytes}",
+        ]
+        lines.extend(f"  {check.render()}" for check in self.checks)
+        lines.extend(f"  [warn] {message}" for message in self.warnings)
+        lines.append(f"  RESULT: {'PASS' if self.ok else 'FAIL'}")
+        return "\n".join(lines)
+
+
+def _sha256(data: bytes) -> str:
+    return hashlib.sha256(data).hexdigest()
+
+
+def _requirement_name(spec: str) -> str:
+    return re.split(r"[<>=!~\[; ]", spec, maxsplit=1)[0].strip().lower().replace("_", "-")
+
+
+def _metadata_message(zf: zipfile.ZipFile, result: WheelCheckResult):
+    candidates = [name for name in zf.namelist() if name.endswith(".dist-info/METADATA")]
+    if not candidates:
+        result.add("metadata-present", False, "no *.dist-info/METADATA entry in the wheel")
+        return None
+    raw = zf.read(candidates[0]).decode("utf-8", errors="replace")
+    message = Parser().parsestr(raw)
+    result.add("metadata-present", True, candidates[0])
+    return message
+
+
+def _check_filename(result: WheelCheckResult, expected_version: str | None) -> None:
+    match = _FILENAME_RE.match(result.wheel.name)
+    if match is None:
+        result.add("filename", False, f"unparsable wheel filename: {result.wheel.name}")
+        return
+    result.name = match.group("name")
+    result.version = match.group("version")
+    result.platform_tag = match.group("platform")
+
+    problems = []
+    if result.name != "orisys":
+        problems.append(f"distribution name is {result.name!r}, expected 'orisys'")
+    if expected_version is not None and result.version != expected_version:
+        problems.append(f"filename version {result.version!r} != expected {expected_version!r}")
+    result.add("filename", not problems, "; ".join(problems) or result.wheel.name)
+
+
+def _check_metadata(
+    result: WheelCheckResult,
+    message,
+    expected_version: str | None,
+    repo_root: Path | None,
+) -> None:
+    if message is None:
+        return
+
+    result.add(
+        "metadata-name",
+        message.get("Name") == "orisys",
+        f"Name={message.get('Name')!r}",
+    )
+
+    declared = message.get("Version")
+    expected = expected_version or result.version
+    if expected is not None and declared != expected:
+        result.add(
+            "metadata-version",
+            False,
+            f"METADATA Version={declared!r} != expected {expected!r}",
+        )
+    else:
+        result.add("metadata-version", True, f"Version={declared!r}")
+
+    requires_python = (message.get("Requires-Python") or "").strip()
+    result.add(
+        "metadata-requires-python",
+        bool(requires_python),
+        f"Requires-Python={requires_python!r}" if requires_python else "Requires-Python is missing",
+    )
+
+    classifiers = message.get_all("Classifier") or []
+    result.add(
+        "metadata-classifiers",
+        bool(classifiers),
+        f"{len(classifiers)} classifier(s)" if classifiers else "no Classifier fields",
+    )
+
+    project_urls = message.get_all("Project-URL") or []
+    result.add(
+        "metadata-project-urls",
+        bool(project_urls),
+        f"{len(project_urls)} Project-URL(s)" if project_urls else "no Project-URL fields",
+    )
+
+    license_values = [
+        (message.get("License") or "").strip(),
+        (message.get("License-Expression") or "").strip(),
+    ]
+    has_license = any(license_values) or any(
+        value.startswith("License ::") for value in classifiers
+    )
+    result.add(
+        "metadata-license",
+        has_license,
+        f"License={license_values[0]!r} License-Expression={license_values[1]!r}"
+        if has_license
+        else "no License / License-Expression / 'License ::' classifier",
+    )
+
+    dynamic = message.get_all("Dynamic") or []
+    result.add(
+        "metadata-no-dynamic-version",
+        "version" not in dynamic,
+        f"Dynamic={dynamic!r}" if dynamic else "no Dynamic fields",
+    )
+    if dynamic:
+        result.warn(f"METADATA still declares Dynamic fields: {dynamic!r}")
+
+    if repo_root is not None and (repo_root / "pyproject.toml").is_file():
+        requires_dist = message.get_all("Requires-Dist") or []
+        provided = {_requirement_name(entry) for entry in requires_dist}
+        missing_core = [
+            spec for spec in install_requires(repo_root) if _requirement_name(spec) not in provided
+        ]
+        result.add(
+            "metadata-requires-dist",
+            not missing_core,
+            f"missing core Requires-Dist entries: {missing_core!r}"
+            if missing_core
+            else f"{len(requires_dist)} Requires-Dist entries",
+        )
+
+        extras = message.get_all("Provides-Extra") or []
+        missing_extras = sorted(set(extras_require(repo_root)) - set(extras))
+        result.add(
+            "metadata-extras",
+            not missing_extras,
+            f"missing Provides-Extra: {missing_extras!r}"
+            if missing_extras
+            else f"Provides-Extra={sorted(extras)!r}",
+        )
+
+
+def _check_compiled_only(result: WheelCheckResult, names: list[str]) -> None:
+    compiled = [name for name in names if _COMPILED_EXT_RE.match(name)]
+    result.add(
+        "compiled-extension",
+        bool(compiled),
+        f"{compiled[0]}" if compiled else "no orisys/__init__.<abi>.pyd|.so entry",
+    )
+
+    # orisys/examples/** is shipped as package data on purpose; every other
+    # orisys/**/*.py means source code leaked past the Nuitka compile step.
+    sources = [
+        name
+        for name in names
+        if name.startswith("orisys/")
+        and name.endswith(".py")
+        and not name.startswith("orisys/examples/")
+    ]
+    result.add(
+        "no-python-sources",
+        not sources,
+        f"python sources leaked into the wheel: {sources[:5]!r}"
+        if sources
+        else "compiled package ships no python sources (examples excluded by design)",
+    )
+
+    blend = [name for name in names if name.startswith("orisys_blend/")]
+    result.add(
+        "orisys-blend-present",
+        "orisys_blend/__init__.py" in blend and "orisys_blend/kernel.py" in blend,
+        f"{sorted(blend)!r}",
+    )
+
+
+def _check_bundle_fidelity(
+    result: WheelCheckResult,
+    zf: zipfile.ZipFile,
+    names: set[str],
+    repo_root: Path | None,
+    strict: bool,
+) -> None:
+    if repo_root is None or not (repo_root / "pyproject.toml").is_file():
+        result.warn("pyproject.toml not found; bundle fidelity checks skipped")
+        return
+
+    missing: list[str] = []
+    mismatched: list[str] = []
+    checked = 0
+
+    for item in bundle_items(repo_root):
+        target = str(item["target"]).replace("\\", "/")
+        source_dir = repo_root / item["source"]
+        for source_file in resolve_bundle_source_files(repo_root, item):
+            if item.get("preserve_tree", False):
+                relative = source_file.relative_to(source_dir).as_posix()
+                entry = f"orisys/{target}/{relative}"
+            else:
+                entry = f"orisys/{target}/{source_file.name}"
+
+            if entry not in names:
+                missing.append(entry)
+                continue
+            checked += 1
+            if _sha256(zf.read(entry)) != _sha256(source_file.read_bytes()):
+                mismatched.append(entry)
+
+    # Both entries here mean "the wheel does not match this revision of the
+    # source tree". Against a fresh build that is fatal; against an already
+    # released wheel it is expected, so ``strict`` (set by preflight, unset by
+    # audit) decides whether it fails or warns.
+    if missing:
+        detail = (
+            f"{len(missing)} declared file(s) absent from the wheel (added to the "
+            f"source tree after this build?): {missing[:5]!r}"
+        )
+        result.add("bundle-completeness", not strict, detail)
+        if not strict:
+            result.warn(detail)
+    else:
+        result.add(
+            "bundle-completeness", True, f"{checked} declared bundled file(s) present"
+        )
+
+    if mismatched:
+        detail = (
+            f"{len(mismatched)} of {checked} bundled file(s) differ from the source "
+            f"tree (wheel predates or postdates it): {mismatched[:5]!r}"
+        )
+        result.add("bundle-fidelity", not strict, detail)
+        if not strict:
+            result.warn(detail)
+    else:
+        result.add(
+            "bundle-fidelity",
+            True,
+            f"{checked} bundled file(s) byte-identical to source",
+        )
+
+
+def _check_forbidden_entries(result: WheelCheckResult, names: list[str]) -> None:
+    offenders = []
+    for name in names:
+        lowered = name.lower()
+        if lowered.startswith(_FORBIDDEN_PREFIXES):
+            offenders.append(name)
+        elif lowered.endswith(_FORBIDDEN_SUFFIXES):
+            offenders.append(name)
+        elif "__pycache__" in lowered or ".egg-info" in lowered:
+            offenders.append(name)
+    result.add(
+        "no-forbidden-entries",
+        not offenders,
+        f"unexpected entries: {offenders[:5]!r}" if offenders else "no caches/leftovers/scratch paths",
+    )
+
+
+def _check_archive_paths(result: WheelCheckResult, names: list[str]) -> None:
+    unsafe = [
+        name
+        for name in names
+        if name.startswith(("/", "\\")) or ".." in Path(name.replace("\\", "/")).parts
+    ]
+    result.add(
+        "archive-paths",
+        not unsafe,
+        f"absolute or traversing entries: {unsafe[:5]!r}" if unsafe else "all entries are relative",
+    )
+
+
+def _check_record(result: WheelCheckResult, zf: zipfile.ZipFile, names: list[str]) -> None:
+    records = [name for name in names if name.endswith(".dist-info/RECORD")]
+    if not records:
+        result.add("record", False, "no *.dist-info/RECORD entry")
+        return
+
+    bad_paths: list[str] = []
+    bad_hashes: list[str] = []
+    bad_sizes: list[str] = []
+    present = set(names)
+
+    for line in zf.read(records[0]).decode("utf-8").splitlines():
+        if not line.strip():
+            continue
+        parts = line.split(",")
+        while len(parts) < 3:
+            parts.append("")
+        path, hash_field, size_field = parts[0], parts[1], parts[2]
+
+        if path not in present:
+            bad_paths.append(path)
+            continue
+        if not hash_field.startswith("sha256="):
+            continue
+
+        expected = hash_field[len("sha256=") :]
+        actual = base64.urlsafe_b64encode(
+            hashlib.sha256(zf.read(path)).digest()
+        ).rstrip(b"=").decode("ascii")
+        if actual != expected:
+            bad_hashes.append(path)
+        if size_field and size_field.isdigit():
+            if int(size_field) != len(zf.read(path)):
+                bad_sizes.append(path)
+
+    problems = []
+    if bad_paths:
+        problems.append(f"paths not in archive: {bad_paths[:5]!r}")
+    if bad_hashes:
+        problems.append(f"sha256 mismatch: {bad_hashes[:5]!r}")
+    if bad_sizes:
+        problems.append(f"size mismatch: {bad_sizes[:5]!r}")
+    result.add(
+        "record",
+        not problems,
+        "; ".join(problems) if problems else f"{records[0]} verifies",
+    )
+
+
+def _check_platform_tag(result: WheelCheckResult) -> None:
+    tag = result.platform_tag
+    if tag is None:
+        return
+    if "win" in tag:
+        ok = tag == "win_amd64"
+        result.add("platform-tag", ok, f"{tag!r} (expected 'win_amd64')")
+        return
+    ok = is_compliant_manylinux_wheel(result.wheel)
+    result.add(
+        "platform-tag",
+        ok,
+        f"{tag!r}" if ok else f"{tag!r} is not a PyPI-accepted manylinux x86_64 tag",
+    )
+
+
+def _check_size(result: WheelCheckResult, max_bytes: int) -> None:
+    result.add(
+        "size-limit",
+        result.file_bytes <= max_bytes,
+        f"{result.file_bytes} bytes (limit {max_bytes})",
+    )
+
+
+def inspect_wheel(
+    wheel_path: Path,
+    *,
+    expected_version: str | None = None,
+    repo_root: Path | None = None,
+    max_bytes: int = MAX_WHEEL_BYTES,
+    strict_bundle: bool = True,
+) -> WheelCheckResult:
+    """Validate one built wheel without installing it.
+
+    ``strict_bundle`` controls how the wheel's bundled files are compared with the
+    current source tree: ``True`` (gate a fresh build, used by
+    ``release preflight``) fails on any missing or changed declared file;
+    ``False`` (audit an already-released wheel) reports the same findings as
+    warnings.
+    """
+    wheel_path = Path(wheel_path).resolve()
+    if repo_root is None:
+        repo_root = REPO_ROOT if (REPO_ROOT / "pyproject.toml").is_file() else None
+    else:
+        repo_root = Path(repo_root).resolve()
+
+    result = WheelCheckResult(wheel=wheel_path)
+    if not wheel_path.is_file():
+        result.add("wheel-exists", False, f"not a file: {wheel_path}")
+        return result
+
+    result.file_bytes = wheel_path.stat().st_size
+    result.add("wheel-exists", True, str(wheel_path))
+    _check_filename(result, expected_version)
+    _check_platform_tag(result)
+    _check_size(result, max_bytes)
+
+    try:
+        zf = zipfile.ZipFile(wheel_path)
+    except zipfile.BadZipFile as exc:
+        result.add("zip-integrity", False, f"not a valid zip: {exc}")
+        return result
+
+    with zf:
+        corrupt = zf.testzip()
+        result.add(
+            "zip-integrity",
+            corrupt is None,
+            "CRC check passed" if corrupt is None else f"corrupt entry: {corrupt}",
+        )
+
+        names = zf.namelist()
+        name_set = set(names)
+        result.entry_count = len(names)
+        result.uncompressed_bytes = sum(info.file_size for info in zf.infolist())
+
+        _check_archive_paths(result, names)
+        _check_forbidden_entries(result, names)
+        message = _metadata_message(zf, result)
+        _check_metadata(result, message, expected_version, repo_root)
+        _check_compiled_only(result, names)
+        _check_bundle_fidelity(result, zf, name_set, repo_root, strict_bundle)
+        _check_record(result, zf, names)
+
+    return result

build/release/__init__.py

@@ -0,0 +1,7 @@
+"""Local release tooling: preflight gate and per-wheel audit.
+
+Entry point is ``python build/run.py release <command>``; see
+:mod:`release.preflight` for the gate steps and :mod:`release.cli` for the CLI.
+Imports are intentionally not re-exported here so importing a submodule never
+triggers the whole subsystem.
+"""

build/release/auth.py

@@ -0,0 +1,398 @@
+"""PyPI credential setup: locate, inspect and write ``~/.pypirc``.
+
+Editing the config from a command rather than by hand avoids the two mistakes
+that actually happen: putting something other than ``__token__`` in ``username``,
+and pasting a TestPyPI token into the ``[pypi]`` section (the two indexes reject
+each other's tokens with 403, and both token kinds start with ``pypi-``).
+
+The writer does targeted text edits rather than rewriting through configparser,
+so the explanatory comments in the file survive.
+"""
+
+from __future__ import annotations
+
+import configparser
+import getpass
+import os
+import sys
+from dataclasses import dataclass, field
+from pathlib import Path
+
+INDEXES: dict[str, dict[str, str | None]] = {
+    "pypi": {
+        "upload_url": "https://upload.pypi.org/legacy/",
+        "json_url": "https://pypi.org/pypi/orisys/json",
+        "simple_url": "https://pypi.org/simple/",
+        "token_url": "https://pypi.org/manage/account/token/",
+        "register_url": None,
+    },
+    "testpypi": {
+        "upload_url": "https://test.pypi.org/legacy/",
+        "json_url": "https://test.pypi.org/pypi/orisys/json",
+        "simple_url": "https://test.pypi.org/simple/",
+        "token_url": "https://test.pypi.org/manage/account/token/",
+        "register_url": "https://test.pypi.org/account/register/",
+    },
+}
+
+# Substrings that mark a token slot that was never filled in.
+PLACEHOLDER_MARKERS = ("PASTE", "REPLACE", "TOKEN-HERE", "YOUR-TOKEN", "XXXX")
+
+DEFAULT_TEMPLATE = """\
+# PyPI / TestPyPI credentials for twine.
+#
+# Keep this file out of any git repository: a token committed once stays in the
+# history even after you delete it.
+#
+#   * username is literally "__token__" - never an account name or email
+#   * PyPI and TestPyPI tokens both start with "pypi-" but are NOT
+#     interchangeable: each index rejects the other's with 403
+#   * TestPyPI is a separate service with a separate account
+
+[distutils]
+index-servers =
+"""
+
+
+@dataclass
+class CredentialState:
+    index: str
+    configured: bool
+    source: str | None = None
+    problem: str | None = None
+
+
+@dataclass
+class TwineLookup:
+    """What twine's own resolver says about one index."""
+
+    available: bool
+    known: bool
+    config: dict = field(default_factory=dict)
+    error: str | None = None
+
+
+def pypirc_path() -> Path:
+    """Where twine looks by default: ``~/.pypirc`` (same expansion twine uses)."""
+    return Path(os.path.expanduser("~")) / ".pypirc"
+
+
+def looks_like_placeholder(token: str) -> bool:
+    upper = token.upper()
+    return any(marker in upper for marker in PLACEHOLDER_MARKERS)
+
+
+def parse_pypirc(text: str) -> dict[str, dict[str, str]]:
+    """Section -> key -> value, tolerating comments and continuation lines."""
+    sections: dict[str, dict[str, str]] = {}
+    current: str | None = None
+    for raw in text.splitlines():
+        line = raw.strip()
+        if not line or line.startswith(("#", ";", "%")):
+            continue
+        if line.startswith("[") and line.endswith("]"):
+            current = line[1:-1].strip()
+            sections.setdefault(current, {})
+            continue
+        if current is not None and "=" in line:
+            key, _, value = line.partition("=")
+            sections[current][key.strip()] = value.strip()
+    return sections
+
+
+def credential_state(
+    index: str,
+    *,
+    path: Path | None = None,
+    env: dict | None = None,
+) -> CredentialState:
+    """Is ``index`` usable by twine, and why not when it is not.
+
+    Delegates to ``twine.utils.get_config`` when twine is importable, because the
+    only definition that matters is twine's. The important subtlety that a naive
+    check misses: **twine ignores any section not listed in
+    ``[distutils] index-servers``** (with a fallback of ``pypi testpypi`` when the
+    key is absent). A ``[testpypi]`` section without that listing looks configured
+    but twine reports "Missing 'testpypi' section".
+    """
+    if index not in INDEXES:
+        raise ValueError(f"unknown index {index!r}; expected one of {sorted(INDEXES)}")
+
+    env = os.environ if env is None else env
+    if env.get("TWINE_PASSWORD"):
+        return CredentialState(index, True, "environment variables")
+
+    path = path or pypirc_path()
+    if not path.is_file():
+        return CredentialState(index, False, None, f"{path} does not exist yet")
+
+    try:
+        text = path.read_text(encoding="utf-8", errors="ignore")
+    except OSError as exc:
+        return CredentialState(index, False, None, f"cannot read {path}: {exc}")
+
+    sections = parse_pypirc(text)
+    if index not in sections and index not in index_servers(text):
+        # Do not blame index-servers for a section that simply is not there.
+        return CredentialState(index, False, None, f"{path} has no [{index}] section")
+
+    lookup = _twine_lookup(index, path)
+    if lookup.error:
+        return CredentialState(index, False, None, f"twine cannot read {path}: {lookup.error}")
+
+    if lookup.available:
+        if not lookup.known:
+            return CredentialState(index, False, None, _ignored_section(index, path, text, sections))
+        username = str(lookup.config.get("username") or "").strip()
+        password = str(lookup.config.get("password") or "").strip()
+        if not password:
+            # twine knows the index but resolved no password for it: almost always
+            # a section that index-servers does not list.
+            detail = _ignored_section(index, path, text, sections)
+            return CredentialState(index, False, None, detail)
+    else:
+        # twine is not installed: replicate its rule locally.
+        if index not in index_servers(text):
+            return CredentialState(index, False, None, _ignored_section(index, path, text, sections))
+        section = sections[index]
+        username = section.get("username", "").strip()
+        password = section.get("password", "").strip()
+
+    if looks_like_placeholder(password):
+        return CredentialState(
+            index, False, str(path), f"[{index}] still contains a placeholder token"
+        )
+    if username != "__token__":
+        return CredentialState(
+            index,
+            False,
+            str(path),
+            f"[{index}] username is {username!r}; API tokens need the literal '__token__'",
+        )
+    return CredentialState(index, True, str(path))
+
+
+def _ignored_section(
+    index: str, path: Path, text: str, sections: dict[str, dict[str, str]]
+) -> str:
+    """Name the real cause: absent section, or present but not listed by twine."""
+    if index not in sections:
+        return f"{path} has no [{index}] section"
+    if index not in index_servers(text):
+        return (
+            f"[{index}] exists in {path} but is not listed in "
+            "[distutils] index-servers, so twine ignores it entirely; "
+            "fix with `release auth --repair`"
+        )
+    return f"twine resolves no password for [{index}] from {path}"
+
+
+def _twine_lookup(index: str, path: Path) -> TwineLookup:
+    """Ask twine itself; ``available=False`` when twine is not installed.
+
+    ``get_config`` is not enough on its own: it always contains a ``pypi`` entry
+    (and a ``testpypi`` one when listed) even when it never copied any
+    credentials, so the resolved username/password are what matter.
+    """
+    try:
+        from twine import utils
+    except ImportError:
+        return TwineLookup(available=False, known=False)
+    try:
+        config = utils.get_config(str(path))
+    except Exception as exc:  # twine reports malformed files as exceptions
+        return TwineLookup(available=True, known=False, error=f"{type(exc).__name__}: {exc}")
+    section = config.get(index)
+    if section is None:
+        return TwineLookup(available=True, known=False)
+    return TwineLookup(available=True, known=True, config=dict(section))
+
+
+def index_servers(text: str) -> set[str]:
+    """Names twine honours from ``[distutils] index-servers``.
+
+    Replicates ``twine.utils.get_config``, including its surprising asymmetry:
+
+    * key **absent**  -> falls back to ``pypi testpypi``
+    * key **present but empty** -> an empty list, so *no* section is honoured
+      (the fallback does not apply), and every section looks configured while
+      twine silently ignores it
+    * continuation lines are part of the value, so ``index-servers =`` followed
+      by indented names is the normal form
+    """
+    parser = configparser.RawConfigParser()
+    try:
+        parser.read_string(text)
+    except configparser.Error:
+        return set()
+    raw = parser.get("distutils", "index-servers", fallback="pypi testpypi")
+    return set(raw.split())
+
+
+def validate_token(token: str) -> list[str]:
+    """Problems with a pasted token. Empty and whitespace are fatal; the rest warn."""
+    return [problem for problem in _token_problems(token) if problem.startswith("ERROR")]
+
+
+def token_warnings(token: str) -> list[str]:
+    return [problem for problem in _token_problems(token) if problem.startswith("WARN")]
+
+
+def _token_problems(token: str) -> list[str]:
+    problems: list[str] = []
+    if not token:
+        problems.append("ERROR the token is empty")
+        return problems
+    if any(char.isspace() for char in token):
+        problems.append("ERROR the token contains whitespace (copy/paste artefact?)")
+    if not token.startswith("pypi-"):
+        problems.append(
+            "WARN PyPI API tokens start with 'pypi-'; a legacy account password also "
+            "works but needs username != '__token__'"
+        )
+    if len(token) < 20:
+        problems.append("WARN the token looks too short; check the paste was complete")
+    return problems
+
+
+def unlisted_sections(path: Path | None = None) -> list[str]:
+    """Known indexes whose section exists but is missing from ``index-servers``."""
+    path = path or pypirc_path()
+    if not path.is_file():
+        return []
+    text = path.read_text(encoding="utf-8", errors="ignore")
+    present = set(parse_pypirc(text))
+    listed = index_servers(text)
+    return [index for index in sorted(INDEXES) if index in present and index not in listed]
+
+
+def repair_index_servers(path: Path | None = None) -> list[str]:
+    """List sections that exist but are not in ``index-servers``.
+
+    This is the state a hand-edited file lands in: the section is present, so it
+    looks configured, but twine ignores it completely. Returns the indexes added.
+    """
+    path = path or pypirc_path()
+    if not path.is_file():
+        return []
+    text = path.read_text(encoding="utf-8")
+    present = set(parse_pypirc(text))
+    added: list[str] = []
+    for index in sorted(INDEXES):
+        if index in present and index not in index_servers(text):
+            text = ensure_index_server(text, index)
+            added.append(index)
+    if added:
+        path.write_text(text, encoding="utf-8", newline="")
+        _restrict_permissions(path)
+    return added
+
+
+def upsert_token(text: str, index: str, token: str) -> str:
+    """Set ``password`` inside ``[index]``, creating the section if needed."""
+    lines = text.splitlines()
+    start = next((i for i, line in enumerate(lines) if line.strip() == f"[{index}]"), None)
+
+    if start is None:
+        if lines and lines[-1].strip():
+            lines.append("")
+        lines.extend(
+            [
+                f"[{index}]",
+                f"repository = {INDEXES[index]['upload_url']}",
+                "username = __token__",
+                f"password = {token}",
+            ]
+        )
+        return "\n".join(lines) + "\n"
+
+    end = len(lines)
+    for offset in range(start + 1, len(lines)):
+        stripped = lines[offset].strip()
+        if stripped.startswith("[") and stripped.endswith("]"):
+            end = offset
+            break
+
+    insert_at = end
+    for offset in range(start + 1, end):
+        stripped = lines[offset].strip()
+        if stripped.startswith("password"):
+            lines[offset] = f"password = {token}"
+            return "\n".join(lines) + "\n"
+        if stripped.startswith(("username", "repository")):
+            insert_at = offset + 1
+    lines.insert(insert_at, f"password = {token}")
+    return "\n".join(lines) + "\n"
+
+
+def ensure_index_server(text: str, index: str) -> str:
+    """Make sure ``[distutils] index-servers`` lists ``index``."""
+    if index in index_servers(text):
+        return text
+
+    lines = text.splitlines()
+    if "[distutils]" not in (line.strip() for line in lines):
+        block = ["[distutils]", "index-servers =", f"    {index}", ""]
+        return "\n".join(block + lines) + "\n"
+
+    start = next(i for i, line in enumerate(lines) if line.strip() == "[distutils]")
+    for offset in range(start + 1, len(lines)):
+        if lines[offset].strip().startswith("index-servers"):
+            lines.insert(offset + 1, f"    {index}")
+            return "\n".join(lines) + "\n"
+    lines.insert(start + 1, f"    {index}")
+    return "\n".join(lines) + "\n"
+
+
+def _restrict_permissions(path: Path) -> None:
+    """Best effort: owner-only. Windows ACLs need icacls, not chmod."""
+    try:
+        os.chmod(path, 0o600)
+    except OSError:
+        pass
+
+
+def write_token(index: str, token: str, *, path: Path | None = None) -> Path:
+    """Write ``token`` into ``[index]`` of the pypirc file, preserving comments."""
+    if index not in INDEXES:
+        raise ValueError(f"unknown index {index!r}; expected one of {sorted(INDEXES)}")
+
+    path = path or pypirc_path()
+    if path.is_file():
+        text = path.read_text(encoding="utf-8")
+    else:
+        text = DEFAULT_TEMPLATE
+    text = upsert_token(text, index, token)
+    text = ensure_index_server(text, index)
+
+    path.parent.mkdir(parents=True, exist_ok=True)
+    path.write_text(text, encoding="utf-8", newline="")
+    _restrict_permissions(path)
+    return path
+
+
+def prompt_for_token(index: str, *, prompt_fn=None, out=None) -> str | None:
+    """Ask for a token with hidden input. Returns ``None`` if input is unavailable."""
+    out = out or sys.stdout
+    meta = INDEXES[index]
+    print(f"PyPI API token for [{index}]", file=out)
+    print(f"  create one at: {meta['token_url']}", file=out)
+    if meta.get("register_url"):
+        print(f"  needs an account first: {meta['register_url']}", file=out)
+    print("  input is hidden and is written only to your pypirc file", file=out)
+
+    ask = prompt_fn or getpass.getpass
+    try:
+        return ask("token: ").strip()
+    except (EOFError, KeyboardInterrupt, OSError):
+        # OSError covers environments where stdin cannot be read at all (pytest
+        # capture, a detached CI stdin): treat that as "cannot prompt", never as a
+        # crash.
+        print("", file=out)
+        print("aborted: no token entered", file=out)
+        return None
+
+
+def read_token_from_stdin() -> str:
+    """For CI: read the token from stdin instead of a prompt or the command line."""
+    return (sys.stdin.readline() or "").strip()

build/release/cli.py

@@ -0,0 +1,420 @@
+"""Command line for ``python build/run.py release``.
+
+Commands: ``preflight`` (local gate), ``audit`` (single wheel), ``auth`` (PyPI
+credentials in ~/.pypirc), ``github`` (sync the public repo + publish a GitHub
+Release), ``pypi`` (TestPyPI then PyPI). The publish commands are dry-run unless
+``--apply`` is passed, and tokens are never accepted as command-line arguments.
+"""
+
+from __future__ import annotations
+
+import argparse
+import sys
+from pathlib import Path
+
+_BUILD_ROOT = Path(__file__).resolve().parents[1]
+if str(_BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(_BUILD_ROOT))
+
+from common.paths import REPO_ROOT  # noqa: E402
+from common.verify.wheel import (  # noqa: E402
+    DEFAULT_RUNTIME_CONFIG,
+    default_verification_video,
+    verify_wheel,
+    verify_wheel_assets,
+    verify_wheel_runtime,
+)
+from common.verify.wheel_contents import inspect_wheel  # noqa: E402
+from release import auth, github, pypi  # noqa: E402
+from release.preflight import PreflightOptions, run_preflight  # noqa: E402
+
+
+def _cmd_preflight(argv: list[str]) -> int:
+    parser = argparse.ArgumentParser(
+        prog="build/run.py release preflight",
+        description="Gate a release locally: version, tests, wheel content, runtime.",
+    )
+    parser.add_argument("--version", help="release version (default: pyproject's dynamic version)")
+    parser.add_argument("--wheel-dir", type=Path, help="directory to inspect (default: SDK/<version>)")
+    parser.add_argument("--video", type=Path, help="clip for the end-to-end runtime check")
+    parser.add_argument("--config", default=DEFAULT_RUNTIME_CONFIG, help="config name for that check")
+    parser.add_argument("--frames", type=int, default=40, help="frames to process (default: 40)")
+    parser.add_argument("--skip-tests", action="store_true", help="skip pytest (recorded in the report)")
+    parser.add_argument("--longrun", action="store_true", help="include the slow long-run stability test")
+    parser.add_argument("--allow-dirty", action="store_true", help="allow a dirty working tree")
+    parser.add_argument(
+        "--force",
+        action="store_true",
+        help="accept a version that a git tag already marks as released",
+    )
+    parser.add_argument("--check-pypi", action="store_true", help="read PyPI and fail if the version exists")
+    parser.add_argument(
+        "--all-wheel-pythons",
+        action="store_true",
+        help="verify cp310/cp311/cp312 wheels, each in its own conda env",
+    )
+    parser.add_argument("--offline", action="store_true", help="reuse parent-env deps instead of PyPI")
+    parser.add_argument("--no-runtime", action="store_true", help="skip the isolated runtime check")
+    parser.add_argument("--no-assets", action="store_true", help="skip the bundled-asset check")
+    parser.add_argument("--keep-going", action="store_true", help="collect every failure instead of stopping")
+    parser.add_argument("--report-dir", type=Path, help="override build/release/reports")
+    args = parser.parse_args(argv)
+
+    options = PreflightOptions(
+        version=args.version,
+        wheel_dir=args.wheel_dir,
+        video=args.video,
+        config_name=args.config,
+        frames=args.frames,
+        skip_tests=args.skip_tests,
+        longrun=args.longrun,
+        allow_dirty=args.allow_dirty,
+        force=args.force,
+        check_pypi=args.check_pypi,
+        all_wheel_pythons=args.all_wheel_pythons,
+        offline=args.offline,
+        keep_going=args.keep_going,
+        report_dir=args.report_dir,
+        no_runtime=args.no_runtime,
+        no_assets=args.no_assets,
+    )
+    return run_preflight(options, repo_root=REPO_ROOT)
+
+
+def _cmd_audit(argv: list[str]) -> int:
+    parser = argparse.ArgumentParser(
+        prog="build/run.py release audit",
+        description="Inspect one built wheel without a release context.",
+    )
+    parser.add_argument("wheel", type=Path, help="path to an .whl")
+    parser.add_argument("--expected-version", help="assert the wheel reports this version")
+    parser.add_argument(
+        "--strict-bundle",
+        action="store_true",
+        help="treat bundled-file drift from the current source tree as a failure",
+    )
+    parser.add_argument("--runtime", action="store_true", help="also install and run the wheel")
+    parser.add_argument("--assets", action="store_true", help="also assert bundled assets load")
+    parser.add_argument("--video", type=Path, help="clip for --runtime")
+    parser.add_argument("--config", default=DEFAULT_RUNTIME_CONFIG)
+    parser.add_argument("--frames", type=int, default=40)
+    parser.add_argument("--offline", action="store_true")
+    parser.add_argument(
+        "--python",
+        type=Path,
+        default=None,
+        help="interpreter to build the verification venv from (default: the running one)",
+    )
+    args = parser.parse_args(argv)
+
+    wheel = args.wheel
+    if not wheel.is_file():
+        print(f"[ERROR] wheel not found: {wheel}", file=sys.stderr)
+        return 2
+
+    exit_code = 0
+
+    result = inspect_wheel(
+        wheel,
+        expected_version=args.expected_version,
+        repo_root=REPO_ROOT,
+        strict_bundle=args.strict_bundle,
+    )
+    print(result.render())
+    if not result.ok:
+        exit_code = 1
+
+    if args.assets and args.runtime:
+        # One venv for both checks: building it (and downloading dependencies in
+        # online mode) is the expensive part.
+        video = args.video or default_verification_video(REPO_ROOT)
+        if video is None:
+            print("[FAIL] runtime: no verification clip; pass --video or set ORISYS_VERIFY_VIDEO")
+            return 1
+        try:
+            record = verify_wheel(
+                wheel,
+                video=video,
+                config_name=args.config,
+                frames=args.frames,
+                python_executable=args.python,
+                offline=args.offline,
+            )
+            print(f"[ok  ] {record['imports']}")
+            print(f"[ok  ] {record['assets']}")
+            print(f"[ok  ] runtime: frames={record['frames']} flow={record['flow_shape']}")
+        except Exception as exc:
+            print(f"[FAIL] isolated verification: {type(exc).__name__}: {exc}")
+            exit_code = 1
+        return exit_code
+
+    if args.assets:
+        try:
+            print(verify_wheel_assets(wheel, python_executable=args.python))
+        except Exception as exc:
+            print(f"[FAIL] bundled assets: {type(exc).__name__}: {exc}")
+            exit_code = 1
+
+    if args.runtime:
+        video = args.video or default_verification_video(REPO_ROOT)
+        if video is None:
+            print("[FAIL] runtime: no verification clip; pass --video or set ORISYS_VERIFY_VIDEO")
+            return 1
+        try:
+            info = verify_wheel_runtime(
+                wheel,
+                video=video,
+                config_name=args.config,
+                frames=args.frames,
+                python_executable=args.python,
+                offline=args.offline,
+            )
+            print(f"[ok  ] runtime: {info}")
+        except Exception as exc:
+            print(f"[FAIL] runtime: {type(exc).__name__}: {exc}")
+            exit_code = 1
+
+    return exit_code
+
+
+def _cmd_github(argv: list[str]) -> int:
+    parser = argparse.ArgumentParser(
+        prog="build/run.py release github",
+        description="Sync orisys-sdk-release, tag, and publish a GitHub Release.",
+    )
+    parser.add_argument(
+        "--version", required=True, help="release version, e.g. <major>.<minor>.<patch>"
+    )
+    parser.add_argument(
+        "--apply",
+        action="store_true",
+        help="actually mutate the release repo, push, and create the release",
+    )
+    parser.add_argument("--notes-file", type=Path, default=None, help="release notes markdown")
+    parser.add_argument(
+        "--attach-preflight",
+        action="store_true",
+        help="also upload the preflight report as a release asset (contains local paths)",
+    )
+    parser.add_argument(
+        "--allow-dirty-release",
+        action="store_true",
+        help="proceed even if the release repo has uncommitted changes",
+    )
+    parser.add_argument("--skip-fetch", action="store_true", help="skip `git fetch --tags`")
+    parser.add_argument(
+        "--skip-checks", action="store_true", help="skip the manifest's downstream checks"
+    )
+    parser.add_argument(
+        "--skip-release-upload",
+        action="store_true",
+        help="stop after pushing the tag and print the `gh release create` command",
+    )
+    args = parser.parse_args(argv)
+
+    return github.publish(
+        github.Options(
+            version=args.version,
+            apply=args.apply,
+            notes_file=args.notes_file,
+            attach_preflight=args.attach_preflight,
+            allow_dirty_release=args.allow_dirty_release,
+            skip_fetch=args.skip_fetch,
+            skip_checks=args.skip_checks,
+            skip_release_upload=args.skip_release_upload,
+        )
+    )
+
+
+def _cmd_auth(argv: list[str]) -> int:
+    parser = argparse.ArgumentParser(
+        prog="build/run.py release auth",
+        description=(
+            "Inspect or set up PyPI credentials in ~/.pypirc. "
+            "Tokens are read from a hidden prompt or stdin, never from argv."
+        ),
+    )
+    parser.add_argument(
+        "--set-token",
+        choices=sorted(auth.INDEXES),
+        default=None,
+        help="store a token for this index (prompts unless --token-stdin)",
+    )
+    parser.add_argument(
+        "--token-stdin",
+        action="store_true",
+        help="read the token from stdin instead of prompting (for scripts/CI)",
+    )
+    parser.add_argument(
+        "--repair",
+        action="store_true",
+        help=(
+            "add existing sections to [distutils] index-servers; twine ignores "
+            "sections that are not listed there"
+        ),
+    )
+    parser.add_argument(
+        "--index",
+        choices=sorted(auth.INDEXES),
+        default="pypi",
+        help="index to report on when not setting a token (default: pypi)",
+    )
+    args = parser.parse_args(argv)
+
+    if args.repair:
+        path = auth.pypirc_path()
+        added = auth.repair_index_servers(path)
+        if added:
+            print(f"[ok  ] added {added} to [distutils] index-servers in {path}")
+        else:
+            print(f"[ok  ] nothing to repair in {path}")
+        for index in sorted(auth.INDEXES):
+            state = auth.credential_state(index)
+            flag = "[ok  ]" if state.configured else "[--  ]"
+            detail = state.source if state.configured else state.problem
+            print(f"{flag} [{index}] {detail}")
+        return 0 if auth.credential_state(args.index).configured else 1
+
+    if args.set_token:
+        if args.token_stdin:
+            token = auth.read_token_from_stdin()
+        else:
+            token = auth.prompt_for_token(args.set_token)
+        if not token:
+            print("[FAIL] no token entered")
+            return 1
+        for problem in auth.validate_token(token):
+            print(f"[FAIL] {problem.removeprefix('ERROR ')}")
+            return 1
+        for warning in auth.token_warnings(token):
+            print(f"[warn] {warning.removeprefix('WARN ')}")
+        path = auth.write_token(args.set_token, token)
+        print(f"[ok  ] wrote [{args.set_token}] credentials to {path}")
+        state = auth.credential_state(args.set_token)
+        if not state.configured:
+            print(f"[FAIL] the file still does not validate: {state.problem}")
+            return 1
+        print(f"[ok  ] [{args.set_token}] credentials verified ({state.source})")
+        return 0
+
+    path = auth.pypirc_path()
+    print(f"config file: {path} ({'exists' if path.is_file() else 'missing'})")
+    for index in sorted(auth.INDEXES):
+        state = auth.credential_state(index)
+        if state.configured:
+            print(f"[ok  ] [{index}] configured ({state.source})")
+        else:
+            print(f"[--  ] [{index}] not usable: {state.problem}")
+
+    unlisted = auth.unlisted_sections(path)
+    if unlisted:
+        print()
+        print(
+            f"[warn] {unlisted} have sections that [distutils] index-servers does not "
+            "list; twine ignores those entirely"
+        )
+        print("       fix with: python build/run.py release auth --repair")
+
+    print()
+    print("set a token with:")
+    for index in sorted(auth.INDEXES):
+        if not auth.credential_state(index).configured:
+            print(f"  python build/run.py release auth --set-token {index}")
+    print("  (TestPyPI needs its own account; if you only hold a production token,")
+    print("   skip it and publish with `release pypi --pypi-only`)")
+
+    return 0 if auth.credential_state(args.index).configured else 1
+
+
+def _cmd_pypi(argv: list[str]) -> int:
+    parser = argparse.ArgumentParser(
+        prog="build/run.py release pypi",
+        description="Upload the certified wheels to TestPyPI and then PyPI.",
+    )
+    parser.add_argument(
+        "--version", required=True, help="release version, e.g. <major>.<minor>.<patch>"
+    )
+    parser.add_argument(
+        "--apply",
+        action="store_true",
+        help="actually upload (uploads are permanent and cannot be overwritten)",
+    )
+    parser.add_argument(
+        "--confirm-pypi",
+        action="store_true",
+        help="after TestPyPI, also publish to the real PyPI",
+    )
+    parser.add_argument(
+        "--pypi-only",
+        action="store_true",
+        help=(
+            "upload straight to PyPI, skipping the TestPyPI rehearsal "
+            "(for when you only hold a production token)"
+        ),
+    )
+    parser.add_argument(
+        "--prompt-credentials",
+        action="store_true",
+        help="if a token is missing, prompt for it and store it in ~/.pypirc",
+    )
+    parser.add_argument(
+        "--token-stdin",
+        action="store_true",
+        help="read a missing token from stdin instead of prompting (scripts/CI)",
+    )
+    parser.add_argument(
+        "--skip-install-verify",
+        action="store_true",
+        help="skip fetching the artifact back out of the index",
+    )
+    parser.add_argument("--skip-check", action="store_true", help="skip `twine check`")
+    args = parser.parse_args(argv)
+
+    if args.pypi_only and args.confirm_pypi:
+        parser.error("--pypi-only and --confirm-pypi are mutually exclusive")
+
+    if args.token_stdin and not args.prompt_credentials:
+        parser.error("--token-stdin requires --prompt-credentials")
+
+    token = auth.read_token_from_stdin() if args.token_stdin else None
+
+    return pypi.publish(
+        pypi.Options(
+            version=args.version,
+            apply=args.apply,
+            confirm_pypi=args.confirm_pypi,
+            verify_install=not args.skip_install_verify,
+            skip_check=args.skip_check,
+            pypi_only=args.pypi_only,
+            prompt_credentials=args.prompt_credentials,
+            token=token,
+        )
+    )
+
+
+def main(argv: list[str] | None = None) -> int:
+    argv = list(sys.argv[1:] if argv is None else argv)
+    if not argv or argv[0] in ("-h", "--help"):
+        print(__doc__)
+        print("Commands: preflight | audit | auth | github | pypi")
+        return 0
+
+    command, rest = argv[0], argv[1:]
+    if command == "preflight":
+        return _cmd_preflight(rest)
+    if command == "audit":
+        return _cmd_audit(rest)
+    if command == "auth":
+        return _cmd_auth(rest)
+    if command == "github":
+        return _cmd_github(rest)
+    if command == "pypi":
+        return _cmd_pypi(rest)
+
+    print(f"Unknown release command: {command!r}", file=sys.stderr)
+    print("Choose from: preflight, audit, auth, github, pypi", file=sys.stderr)
+    return 2
+
+
+if __name__ == "__main__":
+    raise SystemExit(main())

build/release/github.py

@@ -0,0 +1,438 @@
+"""Sync the public release repo and publish a GitHub Release.
+
+``python build/run.py release github`` runs, in order:
+
+1. certified-wheels gate (a passing ``release preflight`` report must exist and
+   every wheel must still hash to what it recorded)
+2. refuse if the version is already tagged or already has a GitHub Release
+3. sync the open-source subset of this checkout into ``orisys-sdk-release``
+   (``tools/sync_downstreams.py`` + the manifest's ``checks``)
+4. stage ``SDK/<version>/*.whl`` into ``orisys-sdk-release/release/<version>/``
+5. commit, tag ``v<version>``, push branch + tag
+6. create the GitHub Release with the wheels attached, then verify the assets
+
+Nothing mutates anything unless ``--apply`` is passed: the default is a dry run
+that prints every command it would run.
+"""
+
+from __future__ import annotations
+
+import json
+import shutil
+import subprocess
+import sys
+from dataclasses import dataclass, field
+from pathlib import Path
+
+_BUILD_ROOT = Path(__file__).resolve().parents[1]
+if str(_BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(_BUILD_ROOT))
+
+from common.paths import REPO_ROOT  # noqa: E402
+from release.publish import GateResult, PublishGateError, load_gate  # noqa: E402
+
+MANIFEST_PATH = REPO_ROOT / "tools" / "downstream_sync_manifest.json"
+SYNC_TOOL = REPO_ROOT / "tools" / "sync_downstreams.py"
+RELEASE_TARGET = "orisys-sdk-release"
+
+
+@dataclass
+class Options:
+    version: str
+    apply: bool = False
+    notes_file: Path | None = None
+    attach_preflight: bool = False
+    allow_dirty_release: bool = False
+    skip_fetch: bool = False
+    skip_checks: bool = False
+    skip_release_upload: bool = False
+
+
+@dataclass
+class CommandStep:
+    description: str
+    argv: list[str]
+    cwd: Path | None = None
+
+
+@dataclass
+class Plan:
+    release_repo: Path
+    branch: str
+    tag: str
+    assets: list[Path] = field(default_factory=list)
+    steps: list[CommandStep] = field(default_factory=list)
+
+
+def manifest_entry() -> dict:
+    """The manifest entry for the public release repo."""
+    payload = json.loads(MANIFEST_PATH.read_text(encoding="utf-8"))
+    for item in payload.get("downstreams", []):
+        if item.get("name") == RELEASE_TARGET:
+            return item
+    raise PublishGateError(f"{MANIFEST_PATH} has no downstream named {RELEASE_TARGET!r}")
+
+
+def release_repo_path() -> Path:
+    return (REPO_ROOT / manifest_entry()["path"]).resolve()
+
+
+def _git(repo: Path, *args: str, check: bool = True) -> str:
+    completed = subprocess.run(
+        ["git", "-C", str(repo), *args],
+        capture_output=True,
+        text=True,
+        check=False,
+    )
+    if check and completed.returncode != 0:
+        raise PublishGateError(
+            f"git {' '.join(args)} failed in {repo}:\n{completed.stderr.strip()}"
+        )
+    return (completed.stdout or "").strip()
+
+
+def build_release_notes(version: str, wheels: list[Path], git_commit: str | None) -> str:
+    lines = [
+        f"orisys {version}",
+        "",
+        "Wheels (Python 3.10 / 3.11 / 3.12, Windows x64 and Linux x86_64):",
+    ]
+    lines.extend(f"- `{wheel.name}`" for wheel in wheels)
+    lines.append("")
+    if git_commit:
+        lines.append(
+            f"Built from `{git_commit[:12]}` and certified by `release preflight`."
+        )
+    return "\n".join(lines) + "\n"
+
+
+def build_github_steps(
+    *,
+    version: str,
+    branch: str,
+    tag: str,
+    assets: list[Path],
+    notes_file: Path | None,
+    create_tag: bool = True,
+    title: str | None = None,
+) -> list[CommandStep]:
+    """The mutating commands, as pure data so they can be asserted in tests.
+
+    ``create_tag=False`` is the resume path: the tag already exists (a previous
+    run pushed it before failing), so only the remaining steps are emitted.
+    """
+    release_argv = [
+        "gh",
+        "release",
+        "create",
+        tag,
+        "--verify-tag",
+        "--title",
+        title or f"v{version}",
+        "--latest",
+    ]
+    if notes_file is not None:
+        release_argv += ["--notes-file", str(notes_file)]
+    release_argv += [str(asset) for asset in assets]
+
+    steps: list[CommandStep] = []
+    if create_tag:
+        steps.append(CommandStep("create tag", ["git", "tag", tag]))
+    steps.append(CommandStep("push branch", ["git", "push", "origin", branch]))
+    steps.append(CommandStep("push tag", ["git", "push", "origin", tag]))
+    steps.append(CommandStep("create GitHub Release with assets", release_argv))
+    return steps
+
+
+def non_github_remote_problem(repo: Path) -> str | None:
+    """Why ``gh`` cannot target this repo, or ``None`` if the remote is fine.
+
+    ``gh`` resolves its repository from the working directory. Running it from
+    this checkout instead of the release repo is a real failure mode: the SDK
+    repo's origin is an internal host, and ``gh`` reports the confusing "none of
+    the git remotes ... point to a known GitHub host".
+    """
+    remote = _git(repo, "remote", "get-url", "origin", check=False)
+    if "github.com" in remote:
+        return None
+    return (
+        f"the release repo's origin is {remote!r}, which is not a GitHub host. "
+        "`gh` resolves the repository from the working directory, so point origin "
+        "at github.com before publishing a release"
+    )
+
+
+def _check_gh(repo: Path) -> list[str]:
+    """Problems that would stop the release step, reported before any mutation."""
+    problems: list[str] = []
+    if shutil.which("gh") is None:
+        problems.append(
+            "the `gh` CLI is not on PATH. Install it (`winget install --id GitHub.cli`) "
+            "and authenticate (`gh auth login`), or use --skip-release-upload"
+        )
+        return problems
+
+    remote_problem = non_github_remote_problem(repo)
+    if remote_problem:
+        problems.append(remote_problem)
+
+    completed = subprocess.run(
+        ["gh", "auth", "status"], capture_output=True, text=True, check=False
+    )
+    if completed.returncode != 0:
+        problems.append("`gh auth status` failed; run `gh auth login` first")
+    return problems
+
+
+def _existing_release_tags(repo: Path, version: str) -> list[str]:
+    wanted = {version, f"v{version}"}
+    tags = set(_git(repo, "tag", "--list").splitlines())
+    return sorted(wanted & tags)
+
+
+def _release_exists(repo: Path, tag: str) -> bool | None:
+    """Is there already a GitHub Release for ``tag``?
+
+    Returns ``None`` when that cannot be determined (``gh`` unavailable), so the
+    caller can distinguish "not published yet" from "unknown" instead of treating
+    a missing tool as proof that nothing was published.
+
+    Must run with ``cwd`` set to the release repo: `gh` resolves the target
+    repository from the working directory, and this checkout's own remote is an
+    internal host.
+    """
+    if shutil.which("gh") is None:
+        return None
+    completed = subprocess.run(
+        ["gh", "release", "view", tag, "--json", "tagName"],
+        capture_output=True,
+        text=True,
+        check=False,
+        cwd=str(repo),
+    )
+    return completed.returncode == 0
+
+
+def _sync(*, run_checks: bool) -> None:
+    """Copy the public subset into the release repo and run its checks."""
+    python = sys.executable
+    for command in (
+        [python, str(SYNC_TOOL), "apply", "--target", RELEASE_TARGET],
+        *(
+            [[python, str(SYNC_TOOL), "run-checks", "--target", RELEASE_TARGET]]
+            if run_checks
+            else []
+        ),
+    ):
+        completed = subprocess.run(command, cwd=REPO_ROOT, check=False)
+        if completed.returncode != 0:
+            raise PublishGateError(
+                f"`{' '.join(command[1:])}` failed with exit {completed.returncode}"
+            )
+
+
+def _stage_wheels(wheels: list[Path], asset_dir: Path) -> None:
+    asset_dir.mkdir(parents=True, exist_ok=True)
+    for wheel in wheels:
+        shutil.copy2(wheel, asset_dir / wheel.name)
+
+
+def publish(options: Options) -> int:
+    version = options.version
+    mode = "APPLY" if options.apply else "DRY RUN"
+    print(f"=== release github: orisys {version} ({mode}) ===")
+
+    # --- 1. gate -------------------------------------------------------
+    try:
+        gate: GateResult = load_gate(REPO_ROOT, version)
+    except PublishGateError as exc:
+        print(f"[FAIL] {exc}")
+        return 1
+    print(f"[ok  ] preflight report: {gate.report_path}")
+    print(f"       certified commit: {gate.git_commit}")
+    for wheel in gate.wheels:
+        print(f"       [ok] {wheel.name} sha256={wheel.sha256[:12]} {wheel.size} bytes")
+    for warning in gate.warnings:
+        print(f"[warn] {warning}")
+
+    # --- 2. target repo ------------------------------------------------
+    try:
+        repo = release_repo_path()
+    except PublishGateError as exc:
+        print(f"[FAIL] {exc}")
+        return 1
+    if not (repo / ".git").exists():
+        print(f"[FAIL] {repo} is not a git repository")
+        return 1
+
+    try:
+        if not options.skip_fetch:
+            _git(repo, "fetch", "--tags", "--quiet")
+            print(f"[ok  ] git fetch --tags in {repo}")
+        branch = _git(repo, "rev-parse", "--abbrev-ref", "HEAD")
+        dirty = _git(repo, "status", "--porcelain")
+    except PublishGateError as exc:
+        print(f"[FAIL] {exc}")
+        return 1
+
+    if dirty and not options.allow_dirty_release:
+        preview = "\n".join(dirty.splitlines()[:10])
+        print(
+            f"[FAIL] {repo} has uncommitted changes; commit or stash them first "
+            f"(or pass --allow-dirty-release):\n{preview}"
+        )
+        return 1
+    print(f"[ok  ] release repo: {repo} ({branch}) clean={not dirty}")
+
+    tag = f"v{version}"
+    existing = _existing_release_tags(repo, version)
+    # A tag that exists without a GitHub Release means a previous run got as far
+    # as pushing the tag and then failed (or the upload was left manual). That is
+    # exactly the resumable state, so continue instead of refusing.
+    create_tag = not existing
+    if existing:
+        print(
+            f"[warn] tag(s) {existing} already exist in {repo}; skipping tag creation "
+            "and continuing to the release upload"
+        )
+    release_state = _release_exists(repo, tag)
+    if release_state is True:
+        print(f"[FAIL] GitHub Release {tag} already exists; nothing to publish")
+        return 1
+    if release_state is None:
+        print(
+            "[warn] cannot tell whether a GitHub Release for "
+            f"{tag} already exists (`gh` not installed); --apply will stop at the gh check"
+        )
+        if create_tag:
+            print(f"[ok  ] tag {tag} does not exist in {repo}")
+    elif create_tag:
+        print(f"[ok  ] no existing tag or GitHub Release for {tag}")
+    else:
+        print(f"[ok  ] no GitHub Release for {tag} yet")
+
+    # A dry run is a preview of what would happen, so missing tooling is a warning
+    # there and a hard stop only when we are about to mutate something.
+    if options.skip_release_upload:
+        print("[warn] --skip-release-upload: the GitHub Release will be left to you")
+    else:
+        gh_problems = _check_gh(repo)
+        if gh_problems:
+            for problem in gh_problems:
+                print(f"[{'FAIL' if options.apply else 'warn'}] {problem}")
+            if options.apply:
+                return 1
+        else:
+            print("[ok  ] gh CLI is installed and authenticated")
+
+    # --- 3. plan the mutating steps ------------------------------------
+    wheels = [REPO_ROOT / "SDK" / version / record.name for record in gate.wheels]
+    missing = [str(wheel) for wheel in wheels if not wheel.is_file()]
+    if missing:
+        print(f"[FAIL] wheels missing from disk: {missing}")
+        return 1
+
+    asset_dir = repo / "release" / version
+    assets = [asset_dir / wheel.name for wheel in wheels]
+    notes_file = options.notes_file
+    steps = build_github_steps(
+        version=version,
+        branch=branch,
+        tag=tag,
+        assets=assets,
+        notes_file=notes_file,
+        create_tag=create_tag,
+    )
+
+    print()
+    print(f"[plan] sync {len(manifest_entry().get('sync', []))} entry(ies) into {repo}")
+    print(f"[plan] stage {len(wheels)} wheel(s) into {asset_dir}")
+    if create_tag:
+        print(f"[plan] commit {repo} and create tag {tag}")
+    else:
+        print(f"[plan] commit {repo} (tag {tag} already exists)")
+    for step in steps:
+        manual = options.skip_release_upload and step.description.startswith(
+            "create GitHub Release"
+        )
+        prefix = "[plan] (left manual)" if manual else "[plan]"
+        print(f"{prefix} {step.description}: {' '.join(step.argv)}")
+    print()
+
+    if not options.apply:
+        print("dry run: nothing was changed. Re-run with --apply to execute.")
+        return 0
+
+    # --- 4. execute ----------------------------------------------------
+    try:
+        commit_before = _git(repo, "rev-parse", "HEAD")
+        _sync(run_checks=not options.skip_checks)
+        _stage_wheels(wheels, asset_dir)
+
+        if options.attach_preflight:
+            shutil.copy2(gate.report_path, asset_dir / f"{version}-preflight.json")
+
+        _git(repo, "add", "-A")
+        pending = _git(repo, "status", "--porcelain")
+        if pending:
+            _git(repo, "commit", "-m", f"release {version}")
+            print(f"[ok  ] committed {len(pending.splitlines())} change(s) in {repo}")
+        else:
+            print("[ok  ] nothing new to commit in the release repo")
+
+        if create_tag:
+            _git(repo, "tag", tag)
+        # Pushing an already-up-to-date ref is a no-op, so resuming is safe.
+        _git(repo, "push", "origin", branch)
+        _git(repo, "push", "origin", tag)
+        print(f"[ok  ] pushed {branch} and {tag}")
+    except PublishGateError as exc:
+        print(f"[FAIL] {exc}")
+        return 1
+
+    release_argv = next(
+        step.argv for step in steps if step.description.startswith("create GitHub Release")
+    )
+
+    if options.skip_release_upload:
+        print()
+        print("[todo] publish the release yourself:")
+        print("       " + " ".join(release_argv))
+        print()
+        print("=== release github: repo synced and tagged; release upload left manual ===")
+        return 0
+
+    # `gh` resolves its target repository from the working directory, so it must
+    # run inside the release repo - this checkout's own origin is an internal host.
+    completed = subprocess.run(release_argv, check=False, cwd=str(repo))
+    if completed.returncode != 0:
+        print(f"[FAIL] gh release create exited {completed.returncode}")
+        return 1
+    print(f"[ok  ] GitHub Release {tag} created")
+
+    # --- 5. verify the published assets --------------------------------
+    completed = subprocess.run(
+        ["gh", "release", "view", tag, "--json", "assets,tagName"],
+        capture_output=True,
+        text=True,
+        check=False,
+        cwd=str(repo),
+    )
+    if completed.returncode != 0:
+        print("[FAIL] could not read back the release to verify assets")
+        return 1
+    payload = json.loads(completed.stdout or "{}")
+    published = {asset["name"] for asset in payload.get("assets", [])}
+    expected = {asset.name for asset in assets}
+    if options.attach_preflight:
+        expected.add(f"{version}-preflight.json")
+    if published != expected:
+        print(
+            f"[FAIL] release asset mismatch:\n  expected {sorted(expected)}\n"
+            f"  published {sorted(published)}"
+        )
+        return 1
+    print(f"[ok  ] verified {len(published)} asset(s) on the release")
+    print()
+    print(f"=== release github PASSED (commit {commit_before[:12]} -> {_git(repo, 'rev-parse', 'HEAD')[:12]}) ===")
+    return 0

build/release/preflight.py

@@ -0,0 +1,570 @@
+"""Local release gate: everything that must hold before publishing a wheel.
+
+``release preflight`` answers one question with an exit code: is this checkout,
+this version and these wheels safe to publish? It never publishes anything, and
+by default it makes no network calls.
+
+Steps, in order:
+
+1. ``repo-state``           - git repository, clean working tree, recorded commit
+2. ``version-consistency``  - __version__ == pyproject dynamic attr == wheel names
+3. ``version-strings``      - no stale version literal left in tracked prose
+4. ``duplicate-guard``      - already-released version (git tag, optionally PyPI)
+5. ``tests``                - pytest (slow/hardware markers excluded)
+6. ``bundle-precheck``      - every bundle item resolves; required assets present
+7. ``wheel-inspection``     - static metadata/content assertions per wheel
+8. ``wheel-runtime``        - one isolated venv per wheel: bundled assets load and
+                              real frames flow through the public pipeline
+
+Output lands in ``build/release/reports/<version>/preflight.{json,txt}``, and is
+the contract the publish commands (``release github`` / ``release pypi``) consume:
+they refuse to ship anything this run did not certify.
+"""
+
+from __future__ import annotations
+
+import hashlib
+import json
+import platform
+import subprocess
+import sys
+import time
+from dataclasses import asdict, dataclass, field
+from datetime import datetime, timezone
+from pathlib import Path
+
+_BUILD_ROOT = Path(__file__).resolve().parents[1]
+if str(_BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(_BUILD_ROOT))
+
+from common.paths import REPO_ROOT  # noqa: E402
+from common.pyproject_utils import bundle_items, get_version  # noqa: E402
+from common.verify.wheel import (  # noqa: E402
+    DEFAULT_RUNTIME_CONFIG,
+    default_verification_video,
+    verify_wheel,
+)
+from common.verify.wheel_contents import inspect_wheel  # noqa: E402
+from release import report as report_mod  # noqa: E402
+from release import version as version_mod  # noqa: E402
+from wheel.layout import resolve_bundle_source_files, verify_required_assets  # noqa: E402
+
+
+@dataclass
+class Step:
+    name: str
+    ok: bool
+    detail: str = ""
+    duration_s: float = 0.0
+    data: dict = field(default_factory=dict)
+
+
+@dataclass
+class PreflightOptions:
+    version: str | None = None
+    wheel_dir: Path | None = None
+    video: Path | None = None
+    config_name: str = DEFAULT_RUNTIME_CONFIG
+    frames: int = 40
+    skip_tests: bool = False
+    longrun: bool = False
+    allow_dirty: bool = False
+    force: bool = False
+    check_pypi: bool = False
+    all_wheel_pythons: bool = False
+    offline: bool = False
+    keep_going: bool = False
+    report_dir: Path | None = None
+    no_runtime: bool = False
+    no_assets: bool = False
+
+
+def _sha256_file(path: Path) -> str:
+    digest = hashlib.sha256()
+    with Path(path).open("rb") as handle:
+        for chunk in iter(lambda: handle.read(1024 * 1024), b""):
+            digest.update(chunk)
+    return digest.hexdigest()
+
+
+def _now() -> str:
+    return datetime.now(timezone.utc).isoformat(timespec="seconds")
+
+
+class Preflight:
+    def __init__(self, options: PreflightOptions, repo_root: Path | None = None) -> None:
+        self.options = options
+        self.repo_root = Path(repo_root or REPO_ROOT)
+        self.steps: list[Step] = []
+        self.git: dict = {"commit": None, "branch": None, "dirty": None}
+        self.wheels: list[Path] = []
+        self.wheel_dir: Path | None = None
+        self.runtime_records: list[dict] = []
+        self.aborted = False
+        self.ok = False
+
+        if options.version:
+            self.version = options.version
+            self.version_source = "explicit --version"
+        elif (self.repo_root / "pyproject.toml").is_file():
+            self.version = get_version(self.repo_root)
+            self.version_source = "pyproject.toml dynamic attr"
+        else:
+            # Not version-shaped on purpose: this is a sentinel for "unresolved",
+            # and it must not look like a release version to the version-string scan.
+            self.version = "unknown"
+            self.version_source = "unresolved"
+
+        self.report_dir = report_mod.reports_root(self.repo_root, options.report_dir) / self.version
+
+    # -- helpers ---------------------------------------------------------
+
+    def _git(self, *args: str) -> str:
+        try:
+            completed = subprocess.run(
+                ["git", *args],
+                cwd=self.repo_root,
+                capture_output=True,
+                text=True,
+                check=False,
+            )
+        except OSError:
+            return ""
+        return (completed.stdout or "").strip()
+
+    def _execute(self, step_fn) -> None:
+        started = time.perf_counter()
+        try:
+            step = step_fn()
+        except Exception as exc:  # a crashed step is a failed step, never a silent pass
+            step = Step(name=getattr(step_fn, "__name__", "step").lstrip("_").replace("_", "-"),
+                        ok=False, detail=f"crashed: {type(exc).__name__}: {exc}")
+        step.duration_s = round(time.perf_counter() - started, 3)
+        self.steps.append(step)
+
+        flag = "ok  " if step.ok else "FAIL"
+        print(f"[{flag}] {step.name} ({step.duration_s:.2f}s)")
+        for line in str(step.detail).splitlines():
+            print(f"        {line}")
+
+        if not step.ok and not self.options.keep_going:
+            self.aborted = True
+            print("        stopping: pass --keep-going to collect every failure")
+
+    # -- steps -----------------------------------------------------------
+
+    def _repo_state(self) -> Step:
+        if not (self.repo_root / ".git").exists():
+            return Step("repo-state", False, f"{self.repo_root} is not a git repository")
+
+        commit = self._git("rev-parse", "HEAD")
+        branch = self._git("rev-parse", "--abbrev-ref", "HEAD")
+        porcelain = self._git("status", "--porcelain")
+        dirty = bool(porcelain)
+        self.git = {"commit": commit, "branch": branch, "dirty": dirty}
+
+        if dirty and not self.options.allow_dirty:
+            preview = "\n".join(porcelain.splitlines()[:20])
+            return Step(
+                "repo-state",
+                False,
+                f"working tree is dirty; commit, stash or pass --allow-dirty:\n{preview}",
+                data=self.git,
+            )
+
+        detail = f"{branch} @ {commit[:12]} dirty={dirty} version={self.version} ({self.version_source})"
+        if dirty:
+            detail += " (accepted via --allow-dirty)"
+        return Step("repo-state", True, detail, data=self.git)
+
+    def _version_consistency(self) -> Step:
+        problems: list[str] = []
+        data: dict = {"version": self.version, "source": self.version_source}
+
+        attr = version_mod.dynamic_version_attr(self.repo_root)
+        data["dynamic_attr"] = attr
+        if attr is None:
+            problems.append(
+                "pyproject.toml no longer declares tool.setuptools.dynamic.version.attr"
+            )
+
+        if (self.repo_root / "pyproject.toml").is_file():
+            resolved = get_version(self.repo_root)
+            data["resolved_version"] = resolved
+            if resolved != self.version:
+                problems.append(
+                    f"src/orisys/__init__.py __version__ is {resolved!r} but the release "
+                    f"version is {self.version!r}"
+                )
+
+        sdk_dirs = version_mod.sdk_versions(self.repo_root)
+        data["sdk_versions"] = sdk_dirs
+        for wheel in version_mod.sdk_wheels(self.repo_root, self.version):
+            found = version_mod.wheel_version(wheel)
+            if found != self.version:
+                problems.append(f"{wheel.name} carries version {found!r}, expected {self.version!r}")
+
+        detail = (
+            f"version={self.version} ({self.version_source}) dynamic_attr={attr}\n"
+            f"SDK/ versions present: {sdk_dirs or 'none'}"
+        )
+        if problems:
+            detail += "\n" + "\n".join(problems)
+        return Step("version-consistency", not problems, detail, data=data)
+
+    def _duplicate_guard(self) -> Step:
+        """Fail only when this version has already been *released*.
+
+        A populated ``SDK/<version>/`` is the normal input to preflight (it is
+        what gets verified), so it is reported, not blocked. What must not happen
+        silently is re-releasing a version that is already out: that is detected
+        offline through git tags and, opt-in, against PyPI.
+        """
+        problems: list[str] = []
+        lines: list[str] = []
+
+        existing = version_mod.sdk_wheels(self.repo_root, self.version)
+        if existing:
+            lines.append(
+                f"SDK/{self.version}/ holds {len(existing)} staged wheel(s) to verify: "
+                f"{[w.name for w in existing]}"
+            )
+        else:
+            lines.append(
+                f"SDK/{self.version}/ is empty; nothing is staged yet "
+                "(build with `python build/run.py wheel-win` / `manylinux`)"
+            )
+
+        tags = version_mod.git_tags(self.repo_root)
+        tag_hits = version_mod.released_tags_for(self.version, tags)
+        if tag_hits:
+            message = f"git tag(s) {tag_hits} already mark {self.version} as released"
+            if self.options.force:
+                lines.append(message + " (accepted via --force)")
+            else:
+                problems.append(
+                    message + "; pass --force to re-verify or intentionally re-release"
+                )
+        else:
+            lines.append(
+                f"no local git tag marks {self.version} as released "
+                f"({len(tags)} tag(s) checked in this repo and {version_mod.RELEASE_REPO_DIRNAME})"
+            )
+
+        if self.options.check_pypi:
+            versions, error = version_mod.pypi_released_versions()
+            if error:
+                problems.append(f"PyPI lookup failed: {error}")
+            elif versions is None:
+                problems.append("PyPI lookup returned no version list")
+            elif self.version in versions:
+                problems.append(
+                    f"orisys {self.version} is already published on PyPI; a PyPI upload "
+                    "cannot be undone. Published: " + ", ".join(versions)
+                )
+            else:
+                lines.append(
+                    f"PyPI has no {self.version}; published: " + (", ".join(versions) or "none")
+                )
+        else:
+            lines.append("PyPI existence check skipped (pass --check-pypi to enable)")
+
+        detail = "\n".join(lines)
+        if problems:
+            detail += "\n" + "\n".join(problems)
+        return Step("duplicate-guard", not problems, detail)
+
+    def _version_strings(self) -> Step:
+        """Keep the version out of prose: one source, everything else derived.
+
+        Scans tracked text for version-looking literals that disagree with the
+        release version. Dependency constraints are ignored by design; deliberate
+        exceptions live in ``version.VERSION_STRING_ALLOWLIST``.
+        """
+        findings = version_mod.find_version_literals(self.repo_root, self.version)
+        if not findings:
+            scanned = len(version_mod.tracked_text_files(self.repo_root))
+            return Step(
+                "version-strings",
+                True,
+                f"no stale version literal in {scanned} scanned file(s); "
+                f"version {self.version} lives only where it is derived from",
+            )
+
+        by_file: dict[str, list[str]] = {}
+        for path, lineno, literal in findings:
+            by_file.setdefault(path, []).append(f"{path}:{lineno} -> {literal}")
+        detail = (
+            f"{len(findings)} version literal(s) disagree with {self.version}. "
+            "Update them, or make the file version-agnostic, or add a documented "
+            "entry to build/release/version.py::VERSION_STRING_ALLOWLIST:\n"
+            + "\n".join(line for lines in by_file.values() for line in lines)
+        )
+        return Step("version-strings", False, detail, data={"count": len(findings)})
+
+    def _tests(self) -> Step:
+        if self.options.skip_tests:
+            return Step(
+                "tests",
+                True,
+                "WARNING: test gate SKIPPED via --skip-tests; this run cannot certify a release",
+                data={"status": "skipped"},
+            )
+
+        marker = "not hardware" if self.options.longrun else "not slow and not hardware"
+        self.report_dir.mkdir(parents=True, exist_ok=True)
+        junit = self.report_dir / "junit.xml"
+        command = [
+            sys.executable,
+            "-m",
+            "pytest",
+            "-q",
+            "-m",
+            marker,
+            f"--junitxml={junit}",
+        ]
+        try:
+            completed = subprocess.run(
+                command, cwd=self.repo_root, capture_output=True, text=True, check=False
+            )
+        except FileNotFoundError as exc:
+            return Step("tests", False, f"cannot run pytest: {exc}")
+
+        ok = completed.returncode == 0
+        tail = ((completed.stdout or "") + (completed.stderr or "")).strip().splitlines()[-12:]
+        detail = f"pytest -m {marker!r} in {sys.executable}\nexit code {completed.returncode}"
+        if tail:
+            detail += "\n" + "\n".join(tail)
+        return Step("tests", ok, detail, data={"marker": marker, "junit": str(junit)})
+
+    def _bundle_precheck(self) -> Step:
+        if not (self.repo_root / "pyproject.toml").is_file():
+            return Step("bundle-precheck", False, "pyproject.toml not found")
+
+        items = bundle_items(self.repo_root)
+        problems: list[str] = []
+        counts: dict[str, int] = {}
+        for item in items:
+            files = resolve_bundle_source_files(self.repo_root, item)
+            counts[str(item.get("name"))] = len(files)
+            if not files:
+                problems.append(
+                    f"bundle item {item.get('name')!r} resolved 0 files; its patterns match nothing"
+                )
+
+        try:
+            verify_required_assets(self.repo_root, items)
+        except FileNotFoundError as exc:
+            problems.append(str(exc))
+
+        detail = "resolved files per bundle item: " + json.dumps(counts)
+        if problems:
+            detail += "\n" + "\n".join(problems)
+        return Step("bundle-precheck", not problems, detail, data={"counts": counts})
+
+    def _discover_wheels(self) -> str | None:
+        """Populate self.wheels; return an error message when nothing was found."""
+        directory = (
+            Path(self.options.wheel_dir)
+            if self.options.wheel_dir
+            else self.repo_root / "SDK" / self.version
+        )
+        self.wheel_dir = directory
+        if not directory.is_dir():
+            return (
+                f"{directory} does not exist. Build first "
+                "(`python build/run.py wheel`) or pass --wheel-dir."
+            )
+
+        self.wheels = sorted(directory.glob("*.whl"))
+        if not self.wheels:
+            return f"no *.whl found in {directory}. Build first or pass --wheel-dir."
+        return None
+
+    def _wheel_inspection(self) -> Step:
+        problem = self._discover_wheels()
+        if problem:
+            return Step("wheel-inspection", False, problem)
+
+        problems: list[str] = []
+        blocks: list[str] = []
+        for wheel in self.wheels:
+            result = inspect_wheel(
+                wheel,
+                expected_version=self.version,
+                repo_root=self.repo_root,
+                strict_bundle=True,
+            )
+            blocks.append(result.render())
+            if not result.ok:
+                problems.append(
+                    f"{wheel.name}: " + ", ".join(check.name for check in result.failures)
+                )
+
+        detail = f"{len(self.wheels)} wheel(s) in {self.wheel_dir}\n" + "\n".join(blocks)
+        if problems:
+            detail += "\nfailed checks:\n" + "\n".join(problems)
+        return Step("wheel-inspection", not problems, detail, data={"count": len(self.wheels)})
+
+    def _platform_token(self) -> str:
+        return "win_amd64" if sys.platform == "win32" else "manylinux"
+
+    def _runtime_targets(self) -> list[tuple[str, Path, Path | None]]:
+        token = self._platform_token()
+        if self.options.all_wheel_pythons:
+            targets: list[tuple[str, Path, Path | None]] = []
+            for tag in ("cp310", "cp311", "cp312"):
+                match = next(
+                    (w for w in self.wheels if f"-{tag}-" in w.name and token in w.name), None
+                )
+                if match is None:
+                    raise RuntimeError(
+                        f"no {tag} {token} wheel among {[w.name for w in self.wheels]}"
+                    )
+                executable = version_mod.python_for_tag(tag)
+                if executable is None:
+                    raise RuntimeError(
+                        f"cannot resolve an interpreter for {tag}; create the conda env "
+                        f"py{tag[2:]} or set CONDA_ENVS_ROOT"
+                    )
+                targets.append((tag, match, executable))
+            return targets
+
+        tag = f"cp{sys.version_info.major}{sys.version_info.minor}"
+        match = next((w for w in self.wheels if f"-{tag}-" in w.name and token in w.name), None)
+        if match is None:
+            raise RuntimeError(
+                f"no {tag} {token} wheel among {[w.name for w in self.wheels]}; pass "
+                "--all-wheel-pythons to verify every ABI in its own environment, or run from "
+                "a matching interpreter"
+            )
+        return [(tag, match, None)]
+
+    def _wheel_runtime(self) -> Step:
+        if self.options.no_runtime:
+            return Step(
+                "wheel-runtime",
+                True,
+                "WARNING: runtime verification SKIPPED via --no-runtime",
+                data={"status": "skipped"},
+            )
+
+        video = self.options.video or default_verification_video(self.repo_root)
+        if video is None:
+            return Step(
+                "wheel-runtime",
+                False,
+                "no verification clip found. Pass --video, set ORISYS_VERIFY_VIDEO, or commit a "
+                "clip under data/sample/. The runtime check is never silently skipped.",
+            )
+        video = Path(video)
+        if not video.is_file():
+            return Step("wheel-runtime", False, f"verification clip not found: {video}")
+
+        try:
+            targets = self._runtime_targets()
+        except RuntimeError as exc:
+            return Step("wheel-runtime", False, str(exc))
+
+        problems: list[str] = []
+        lines: list[str] = [f"clip: {video}", f"config: {self.options.config_name}"]
+        for tag, wheel, executable in targets:
+            label = f"{tag} {wheel.name}"
+            try:
+                # One venv per wheel: it runs the import smoke test, the bundled
+                # asset check and the frame pipeline together.
+                record = verify_wheel(
+                    wheel,
+                    video=video,
+                    config_name=self.options.config_name,
+                    frames=self.options.frames,
+                    python_executable=executable,
+                    offline=self.options.offline,
+                    check_assets=not self.options.no_assets,
+                )
+            except subprocess.CalledProcessError as exc:
+                problems.append(f"{label}: command failed ({exc})")
+                continue
+            except Exception as exc:
+                problems.append(f"{label}: {type(exc).__name__}: {exc}")
+                continue
+
+            lines.append(
+                f"{label}: {record['assets']} | frames={record['frames']} "
+                f"flow={record['flow_shape']}"
+            )
+            self.runtime_records.append({"tag": tag, **record})
+
+        detail = "\n".join(lines)
+        if problems:
+            detail += "\nfailures:\n" + "\n".join(problems)
+        return Step("wheel-runtime", not problems, detail, data={"records": self.runtime_records})
+
+    # -- driver ----------------------------------------------------------
+
+    def run(self) -> int:
+        started_at = _now()
+        started = time.perf_counter()
+        print(f"=== orisys release preflight: version {self.version} ({self.version_source}) ===")
+        print(f"repo: {self.repo_root}")
+        print(f"report: {self.report_dir}")
+        print()
+
+        try:
+            for step_fn in (
+                self._repo_state,
+                self._version_consistency,
+                self._version_strings,
+                self._duplicate_guard,
+                self._tests,
+                self._bundle_precheck,
+                self._wheel_inspection,
+                self._wheel_runtime,
+            ):
+                self._execute(step_fn)
+                if self.aborted:
+                    break
+        finally:
+            self.ok = bool(self.steps) and all(step.ok for step in self.steps) and not self.aborted
+            duration = round(time.perf_counter() - started, 3)
+            payload = {
+                "version": self.version,
+                "version_source": self.version_source,
+                "ok": self.ok,
+                "aborted": self.aborted,
+                "started_at": started_at,
+                "finished_at": _now(),
+                "duration_s": duration,
+                "git": self.git,
+                "interpreter": {
+                    "executable": sys.executable,
+                    "version": platform.python_version(),
+                    "platform": sys.platform,
+                },
+                "options": {key: value for key, value in asdict(self.options).items()
+                            if not isinstance(value, Path)},
+                "steps": [asdict(step) for step in self.steps],
+                "wheels": [
+                    {
+                        "name": wheel.name,
+                        "size": wheel.stat().st_size,
+                        "sha256": _sha256_file(wheel),
+                    }
+                    for wheel in self.wheels
+                ],
+            }
+            payload["options"]["wheel_dir"] = str(self.options.wheel_dir) if self.options.wheel_dir else None
+            payload["options"]["video"] = str(self.options.video) if self.options.video else None
+
+            json_path, text_path = report_mod.write_report(payload, self.report_dir)
+            print()
+            print(f"report: {json_path}")
+            print(f"report: {text_path}")
+
+        print()
+        print(f"=== preflight {'PASSED' if self.ok else 'FAILED'} ({duration}s) ===")
+        return 0 if self.ok else 1
+
+
+def run_preflight(options: PreflightOptions, repo_root: Path | None = None) -> int:
+    return Preflight(options, repo_root=repo_root).run()

build/release/publish.py

@@ -0,0 +1,158 @@
+"""Shared publish gate: certify a release from its preflight report.
+
+Both publish commands (``release github`` and ``release pypi``) refuse to act
+unless a passing ``release preflight`` report exists for the exact version and
+every wheel still hashes to what that report recorded. The report is the contract
+between "we verified this" and "we shipped this"; re-deriving the checks here
+would just be a second, weaker opinion.
+"""
+
+from __future__ import annotations
+
+import hashlib
+import json
+from dataclasses import dataclass, field
+from pathlib import Path
+
+# Options that weaken the gate. A release must not be certified by a run that
+# waived any of them: re-run preflight on a clean commit instead.
+WAIVED_GUARD_KEYS = ("skip_tests", "allow_dirty", "force", "no_runtime", "no_assets")
+
+
+class PublishGateError(RuntimeError):
+    """The preflight report does not certify these wheels."""
+
+
+@dataclass
+class WheelRecord:
+    name: str
+    sha256: str
+    size: int = 0
+
+
+@dataclass
+class GateResult:
+    version: str
+    git_commit: str | None
+    report_path: Path
+    wheels: list[WheelRecord] = field(default_factory=list)
+    warnings: list[str] = field(default_factory=list)
+
+
+def sha256_file(path: Path) -> str:
+    digest = hashlib.sha256()
+    with Path(path).open("rb") as handle:
+        for chunk in iter(lambda: handle.read(1024 * 1024), b""):
+            digest.update(chunk)
+    return digest.hexdigest()
+
+
+def evaluate_gate(
+    payload: dict,
+    version: str,
+    wheels: dict[str, Path],
+    *,
+    head_commit: str | None = None,
+) -> tuple[list[str], list[str]]:
+    """Return ``(problems, warnings)`` for a report payload and the wheels on disk.
+
+    Pure function: no I/O beyond hashing the wheels, so it is cheap to test.
+    """
+    problems: list[str] = []
+    warnings: list[str] = []
+
+    if str(payload.get("version")) != version:
+        problems.append(
+            f"report is for version {payload.get('version')!r}, not {version!r}"
+        )
+    if not payload.get("ok"):
+        problems.append(
+            "report result is FAIL - run `release preflight --keep-going` and fix "
+            "everything before publishing"
+        )
+    if payload.get("aborted"):
+        problems.append("report stopped early (aborted); it certifies nothing")
+
+    options = payload.get("options") or {}
+    waived = sorted(key for key in WAIVED_GUARD_KEYS if options.get(key))
+    if waived:
+        problems.append(
+            "report waived gate options "
+            + ", ".join(f"--{key.replace('_', '-')}" for key in waived)
+            + "; commit the tree and re-run `release preflight` without them"
+        )
+
+    recorded = {item.get("name"): item.get("sha256") for item in payload.get("wheels") or []}
+    if not recorded:
+        problems.append("report lists no wheels")
+
+    missing = sorted(set(recorded) - set(wheels))
+    if missing:
+        problems.append(f"wheels in the report are missing from disk: {missing}")
+    extra = sorted(set(wheels) - set(recorded))
+    if extra:
+        problems.append(f"wheels on disk are not covered by the report: {extra}")
+
+    for name in sorted(set(recorded) & set(wheels)):
+        actual = sha256_file(wheels[name])
+        if actual != recorded[name]:
+            problems.append(
+                f"{name} changed after preflight: report {recorded[name][:12]}, "
+                f"disk {actual[:12]} - rebuild and re-run preflight"
+            )
+
+    commit = payload.get("git", {}).get("commit") if isinstance(payload.get("git"), dict) else None
+    if head_commit and commit and commit != head_commit:
+        warnings.append(
+            f"report certifies commit {commit[:12]} but HEAD is {head_commit[:12]}; "
+            "the wheels are unchanged, so this is usually just a later commit"
+        )
+    return problems, warnings
+
+
+def load_gate(repo_root: Path, version: str) -> GateResult:
+    """Load and enforce the preflight report for ``version``.
+
+    Raises :class:`PublishGateError` with every problem found, so one run reports
+    all of them instead of stopping at the first.
+    """
+    repo_root = Path(repo_root)
+    report_path = repo_root / "build" / "release" / "reports" / version / "preflight.json"
+    if not report_path.is_file():
+        raise PublishGateError(
+            f"no preflight report at {report_path}. Run:\n"
+            f"  python build/run.py release preflight\n"
+            f"(the publish commands only ship what preflight certified)"
+        )
+
+    try:
+        payload = json.loads(report_path.read_text(encoding="utf-8"))
+    except (OSError, json.JSONDecodeError) as exc:
+        raise PublishGateError(f"cannot read {report_path}: {exc}") from exc
+
+    wheel_dir = repo_root / "SDK" / version
+    wheels = {path.name: path for path in sorted(wheel_dir.glob("*.whl"))}
+    if not wheels:
+        raise PublishGateError(
+            f"no wheels in {wheel_dir}; build first (`python build/run.py wheel-win` / "
+            "`manylinux`) and re-run preflight"
+        )
+
+    problems, warnings = evaluate_gate(payload, version, wheels)
+    if problems:
+        raise PublishGateError(
+            f"the preflight report at {report_path} does not certify orisys {version}:\n  "
+            + "\n  ".join(problems)
+        )
+
+    git_payload = payload.get("git") if isinstance(payload.get("git"), dict) else {}
+    return GateResult(
+        version=version,
+        git_commit=git_payload.get("commit"),
+        report_path=report_path,
+        wheels=[
+            WheelRecord(name=name, sha256=sha256_file(path), size=path.stat().st_size)
+            for name, path in wheels.items()
+        ],
+        warnings=warnings,
+    )

build/release/pypi.py

@@ -0,0 +1,458 @@
+"""Upload the certified wheels to TestPyPI, then (on confirmation) to PyPI.
+
+``python build/run.py release pypi`` runs:
+
+1. certified-wheels gate (same contract as ``release github``)
+2. ``twine check`` on every wheel - the wheel metadata is generated, so its
+   long description and classifiers are worth validating before an upload that
+   cannot be undone
+3. refuse if the version already exists on the target index (read-only probe)
+4. upload to TestPyPI, then verify by fetching it back from the index
+5. stop there unless ``--confirm-pypi`` is given; then repeat 3-4 against PyPI
+
+PyPI uploads are permanent: a version number can never be reused, and a bad
+artifact cannot be replaced. Hence the TestPyPI stage, the read-only existence
+probe, and ``--apply`` being required even to reach TestPyPI.
+"""
+
+from __future__ import annotations
+
+import json
+import shutil
+import subprocess
+import sys
+import tempfile
+import time
+import urllib.error
+import urllib.request
+from dataclasses import dataclass, field
+from pathlib import Path
+
+_BUILD_ROOT = Path(__file__).resolve().parents[1]
+if str(_BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(_BUILD_ROOT))
+
+from common.paths import REPO_ROOT  # noqa: E402
+from release import auth  # noqa: E402
+from release.publish import GateResult, PublishGateError, load_gate  # noqa: E402
+
+INDEX_JSON = {name: str(meta["json_url"]) for name, meta in auth.INDEXES.items()}
+INDEX_SIMPLE = {name: str(meta["simple_url"]) for name, meta in auth.INDEXES.items()}
+
+
+@dataclass
+class Options:
+    version: str
+    apply: bool = False
+    confirm_pypi: bool = False
+    verify_install: bool = True
+    skip_check: bool = False
+    # Upload straight to PyPI, skipping the TestPyPI rehearsal. Needed when you
+    # only hold a production token, since the two indexes reject each other's.
+    pypi_only: bool = False
+    # Offer to enter a missing token now instead of just failing.
+    prompt_credentials: bool = False
+    # Token supplied non-interactively (e.g. --token-stdin), used once.
+    token: str | None = None
+
+
+def upload_phases(options: Options) -> list[str]:
+    """The indexes to upload to, in order."""
+    if options.pypi_only:
+        return ["pypi"]
+    return ["testpypi", "pypi"] if options.confirm_pypi else ["testpypi"]
+
+
+@dataclass
+class IndexState:
+    versions: list[str] = field(default_factory=list)
+    error: str | None = None
+
+    @property
+    def known(self) -> bool:
+        return self.error is None
+
+
+def twine_check_argv(wheels: list[Path]) -> list[str]:
+    return [sys.executable, "-m", "twine", "check", *[str(w) for w in wheels]]
+
+
+def twine_upload_argv(wheels: list[Path], repository: str | None) -> list[str]:
+    argv = [sys.executable, "-m", "twine", "upload"]
+    if repository:
+        argv += ["--repository", repository]
+    argv += [str(wheel) for wheel in wheels]
+    return argv
+
+
+def credentials_hint(index: str) -> str | None:
+    """Guidance when ``index`` has no usable credentials, else ``None``.
+
+    More than "does the file exist": a placeholder or the wrong ``username`` is
+    treated as missing, because twine would only find out at upload time.
+    """
+    state = auth.credential_state(index)
+    if state.configured:
+        return None
+    lines = [f"no usable credentials for [{index}]: {state.problem}"]
+    lines.append(f"  set it up with: python build/run.py release auth --set-token {index}")
+    if index == "testpypi":
+        lines.append(
+            "  (TestPyPI needs its own account and token; if you only hold a "
+            "production token, use --pypi-only to skip the rehearsal)"
+        )
+    lines.append(
+        "  or set TWINE_USERNAME=__token__ and TWINE_PASSWORD for this session only"
+    )
+    return "\n".join(lines)
+
+
+def _ensure_credentials(
+    indexes: list[str], options: Options, *, interactive: bool | None = None
+) -> bool:
+    """Make sure every index that will be uploaded to has credentials.
+
+    Prompts for a missing token when there is a terminal to prompt on; a piped or
+    CI run fails fast instead of hanging on a hidden-input prompt.
+    """
+    missing = [index for index in indexes if not auth.credential_state(index).configured]
+    if not missing:
+        for index in indexes:
+            state = auth.credential_state(index)
+            print(f"[ok  ] credentials for [{index}] ({state.source})")
+        return True
+
+    if interactive is None:
+        interactive = sys.stdin.isatty()
+    allow_prompt = options.prompt_credentials or (interactive and options.apply)
+
+    if not allow_prompt:
+        for index in missing:
+            print(f"[{'FAIL' if options.apply else 'warn'}] {credentials_hint(index)}")
+        if not options.apply:
+            print(
+                "[info] dry run continues so you can review the plan; "
+                "--apply would stop here until the credentials exist"
+            )
+            return True
+        if not interactive:
+            print(
+                "[info] stdin is not a terminal, so nothing was prompted; run "
+                "`release auth --set-token <index>` or pass --prompt-credentials"
+            )
+        return False
+
+    for index in missing:
+        print(f"[warn] {credentials_hint(index)}")
+        token = options.token or auth.prompt_for_token(index)
+        if not token:
+            print(f"[FAIL] no token entered for [{index}]")
+            return False
+        for problem in auth.validate_token(token):
+            print(f"[FAIL] {problem.removeprefix('ERROR ')}")
+            return False
+        for warning in auth.token_warnings(token):
+            print(f"[warn] {warning.removeprefix('WARN ')}")
+        path = auth.write_token(index, token)
+        print(f"[ok  ] wrote [{index}] credentials to {path}")
+        options.token = None  # only the first index may consume a piped token
+    return True
+
+
+def index_state(index: str, *, timeout: float = 20.0) -> IndexState:
+    """Read the published versions of orisys from an index (read-only)."""
+    url = INDEX_JSON[index]
+    request = urllib.request.Request(
+        url, headers={"User-Agent": "orisys-release-publish", "Accept": "application/json"}
+    )
+    try:
+        with urllib.request.urlopen(request, timeout=timeout) as response:
+            payload = json.load(response)
+    except urllib.error.HTTPError as exc:
+        if exc.code == 404:
+            return IndexState(versions=[])
+        return IndexState(error=f"{index} returned HTTP {exc.code}")
+    except Exception as exc:  # network, DNS, TLS, JSON
+        return IndexState(error=f"{index} lookup failed: {type(exc).__name__}: {exc}")
+
+    releases = payload.get("releases")
+    if not isinstance(releases, dict):
+        return IndexState(error=f"unexpected {index} response (no 'releases' mapping)")
+    return IndexState(
+        versions=sorted(name for name, files in releases.items() if files)
+    )
+
+
+def index_files(
+    index: str, version: str, *, timeout: float = 20.0
+) -> tuple[list[str] | None, str | None]:
+    """Filenames published for ``version``, as ``(filenames, error)``.
+
+    ``(None, None)``   - the index does not serve this version (yet)
+    ``(None, "why")``  - the lookup itself failed, which is NOT evidence of absence
+    ``([...], None)``  - the version is published with those files
+
+    Keeping those apart matters: reporting a network hiccup as "not published
+    yet" is how a successful upload gets mistaken for a failure.
+    """
+    url = INDEX_JSON[index]
+    request = urllib.request.Request(
+        url, headers={"User-Agent": "orisys-release-publish", "Accept": "application/json"}
+    )
+    try:
+        with urllib.request.urlopen(request, timeout=timeout) as response:
+            payload = json.load(response)
+    except urllib.error.HTTPError as exc:
+        if exc.code == 404:
+            return None, None
+        return None, f"{index} returned HTTP {exc.code}"
+    except Exception as exc:
+        return None, f"{index} lookup failed: {type(exc).__name__}: {exc}"
+
+    files = (payload.get("releases") or {}).get(version)
+    if not isinstance(files, list) or not files:
+        return None, None
+    return sorted(str(item.get("filename", "")) for item in files), None
+
+
+def wait_for_release(
+    index: str,
+    version: str,
+    *,
+    attempts: int = 6,
+    delay: float = 5.0,
+    sleep=None,
+    timeout: float = 20.0,
+) -> tuple[list[str] | None, str | None]:
+    """Poll until the index serves ``version`` (uploads are not instantly visible).
+
+    TestPyPI in particular lags the upload response by seconds. Returns the last
+    ``(filenames, error)`` observed.
+    """
+    sleep = sleep or time.sleep
+    last_error: str | None = None
+    for attempt in range(1, max(1, attempts) + 1):
+        filenames, error = index_files(index, version, timeout=timeout)
+        if filenames is not None:
+            return filenames, None
+        last_error = error
+        if attempt < attempts:
+            print(
+                f"[info] {index} does not serve {version} yet "
+                f"({'lookup failed' if error else 'indexing'}), retry {attempt}/{attempts - 1}",
+                flush=True,
+            )
+            sleep(delay)
+    return None, last_error
+
+
+def existing_release_state(index: str, version: str, expected: set[str]) -> str:
+    """``"satisfied"`` | ``"conflict"`` | ``"absent"`` for this index and version.
+
+    An index version can never be replaced, so "already published with exactly
+    these files" is the only successful terminal state; treating it as an error
+    would make a re-run after a partial failure look like a new failure. A
+    different file set is a genuine conflict and must stop the run.
+    """
+    published, error = index_files(index, version)
+    if published is None:
+        if error:
+            print(f"[warn] could not check {index} for an existing release: {error}")
+        return "absent"
+    if set(published) == expected:
+        print(
+            f"[ok  ] {index} already serves orisys {version} with all "
+            f"{len(published)} file(s)"
+        )
+        return "satisfied"
+    extra = sorted(set(published) - expected)
+    missing = sorted(expected - set(published))
+    print(
+        f"[FAIL] {index} already serves orisys {version} with a different file set"
+        + (f"; unexpected: {extra}" if extra else "")
+        + (f"; missing: {missing}" if missing else "")
+    )
+    return "conflict"
+
+
+def _upload(wheels: list[Path], repository: str | None) -> int:
+    argv = twine_upload_argv(wheels, repository)
+    print(f"[run ] {' '.join(str(part) for part in argv)}")
+    completed = subprocess.run(argv, check=False)
+    return completed.returncode
+
+
+def _fetch_back(index: str, version: str, wheel: Path) -> int:
+    """Download the freshly uploaded wheel back out of the index."""
+    with tempfile.TemporaryDirectory(prefix="orisys-fetch-") as tmp:
+        target = Path(tmp) / "out"
+        argv = [
+            sys.executable,
+            "-m",
+            "pip",
+            "download",
+            "--no-deps",
+            "--no-cache-dir",
+            "--index-url",
+            INDEX_SIMPLE[index],
+            "--dest",
+            str(target),
+            f"orisys=={version}",
+        ]
+        if index == "testpypi":
+            # TestPyPI mirrors only what was uploaded there; deps live on PyPI.
+            # --no-deps keeps this a pure "is the artifact fetchable" probe.
+            argv += ["--extra-index-url", INDEX_SIMPLE["pypi"]]
+        print(f"[run ] {' '.join(argv)}")
+        completed = subprocess.run(argv, check=False)
+        if completed.returncode != 0:
+            return completed.returncode
+
+        fetched = sorted(target.glob(f"orisys-{version}*"))
+        if not fetched:
+            print(f"[FAIL] pip download produced nothing for orisys=={version}")
+            return 1
+        print(f"[ok  ] fetched {[p.name for p in fetched]} from {index}")
+        if wheel.name not in {path.name for path in fetched}:
+            print(
+                f"[warn] {wheel.name} was not the file fetched "
+                "(the index may serve a different platform first)"
+            )
+        return 0
+
+
+def publish(options: Options) -> int:
+    version = options.version
+    mode = "APPLY" if options.apply else "DRY RUN"
+    print(f"=== release pypi: orisys {version} ({mode}) ===")
+
+    # --- 1. gate -------------------------------------------------------
+    try:
+        gate: GateResult = load_gate(REPO_ROOT, version)
+    except PublishGateError as exc:
+        print(f"[FAIL] {exc}")
+        return 1
+    print(f"[ok  ] preflight report: {gate.report_path}")
+    for wheel in gate.wheels:
+        print(f"       [ok] {wheel.name} sha256={wheel.sha256[:12]}")
+    for warning in gate.warnings:
+        print(f"[warn] {warning}")
+
+    wheels = [REPO_ROOT / "SDK" / version / record.name for record in gate.wheels]
+    missing = [str(wheel) for wheel in wheels if not wheel.is_file()]
+    if missing:
+        print(f"[FAIL] wheels missing from disk: {missing}")
+        return 1
+
+    # --- 2. credentials + twine check (before anything irreversible) ----
+    phases = upload_phases(options)
+    if options.pypi_only:
+        print(
+            "[warn] --pypi-only: uploading straight to PyPI with no TestPyPI "
+            "rehearsal. An index version can never be reused or replaced."
+        )
+    if not _ensure_credentials(phases, options):
+        return 1
+
+    if not options.skip_check:
+        argv = twine_check_argv(wheels)
+        print(f"[run ] {' '.join(str(part) for part in argv)}")
+        completed = subprocess.run(argv, check=False)
+        if completed.returncode != 0:
+            print("[FAIL] twine check reported problems; fix the wheel metadata first")
+            return 1
+        print("[ok  ] twine check passed")
+
+    # --- 3. phase plan -------------------------------------------------
+    expected = {wheel.name for wheel in wheels}
+    remaining: list[str] = []
+    for index in phases:
+        state = existing_release_state(index, version, expected)
+        if state == "conflict":
+            return 1
+        if state == "absent":
+            remaining.append(index)
+    phases = remaining
+
+    print()
+    for index in phases:
+        state = index_state(index)
+        if not state.known:
+            print(f"[FAIL] {state.error}; cannot safely check for duplicate uploads")
+            return 1
+        if version in state.versions:
+            print(
+                f"[FAIL] orisys {version} already exists on {index} "
+                f"(published: {', '.join(state.versions) or 'none'}) - "
+                "an index version cannot be reused"
+            )
+            return 1
+        print(f"[ok  ] {index}: {version} not present (published: {', '.join(state.versions) or 'none'})")
+
+    if not phases:
+        print()
+        print("=== release pypi: every requested index already has this release ===")
+        return 0
+
+    print()
+    for index in phases:
+        print(f"[plan] upload {len(wheels)} wheel(s) to {index}")
+    if phases == ["testpypi"]:
+        print(
+            "[plan] stop after TestPyPI. Re-run with "
+            "`--confirm-pypi --apply` to publish to the real PyPI."
+        )
+    print()
+
+    if not options.apply:
+        print("dry run: nothing was uploaded. Re-run with --apply to execute.")
+        return 0
+
+    # --- 4. upload ----------------------------------------------------
+    for index in phases:
+        if _upload(wheels, index) != 0:
+            print(f"[FAIL] twine upload to {index} failed")
+            return 1
+        print(f"[ok  ] uploaded to {index}")
+
+        published, error = wait_for_release(index, version)
+        if published is None:
+            # The upload itself succeeded, so this is a confirmation problem, not
+            # a publishing failure. Say so plainly and do not imply data loss.
+            reason = f"lookup kept failing ({error})" if error else "the index has not indexed it yet"
+            print(
+                f"[warn] uploaded, but could not confirm it on {index} yet: {reason}.\n"
+                f"       check https://{'test.' if index == 'testpypi' else ''}pypi.org/project/orisys/{version}/"
+                "\n       re-running this command is safe: an already-published version is skipped"
+            )
+            print(f"\n=== release pypi: {index} upload SUCCEEDED (verification inconclusive) ===")
+            return 0
+        if set(published) != expected:
+            print(
+                f"[FAIL] {index} file set mismatch:\n  expected {sorted(expected)}\n"
+                f"  got      {sorted(published)}"
+            )
+            return 1
+        print(f"[ok  ] {index} serves all {len(published)} file(s) for {version}")
+
+        if options.verify_install:
+            if _fetch_back(index, version, wheels[0]) != 0:
+                print(
+                    f"[warn] {index} artifact is not fetchable yet; the upload is "
+                    "published, so this is a propagation delay rather than a failure"
+                )
+            else:
+                print(f"[ok  ] fetched the published artifact back from {index}")
+
+    if phases == ["testpypi"]:
+        print()
+        print("=== release pypi: TestPyPI stage PASSED; PyPI untouched ===")
+        print("next: python build/run.py release pypi --confirm-pypi --apply")
+        return 0
+
+    print()
+    if options.pypi_only:
+        print(f"=== release pypi PASSED (PyPI only, no TestPyPI rehearsal) ===")
+    else:
+        print("=== release pypi PASSED (TestPyPI + PyPI) ===")
+    return 0

build/release/report.py

@@ -0,0 +1,71 @@
+"""Structured preflight reports.
+
+A preflight run writes both a machine-readable ``preflight.json`` (the contract a
+future publish step will consume and re-verify) and a human ``preflight.txt``.
+"""
+
+from __future__ import annotations
+
+import json
+from pathlib import Path
+
+REPORTS_RELPATH = Path("build") / "release" / "reports"
+SCHEMA_VERSION = 1
+
+
+def reports_root(repo_root: Path, override: Path | None = None) -> Path:
+    return Path(override) if override else Path(repo_root) / REPORTS_RELPATH
+
+
+def render_text(payload: dict) -> str:
+    git = payload.get("git") or {}
+    interpreter = payload.get("interpreter") or {}
+    lines = [
+        f"orisys release preflight :: version {payload.get('version')}",
+        f"  result:      {'PASS' if payload.get('ok') else 'FAIL'}",
+        f"  git:         {git.get('branch')} @ {git.get('commit')} (dirty={git.get('dirty')})",
+        f"  interpreter: {interpreter.get('version')} at {interpreter.get('executable')}",
+        f"  duration:    {payload.get('duration_s')}s",
+        "",
+    ]
+
+    for step in payload.get("steps", []):
+        flag = "ok  " if step.get("ok") else "FAIL"
+        lines.append(f"[{flag}] {step.get('name')} ({step.get('duration_s')}s)")
+        for detail_line in str(step.get("detail") or "").splitlines():
+            lines.append(f"        {detail_line}")
+        lines.append("")
+
+    wheels = payload.get("wheels") or []
+    if wheels:
+        lines.append("wheels:")
+        for wheel in wheels:
+            lines.append(
+                f"  {wheel.get('name')}  {wheel.get('size')} bytes  sha256={wheel.get('sha256')}"
+            )
+        lines.append("")
+
+    options = payload.get("options") or {}
+    waived = [
+        key
+        for key, value in options.items()
+        if value and key in {"skip_tests", "allow_dirty", "force", "no_runtime", "no_assets"}
+    ]
+    if waived:
+        lines.append(f"waived guards: {', '.join(sorted(waived))}")
+        lines.append("")
+
+    return "\n".join(lines).rstrip() + "\n"
+
+
+def write_report(payload: dict, out_dir: Path) -> tuple[Path, Path]:
+    out_dir = Path(out_dir)
+    out_dir.mkdir(parents=True, exist_ok=True)
+
+    payload = {**payload, "schema": SCHEMA_VERSION}
+    json_path = out_dir / "preflight.json"
+    text_path = out_dir / "preflight.txt"
+
+    json_path.write_text(json.dumps(payload, indent=2, sort_keys=False), encoding="utf-8")
+    text_path.write_text(render_text(payload), encoding="utf-8")
+    return json_path, text_path

build/release/version.py

@@ -0,0 +1,272 @@
+"""Version consistency and duplicate-release guards for the release gate."""
+
+from __future__ import annotations
+
+import json
+import os
+import re
+import subprocess
+import urllib.error
+import urllib.request
+from pathlib import Path
+
+PYPI_JSON_URL = "https://pypi.org/pypi/orisys/json"
+
+# Sibling repository that carries the public GitHub releases and their tags.
+RELEASE_REPO_DIRNAME = "orisys-sdk-release"
+
+# orisys-<version>-<pytag>-<abitag>-<platformtag>.whl
+_WHEEL_NAME_RE = re.compile(r"^orisys-(?P<version>[^-]+)-[^-]+-[^-]+-.+\.whl$")
+
+
+def wheel_version(wheel_path: Path) -> str | None:
+    match = _WHEEL_NAME_RE.match(Path(wheel_path).name)
+    return match.group("version") if match else None
+
+
+def sdk_versions(repo_root: Path) -> list[str]:
+    """Version directory names present under ``SDK/``, in ascending order.
+
+    Only digit-leading names count as versions, so stray directories (``tmp``,
+    ``latest``) never appear as releases.
+    """
+    sdk_root = Path(repo_root) / "SDK"
+    if not sdk_root.is_dir():
+        return []
+
+    return sorted(
+        (
+            entry.name
+            for entry in sdk_root.iterdir()
+            if entry.is_dir() and entry.name[:1].isdigit()
+        ),
+        key=_version_sort_key,
+    )
+
+
+def sdk_wheels(repo_root: Path, version: str) -> list[Path]:
+    """Wheels already published into ``SDK/<version>/``."""
+    version_dir = Path(repo_root) / "SDK" / version
+    if not version_dir.is_dir():
+        return []
+    return sorted(version_dir.glob("*.whl"))
+
+
+def dynamic_version_attr(repo_root: Path) -> str | None:
+    """Return pyproject's configured dynamic version attr (e.g. orisys.__version__)."""
+    from common.pyproject_utils import load_pyproject
+
+    config = (
+        load_pyproject(Path(repo_root))
+        .get("tool", {})
+        .get("setuptools", {})
+        .get("dynamic", {})
+        .get("version")
+    )
+    if isinstance(config, dict):
+        attr = config.get("attr")
+        if isinstance(attr, str):
+            return attr
+    return None
+
+
+def pypi_released_versions(timeout: float = 20.0) -> tuple[list[str] | None, str | None]:
+    """Read the published version list from PyPI.
+
+    Returns ``(versions, error)``; ``versions`` is ``None`` when the lookup
+    failed. This is the only network call in the release gate and it is
+    read-only, so it is safe to run before an irreversible upload.
+    """
+    request = urllib.request.Request(
+        PYPI_JSON_URL,
+        headers={"User-Agent": "orisys-release-preflight", "Accept": "application/json"},
+    )
+    try:
+        with urllib.request.urlopen(request, timeout=timeout) as response:
+            payload = json.load(response)
+    except urllib.error.HTTPError as exc:
+        if exc.code == 404:
+            return [], None
+        return None, f"PyPI returned HTTP {exc.code}"
+    except Exception as exc:  # network, DNS, TLS, JSON
+        return None, f"{type(exc).__name__}: {exc}"
+
+    releases = payload.get("releases")
+    if not isinstance(releases, dict):
+        return None, "unexpected PyPI response shape (no 'releases' mapping)"
+    listed = [
+        str(version)
+        for version, files in releases.items()
+        if isinstance(files, list) and files
+    ]
+    return sorted(listed, key=_version_sort_key), None
+
+
+def _version_sort_key(name: str):
+    parts = re.findall(r"\d+", name)
+    return ([int(part) for part in parts] or [0], name)
+
+
+def git_tags(repo_root: Path) -> list[str]:
+    """Local git tags from this repo and the sibling release repo.
+
+    Tags are the only offline evidence that a version was already released
+    (``v0.5.1`` in ``orisys-sdk-release`` marks a published GitHub release), so
+    the duplicate guard works without network access.
+    """
+    roots = [Path(repo_root)]
+    sibling = Path(repo_root).parent / RELEASE_REPO_DIRNAME
+    if sibling.is_dir():
+        roots.append(sibling)
+
+    tags: set[str] = set()
+    for root in roots:
+        try:
+            completed = subprocess.run(
+                ["git", "-C", str(root), "tag", "--list"],
+                capture_output=True,
+                text=True,
+                check=False,
+            )
+        except OSError:
+            continue
+        if completed.returncode != 0:
+            continue
+        tags.update(
+            line.strip() for line in (completed.stdout or "").splitlines() if line.strip()
+        )
+    return sorted(tags)
+
+
+def released_tags_for(version: str, tags: list[str]) -> list[str]:
+    """Tag spellings that mark ``version`` as already released."""
+    return sorted({version, f"v{version}"} & set(tags))
+
+
+# Version literals that are deliberately not the package version. Keyed by
+# repo-relative path; each entry documents *why* the literal may stay.
+VERSION_STRING_ALLOWLIST: dict[str, frozenset[str]] = {
+    # Historical release records: rewriting these would destroy the audit trail.
+    "docs/publishing.md": frozenset({"0.4.2", "0.4.3", "0.4.4", "0.5.0", "0.5.1", "0.5.2"}),
+    # Unrelated third-party/CUDA versions quoted in prose.
+    "docs/get_started.md": frozenset({"12.9.0"}),
+}
+
+# Paths never scanned: tests deliberately use synthetic versions, reports are
+# generated output, and this module's own allowlist/sentinel literals would
+# otherwise flag themselves.
+VERSION_SCAN_EXCLUDED_PREFIXES = (
+    "tests/",
+    "build/release/reports/",
+    "build/nuitka/",
+    "build/lib/",
+    "dist/",
+    "SDK/",
+    "data/",
+)
+VERSION_SCAN_EXCLUDED_FILES = ("build/release/version.py",)
+
+_VERSION_LITERAL_RE = re.compile(
+    r"(?<![<>=!~\w.])v?(\d+\.\d+\.\d+(?:[-+][0-9A-Za-z.]+)?)(?![0-9A-Za-z.])"
+)
+_SCANNED_SUFFIXES = (".md", ".py", ".txt", ".toml", ".cfg", ".ini", ".rst")
+
+
+def tracked_text_files(repo_root: Path) -> list[Path]:
+    """Tracked files worth scanning for version literals."""
+    repo_root = Path(repo_root)
+    try:
+        completed = subprocess.run(
+            ["git", "-C", str(repo_root), "ls-files", "-z"],
+            capture_output=True,
+            text=True,
+            check=False,
+        )
+        names = [n for n in (completed.stdout or "").split("\0") if n]
+    except OSError:
+        names = []
+
+    if not names:
+        names = [
+            str(path.relative_to(repo_root)).replace("\\", "/")
+            for path in repo_root.rglob("*")
+            if path.is_file()
+        ]
+
+    selected = []
+    for name in names:
+        if name.startswith(VERSION_SCAN_EXCLUDED_PREFIXES):
+            continue
+        if name in VERSION_SCAN_EXCLUDED_FILES:
+            continue
+        if not name.endswith(_SCANNED_SUFFIXES):
+            continue
+        selected.append(Path(name))
+    return selected
+
+
+def find_version_literals(
+    repo_root: Path, version: str
+) -> list[tuple[str, int, str]]:
+    """``(path, lineno, literal)`` for every version-looking string != ``version``.
+
+    Dependency constraints are skipped by the regex lookbehind (``numpy>=1.24.4``
+    is not a version reference), and historical/third-party literals require an
+    explicit entry in :data:`VERSION_STRING_ALLOWLIST`.
+    """
+    repo_root = Path(repo_root)
+    findings: list[tuple[str, int, str]] = []
+    for relative in tracked_text_files(repo_root):
+        absolute = repo_root / relative
+        try:
+            text = absolute.read_text(encoding="utf-8", errors="ignore")
+        except OSError:
+            continue
+        if "\0" in text:
+            continue
+        allowed = VERSION_STRING_ALLOWLIST.get(relative.as_posix(), frozenset())
+        for lineno, line in enumerate(text.splitlines(), start=1):
+            for match in _VERSION_LITERAL_RE.finditer(line):
+                literal = match.group(1)
+                if literal == version or literal in allowed:
+                    continue
+                findings.append((relative.as_posix(), lineno, literal))
+    return findings
+
+
+def conda_envs_root() -> Path | None:
+    """Locate the conda envs directory the same way build/wheel/win.bat does."""
+    override = os.getenv("CONDA_ENVS_ROOT")
+    if override:
+        path = Path(override)
+        return path if path.is_dir() else None
+
+    home = Path.home()
+    candidates = (
+        home / "anaconda3" / "envs",
+        home / "miniconda3" / "envs",
+        Path(os.getenv("LOCALAPPDATA", "")) / "anaconda3" / "envs",
+        Path(os.getenv("LOCALAPPDATA", "")) / "miniconda3" / "envs",
+    )
+    for candidate in candidates:
+        if candidate.is_dir():
+            return candidate
+    return None
+
+
+def python_for_tag(tag: str, envs_root: Path | None = None) -> Path | None:
+    """Resolve an interpreter for a wheel tag like ``cp310`` (env ``py310``)."""
+    digits = tag[2:] if tag.startswith("cp") else tag
+    env_name = f"py{digits}"
+    root = envs_root or conda_envs_root()
+    if root is None:
+        return None
+
+    for relative in (
+        Path(env_name) / "python.exe",
+        Path(env_name) / "bin" / "python",
+    ):
+        candidate = root / relative
+        if candidate.is_file():
+            return candidate
+    return None

build/run.py

@@ -8,6 +8,8 @@ Usage (from repo root):
   python build/run.py gui finger|mini|box
   python build/run.py verify [wheel.whl]
   python build/run.py verify --gui-dist [--product ory_finger]
+  python build/run.py release preflight [--version V]
+  python build/run.py release audit <wheel.whl>
 
 See build/README.md for details.
 """
@@ -74,15 +76,23 @@ def _cmd_verify(argv: list[str]) -> int:
     return verify_main(argv)
 
 
+def _cmd_release(argv: list[str]) -> int:
+    from release.cli import main as release_main
+
+    return release_main(argv)
+
+
 def main(argv: list[str] | None = None) -> int:
     argv = list(sys.argv[1:] if argv is None else argv)
     if not argv or argv[0] in ("-h", "--help"):
         print(__doc__)
-        print("Commands: wheel | wheel-win | manylinux | gui | verify")
+        print("Commands: wheel | wheel-win | manylinux | gui | verify | release")
         print("Examples:")
         print("  python build/run.py wheel --help")
         print("  python build/run.py gui finger")
         print("  python build/run.py manylinux -PythonVersions 3.10")
+        print("  python build/run.py release preflight --version <version>")
+        print("  python build/run.py release audit SDK\\<version>\\orisys-<version>-cp312-cp312-win_amd64.whl")
         return 0
 
     command, rest = argv[0], argv[1:]
@@ -92,10 +102,14 @@ def main(argv: list[str] | None = None) -> int:
         "wheel-manylinux": _cmd_manylinux,
         "gui": _cmd_gui,
         "verify": _cmd_verify,
+        "release": _cmd_release,
     }
     if command not in dispatch:
         print(f"Unknown command: {command!r}", file=sys.stderr)
-        print("Choose from: wheel, wheel-win, manylinux, gui, verify", file=sys.stderr)
+        print(
+            "Choose from: wheel, wheel-win, manylinux, gui, verify, release",
+            file=sys.stderr,
+        )
         return 2
     return dispatch[command](rest)
 

build/wheel/build.py

@@ -30,7 +30,13 @@ if str(_BUILD_ROOT) not in sys.path:
     sys.path.insert(0, str(_BUILD_ROOT))
 
 from common.paths import NUITKA_COMPILE_DIR, NUITKA_WHEEL_DIR, REPO_ROOT, repaired_wheel_dir, repo_path
-from common.pyproject_utils import bundle_items, extras_require, get_version, install_requires
+from common.pyproject_utils import (
+    bundle_items,
+    extras_require,
+    get_version,
+    install_requires,
+    project_metadata,
+)
 from common.verify.wheel import verify_built_wheel
 from wheel.compile import compile_orisys, copy_compiled_orisys, install_nuitka
 from wheel.layout import (
@@ -41,6 +47,7 @@ from wheel.layout import (
 from wheel.package import (
     is_compliant_manylinux_wheel,
     publish_wheel_to_sdk,
+    read_long_description,
     repair_linux_wheel,
     run_bdist_wheel,
     write_wheel_setup,
@@ -111,10 +118,12 @@ def build(*, target: str = "internal", verify: bool | None = None) -> Path:
     # Bundle rules live in pyproject.toml → [[tool.orisys.bundle.items]]
     bundle = bundle_items(REPO_ROOT)
     copied_counts = copy_bundle_items(REPO_ROOT, pkg_dir, bundle)
-    print(f"Copied {copied_counts['configs']} JSON config files")
-    print(f"Copied {copied_counts['examples']} example files to orisys/examples/")
-    print(f"Copied {copied_counts['docs']} doc files to orisys/docs/")
-    print(f"Copied {copied_counts['sensors']} sensor bundle files to orisys/sensors/")
+    for item in bundle:
+        destination = f"orisys/{item['target']}/"
+        print(
+            f"Copied {copied_counts.get(item['name'], 0)} file(s) "
+            f"for bundle item {item['name']!r} to {destination}"
+        )
 
     write_wheel_setup(
         NUITKA_WHEEL_DIR,
@@ -122,6 +131,8 @@ def build(*, target: str = "internal", verify: bool | None = None) -> Path:
         package_data=package_data_from_bundle(ext_suffix, bundle),
         install_requires=install_requires(REPO_ROOT),
         extras_require=extras_require(REPO_ROOT),
+        project=project_metadata(REPO_ROOT),
+        long_description=read_long_description(REPO_ROOT),
     )
 
     # --- 3. Build wheel, repair on Linux, publish to SDK/ ---

build/wheel/compile.py

@@ -32,12 +32,20 @@ NUITKA_NOFOLLOW_IMPORTS = (
     "cv2",
     "numba",
     "orisys_blend",
+    # Optional accelerators / GUIs: imported behind try/except, resolved from the
+    # user's environment at runtime. Listing them here is not optional - without
+    # it, Nuitka follows whatever happens to be installed in the *build*
+    # environment, which blows up compile time and makes wheel contents depend on
+    # ambient packages. tests/test_nuitka_nofollow.py enforces full coverage.
     "cupy",
     "cupyx",
     "pyopencl",
+    "pyvkfft",
     "open3d",
     "PyQt5",
     "pyqtgraph",
+    "torch",
+    "torchvision",
 )
 
 

build/wheel/docker/Dockerfile.manylinux

@@ -4,23 +4,51 @@
 FROM quay.io/pypa/manylinux_2_28_x86_64:latest
 
 ENV PIP_DISABLE_PIP_VERSION_CHECK=1 \
-    PIP_ROOT_USER_ACTION=ignore
+    PIP_ROOT_USER_ACTION=ignore \
+    ORISYS_WHEELHOUSE_ROOT=/opt/orisys-wheelhouse
 
-# Only install compile/repair tooling here. Runtime deps (numpy/scipy/opencv/numba)
-# are declared in the wheel metadata and installed by pip when users install orisys.
-# Nuitka is configured with --nofollow-import-to for those packages.
-RUN for PYBIN in \
-        /opt/python/cp310-cp310/bin \
-        /opt/python/cp311-cp311/bin \
-        /opt/python/cp312-cp312/bin; do \
-      echo "=== Installing build tooling into ${PYBIN} ===" && \
-      "${PYBIN}/python" -m pip install --upgrade pip setuptools wheel && \
-      "${PYBIN}/python" -m pip install \
-          "nuitka>=2.0" \
-          ordered-set \
-          zstandard \
-          auditwheel; \
-    done
+# Per-ABI build tooling plus a per-ABI wheelhouse of every package the release
+# flow installs at build time:
+#
+#   * build tooling  - nuitka/auditwheel etc. baked in, so the entrypoint does
+#     not have to re-resolve them from PyPI on every container start
+#     (ORISYS_UPDATE_BUILD_TOOLS=1 opts back in to that).
+#   * wheelhouse     - `build/wheel/build.py --target pypi-linux` force-enables
+#     verification, which creates a throwaway venv and pip-installs the built
+#     wheel plus its declared runtime deps. Runtime deps are deliberately NOT
+#     installed into the image interpreter (users get them from the wheel
+#     metadata), so without a wheelhouse every build re-downloaded
+#     numpy/scipy/opencv/numba — roughly 200 MB, three times over, once per ABI.
+#     The entrypoint points pip at the wheelhouse with
+#     PIP_NO_INDEX/PIP_FIND_LINKS, which keeps the venv isolated and still
+#     exercises real dependency resolution, just without the network.
+#
+# --only-binary=:all: makes a missing wheel a loud image-build failure instead of
+# a slow source build inside the container.
+RUN set -eux; \
+    for TAG in cp310-cp310 cp311-cp311 cp312-cp312; do \
+        PYBIN="/opt/python/${TAG}/bin"; \
+        echo "=== build tooling for ${TAG} ==="; \
+        "${PYBIN}/python" -m pip install --upgrade pip setuptools wheel; \
+        "${PYBIN}/python" -m pip install \
+            "nuitka>=2.0" \
+            ordered-set \
+            zstandard \
+            auditwheel; \
+        echo "=== wheelhouse for ${TAG} ==="; \
+        "${PYBIN}/python" -m pip download \
+            --only-binary=:all: \
+            --dest "${ORISYS_WHEELHOUSE_ROOT}/${TAG}" \
+            pip \
+            setuptools \
+            wheel \
+            auditwheel \
+            numpy \
+            scipy \
+            opencv-python \
+            numba; \
+    done; \
+    du -sh "${ORISYS_WHEELHOUSE_ROOT}"/*
 
 WORKDIR /src
 ENTRYPOINT ["/bin/bash", "/src/build/wheel/docker/entrypoint.sh"]

build/wheel/docker/entrypoint.sh

@@ -6,12 +6,18 @@ set -euo pipefail
 TARGET="${ORISYS_BUILD_TARGET:-pypi-linux}"
 # Comma-separated manylinux tags, e.g. "cp310-cp310,cp311-cp311,cp312-cp312"
 PYTHON_TAGS="${ORISYS_PYTHON_TAGS:-cp310-cp310,cp311-cp311,cp312-cp312}"
+WHEELHOUSE_ROOT="${ORISYS_WHEELHOUSE_ROOT:-/opt/orisys-wheelhouse}"
+# The image already bakes in pip/setuptools/wheel/nuitka/auditwheel. Re-resolving
+# them from PyPI on every container start costs a network round-trip per ABI and
+# lets the running container drift from the image it was built from.
+UPDATE_BUILD_TOOLS="${ORISYS_UPDATE_BUILD_TOOLS:-0}"
 
 cd /src
 
 echo "=== manylinux entrypoint ==="
 echo "Target: ${TARGET}"
 echo "Python tags: ${PYTHON_TAGS}"
+echo "Wheelhouse root: ${WHEELHOUSE_ROOT}"
 uname -a
 
 IFS=',' read -r -a TAG_ARRAY <<< "${PYTHON_TAGS}"
@@ -40,7 +46,27 @@ for tag in "${TAG_ARRAY[@]}"; do
   export PATH="${PYBIN}:${PATH}"
   export PYTHONPATH="/src/src${PYTHONPATH:+:${PYTHONPATH}}"
 
-  "${PYBIN}/python" -m pip install -q --upgrade pip setuptools wheel auditwheel
+  # Point pip at the per-ABI wheelhouse baked into the image. The pypi-linux
+  # target force-enables verification, which creates a throwaway venv and
+  # pip-installs the built wheel plus its declared runtime deps; serving those
+  # from the wheelhouse keeps the venv isolated (no --system-site-packages) while
+  # removing a ~200 MB download per ABI. PIP_* is inherited by every pip
+  # subprocess, including that venv.
+  wheelhouse="${WHEELHOUSE_ROOT}/${tag}"
+  if [[ -d "${wheelhouse}" ]]; then
+    export PIP_NO_INDEX=1
+    export PIP_FIND_LINKS="${wheelhouse}"
+    echo "[info] pip is offline, installing from ${wheelhouse}"
+  else
+    echo "[warn] no wheelhouse at ${wheelhouse}; pip will use the network." >&2
+    echo "[warn] rebuild the image without -SkipImageBuild to bake it in." >&2
+    unset PIP_NO_INDEX PIP_FIND_LINKS || true
+  fi
+
+  if [[ "${UPDATE_BUILD_TOOLS}" == "1" ]]; then
+    echo "[info] refreshing build tooling (ORISYS_UPDATE_BUILD_TOOLS=1)"
+    "${PYBIN}/python" -m pip install -q --upgrade pip setuptools wheel auditwheel
+  fi
 
   if "${PYBIN}/python" build/wheel/build.py --target "${TARGET}"; then
     BUILT+=("${tag}")
@@ -48,6 +74,8 @@ for tag in "${TAG_ARRAY[@]}"; do
     echo "[ERROR] Build failed for ${tag}" >&2
     FAILED=1
   fi
+
+  unset PIP_NO_INDEX PIP_FIND_LINKS || true
 done
 
 echo ""

build/wheel/package.py

@@ -19,6 +19,76 @@ _MANYLINUX_TAG_RE = re.compile(
     r"(?:manylinux2014|manylinux_2_(?:17|24|27|28|31|34|35))_x86_64"
 )
 
+# Source of the PyPI project description (see read_long_description).
+PYPI_README_RELPATH = Path("docs") / "pypi_readme.md"
+
+
+def _license_text(project: dict) -> str | None:
+    """Extract free-text license from either pyproject license form."""
+    declared = project.get("license")
+    if isinstance(declared, str):
+        return declared
+    if isinstance(declared, dict):
+        text = declared.get("text")
+        if isinstance(text, str):
+            return text
+    return None
+
+
+def _person_strings(entries) -> list[str]:
+    """Render PEP 621 author/maintainer tables as ``Name <email>`` strings."""
+    rendered: list[str] = []
+    for entry in entries or []:
+        if not isinstance(entry, dict):
+            continue
+        name = (entry.get("name") or "").strip()
+        email = (entry.get("email") or "").strip()
+        if name and email:
+            rendered.append(f"{name} <{email}>")
+        elif name or email:
+            rendered.append(name or email)
+    return rendered
+
+
+def metadata_kwargs(project: dict) -> dict:
+    """Translate a pyproject ``[project]`` table into ``setup()`` keywords.
+
+    The Nuitka wheel is built by a generated ``setup.py`` outside the normal
+    setuptools pipeline, so every PyPI-visible field has to be passed through
+    explicitly. Omitting them is what left the early PyPI releases with no
+    ``Requires-Python``, classifiers, project URLs or license on the project page.
+    """
+    authors = _person_strings(project.get("authors"))
+    maintainers = _person_strings(project.get("maintainers"))
+    candidates = {
+        "description": project.get("description"),
+        "python_requires": project.get("requires-python"),
+        "classifiers": list(project.get("classifiers") or []),
+        "project_urls": dict(project.get("urls") or {}),
+        "license": _license_text(project),
+        "author": authors[0] if authors else None,
+        "author_email": None,
+        "maintainer": maintainers[0] if maintainers else None,
+    }
+    return {key: value for key, value in candidates.items() if value}
+
+
+def read_long_description(repo_root: Path) -> str | None:
+    """Return the PyPI long description, or ``None`` when it is missing.
+
+    Deliberately not the repository ``README.md``: that file documents the
+    closed-source build/publishing layout, which should not end up on the PyPI
+    project page.
+    """
+    path = Path(repo_root) / PYPI_README_RELPATH
+    if not path.is_file():
+        print(
+            f"[WARN] {PYPI_README_RELPATH.as_posix()} not found; the wheel will be "
+            "published without a long description."
+        )
+        return None
+    return path.read_text(encoding="utf-8")
+
 
 def write_wheel_setup(
     wheel_dir: Path,
@@ -27,7 +97,17 @@ def write_wheel_setup(
     package_data: dict[str, list[str]],
     install_requires: list[str],
     extras_require: dict[str, list[str]],
+    project: dict | None = None,
+    long_description: str | None = None,
 ) -> Path:
+    metadata_lines = ""
+    if project:
+        for key, value in sorted(metadata_kwargs(project).items()):
+            metadata_lines += f"    {key}={value!r},\n"
+    if long_description:
+        metadata_lines += "    long_description=_LONG_DESCRIPTION,\n"
+        metadata_lines += '    long_description_content_type="text/markdown",\n'
+
     setup_py_path = wheel_dir / "setup.py"
     setup_content = f"""
 from setuptools import setup, Distribution
@@ -36,12 +116,12 @@ class BinaryDistribution(Distribution):
     def has_ext_modules(self):
         return True
 
+{'_LONG_DESCRIPTION = ' + repr(long_description) if long_description else ''}
+
 setup(
     name="orisys",
     version="{version}",
-    description="Orisys - Optical Tactile Sensor SDK (Nuitka Compiled)",
-    author="Orisys",
-    packages=['orisys', 'orisys.examples', 'orisys_blend'],
+{metadata_lines}    packages=['orisys', 'orisys.examples', 'orisys_blend'],
     package_dir={{'': 'wheel_root'}},
     package_data={package_data},
     include_package_data=True,

docs/api.md

@@ -17,7 +17,7 @@ description: Orisys SDK Python API 中文参考
 
 * **vid_src** (`int | str`, 必填): 传感器 ID、相机编号或视频路径。默认为 `0`。  
 * **config_name** (`str`，可选): 传感器配置文件名称或 `json` 文件路径，用于加载对应的参数配置；例如 `box` 或 `./config/box.json`。  
-* **cal_path** (`str`，可选，已弃用): 该参数仅为兼容旧代码保留，当前版本中不再使用，传入后也会被忽略。  
+* **cal_path** (`str`，可选): 显式的 `force_calibration.json` 路径；传入后优先于 `sensors/<type>/force_calibration.json`。不传时按 `config_name` 自动加载产品包中的标定文件。 
 * **backend** (`str`，可选): 光流场解耦计算后端，默认为 `auto`，可选`cupy`,`opencl`,`cpu`。  
 * **verbose** (`bool`，可选): 是否输出初始化及运行过程中的详细日志信息，默认为 `False`。  
 
@@ -577,6 +577,26 @@ finally:
 
 * 导出内置的`config_name`配置参数字典至`path`
 
+### `export_sensor_bundle` / `export_sensor_bundles` 方法
+
+#### 描述
+将已安装的 `sensors/<name>/` 传感器包复制到目标目录，供下游应用（如桌面 App）做本地可编辑配置，无需硬编码 wheel 路径。解析顺序与 `resolve_sensor_bundle` 相同（含 `importlib.resources` 打包布局）。
+
+#### 输入参数
+* **name** / **names**: 单个名字，或名字列表；`export_sensor_bundles` 省略 `names` 时导出所有可解析的产品包（`box` / `mini` / `finger`）
+* **dest_dir**: 目标根目录；实际写入 `dest_dir/<name>/`
+* **include_assets**: 默认 `False`，仅复制 `sensor.json` 以及存在的 `force_calibration.json` / `manifest.json`；为 `True` 时复制完整目录树（含 `assets/`）
+* **overwrite**: 默认 `True`；为 `False` 且目标已存在时抛出 `FileExistsError`
+
+#### 返回
+* `Path` 或 `list[Path]`：导出后的包目录路径
+
+#### CLI
+```bash
+python -m orisys.export_sensors --dest ./out/sensors --names box,mini
+python -m orisys.export_sensors --dest ./out/sensors --include-assets
+```
+
 ## 常见问题解答 (FAQ)
 ### Q1:为什么必须先调用`get_img()`，再调用`compute_deformation()`？
 A：`compute_deformation()`依赖最近一次获取并拼接的图像数据进行形变与力计算。

docs/filters.md

@@ -0,0 +1,118 @@
+# 滤波：三级、预设与可追溯性
+
+`json.load` 不支持注释（见 `src/orisys/configs.py`），所以"建议的滤波"**不写在 JSON 注释里**，
+而是写成**代码里的预设**（`src/orisys/sensor.py::FILTER_PRESETS`）+ 这份文档 +
+`examples/filters/` 里可直接复制的配置。预设是可执行、可回显、可审计的；注释不是。
+
+---
+
+## 1. 三级滤波，位置不同、性质不同
+
+| 级 | 配置键 | 作用位置 | 性质 |
+|---|---|---|---|
+| 光流时间 EMA | `flow_ema_alpha` | `compute_flow()` 内，**HHD 之前** | **改变测量**：改 `vnormal`/接触统计与 `_force_raw` 的值。两个 `alpha` 不同的录制**不可比** |
+| 力中值 | `force_median_window` | `_apply_force_filter()`：raw → 中值 → 低通 → 标定 | **读数滤波**：删除单点尖峰（因果滑动中值） |
+| 力低通 | `force_lowpass_cutoff_hz` / `_order` / `_sample_rate_hz` | 同上（中值之后） | **读数滤波**：因果 Butterworth IIR（`sosfilt` + 持久状态） |
+
+因此 `filters_state()` 把它们分成两组：`measurement`（测量身份）与 `readout`（读数滤波）。
+标定/可比性检查应比对 `measurement`，记录里两者都记。
+
+## 2. 取值规则（自描述，无隐藏覆盖）
+
+- **每个级由自己的值开关**：`flow_ema_alpha >= 1`、`force_median_window <= 1`、
+  `force_lowpass_cutoff_hz <= 0` 都是"关"。
+- **配置没写的键 = 关**：缺省不是"我们觉得合理的那档"，而是"不滤波"。因此**没有 `filters`
+  段的配置文件什么都不滤**，出厂 bundle 也把三个值显式写成全关 —— 想让哪一级跑起来，
+  必须在文件里写出来（数值或 `preset`）。这样"文件说的"和"设备跑的"才总是一致。
+- **非法值 → 关**，绝不回落到"默认开"。
+- `filters.enabled` 是**废弃别名**，显式 `false` 表示"三级全关"；没有任何开关能覆盖已写的值。
+- `filters.preset` 可引用下面的预设；**显式键优先于预设值**（可从预设出发只改一个旋钮）。
+- 任何时刻的**真值**是 `Sensor.filters_state()`，不是配置文件 —— 运行时 `configure()` 可以改它。
+
+## 3. 预设（`FILTER_PRESETS`）
+
+| 预设 | `flow_ema_alpha` | `force_median_window` | `force_lowpass_cutoff_hz` | 延迟 @30fps | 用途 |
+|---|---|---|---|---|---|
+| `off` | 1.0 | 1 | 0.0 | 0 帧 | 原始读数；文件说什么就跑什么 |
+| `low_latency` | 1.0 | 3 | 0.0 | ≈1 帧（33 ms） | 延迟敏感，只去尖峰 |
+| `balanced` | 0.5 | 3 | 0.0 | ≈2 帧（67 ms） | 建议起步档：EMA 干掉力级滤波够不到的光流抖动 |
+| `low_noise` | 0.3 | 3 | 10.0 | ≈3 帧（100 ms） | 底噪优先，读数再低通一道 |
+
+延迟换算 @60fps 减半；数字来自 `_perf/`（对照表见 `orisys-sdk-perf-plan.md`）。
+≥1 帧的延迟与相位差是**因果滤波的代价**：旧显示端曾用零相位 `filtfilt`，那需要"未来"，
+无法在采集里做，也让"显示 == 记录"不可能——所以现在只有一条因果链。
+
+## 4. 怎么用
+
+```jsonc
+// sensors/mini/sensor.json（片段；完整可复制版本见 examples/filters/）
+"filters": { "preset": "balanced" }
+```
+```python
+# 或运行时（UI 的齿轮就走这条路；不重连相机）
+sensor.configure(flow_ema_alpha=0.5, force_median_window=3, lowpass_cutoff_hz=0.0)
+print(sensor.filters_state())      # 实际生效值 + preset + applied 标志
+```
+UI 想列出可选档位：`from orisys.sensor import available_filter_presets`。
+
+## 5. 两个 buffer：滤波前 / 滤波后
+
+```python
+t = sensor.force_triplets()
+t["filtered"]["raw"],   t["filtered"]["newton"]     # 记录与显示用的值（同一套）
+t["unfiltered"]["raw"], t["unfiltered"]["newton"]   # 中值/低通之前；同帧、同标定系数
+```
+- `filtered.raw` = 链的输出（标定前），`unfiltered.raw` = 设备计数；
+- 两个 `newton` 用同一份 `force_calibration.json`，差异**只**来自滤波链；
+- 实测：注入 `10,10,10,999,10,10`（中值窗口 3）→ `filtered.raw` 在尖峰帧为 `10.0`、
+  `unfiltered.raw` 为 `999.0`。
+
+## 6. 可追溯性清单
+
+1. 录制元数据写 `sensor.filters_state()` 的**生效值**（不是配置文件内容），并含 `preset` 与
+   `"source": "sensor.filters_state"` + `sdk_version`。
+2. 界面显示"实际生效"而不是"我填的值"；两者不一致时以实际为准并提示。
+3. 记录里主列 = 滤波后（与界面一致），未滤波列另存；列结构与格式版本可区分。
+4. 标定/可比性指纹用 `measurement` 组；`readout` 组变化只记录、不拦截。
+5. 双份数据在同一帧、同一份标定系数下产生，差异可完全归因于滤波链。
+
+## 7. 指纹：标定文件里怎么记（已实现）
+
+`orisys.calibration` 负责把滤波设置写进标定文件的 `meta`，并在读回时还原：
+
+```python
+from orisys.calibration import filters_fingerprint, filter_mismatches, pipeline_from_sensor_json
+
+pipeline = pipeline_from_sensor_json(config_path, filters_state=sensor.filters_state())
+# {"stitch_resolution": …, "dis_mode": …, "hhd_downsample": …, "config_ref": …,
+#  "filters": {"measurement": {"flow_ema_alpha": 0.5},
+#              "readout": {"force_median_window": 3, "force_lowpass_cutoff_hz": 0.0},
+#              "preset": "balanced", "source": "sensor.filters_state"}}
+```
+
+写入的文件长这样（`meta` 里同时保留扁平键供旧读者按名取用）：
+
+```json
+"meta": {
+  "filters": {
+    "measurement": {"flow_ema_alpha": 0.5},
+    "readout": {"force_median_window": 3, "force_lowpass_cutoff_hz": 0.0},
+    "preset": "balanced",
+    "source": "sensor.filters_state"
+  },
+  "flow_ema_alpha": 0.5,
+  "force_median_window": 3
+}
+```
+
+规则：
+
+- **生效值优先**：传了 `filters_state=` 就用它；没传才读文件的 `filters` 段，并标成
+  `"source": "sensor.json.filters"`（那是"意图"，不一定等于设备正在做的事）。
+- **不猜**：来源没写的键**不出现**在指纹里。`{}` 表示"没有任何记录"，绝不表示"大概是关的"。
+  旧文档写的扁平键（`meta.flow_ema_alpha` …）在读回时会被折进对应的组，因此仍可比。
+- **`enabled: false`** 只作为"全部关"的废弃别名保留（`flow_ema_alpha=1`、中值 `1`、低通 `0`）。
+- **分组判读**：`calibration.check(doc, pipeline=…)` 把两组的差异分开报告 —— measurement 组的
+  差异进 `warnings`（措辞含 `not comparable`，即"两份记录不可比"），readout 组的差异进
+  `notes`（只记录，不拦截）。`CheckResult.notes` 是为此新增的字段。
+

docs/get_started.md

@@ -5,8 +5,6 @@ description: 安装并运行 Orisys SDK 的基础步骤
 
 # 快速开始
 
-版本：0.5.0
-
 ## 简介
 本文件介绍如何上手和运行叠动视触觉传感器配套的开发套件。本套件是配合叠动视触觉传感器进行图像处理，计算形变、力以及接触信息。它可以从摄像头或视频文件中读取图像，处理后打印和展示处理后信息。  
 支持操作系统：Windows、Ubuntu  
@@ -84,9 +82,9 @@ pip install --upgrade orisys
 ### 使用 .whl 文件安装（离线或指定版本）
 从官方渠道获取 .whl 文件，文件名格式通常为：
 orisys-{版本}-{Python版本}-{Python版本}-{操作系统}_{硬件架构}.whl
-例如：orisys-0.5.0-cp310-cp310-win_amd64.whl 表示：
+例如 `orisys-<版本>-cp310-cp310-win_amd64.whl` 表示：
 
-版本：0.5.0
+版本：`<版本>`（以实际下载的文件名为准，可用 `python -c "import orisys; print(orisys.__version__)"` 确认）
 Python 版本：3.10（cp310）
 操作系统：Windows（win）
 硬件架构：64位（amd64）
@@ -97,7 +95,7 @@ Python 版本：3.10（cp310）
 
 ```bash
 # 请将文件名替换为您实际下载的文件名
-pip install orisys-0.5.0-cp310-cp310-win_amd64.whl
+pip install orisys-<版本>-cp310-cp310-win_amd64.whl
 ```
 
 ### 安装 CuPy（可选）
@@ -139,7 +137,7 @@ python
 import orisys
 print(orisys.__version__)
 ```
-如果输出版本号（例如 0.5.0），则说明安装成功。
+如果打印出版本号，则说明安装成功。
 
 ## 使用方法
 ### 运行示例程序

docs/publishing.md

@@ -0,0 +1,399 @@
+# 发布流程（构建 → 校验 → 发布）
+
+本文档说明如何构建 orisys 的 Nuitka 二进制 wheel、如何在发布前用一条命令做完整门禁，以及当前仍需人工执行的发布步骤。
+
+> 历史说明：`README.md` 与 `build/wheel/docker/run.ps1` 早就引用了本文件，但它此前并不存在。本文件补齐该引用。
+
+---
+
+## 0. 环境准备
+
+推荐用 `py310` conda 环境执行构建与校验（它同时具备 pytest / twine / numba / Nuitka / open3d / PyQt5）：
+
+```powershell
+conda activate py310
+python -m pytest -m "not slow and not hardware"   # 开发期快速回归
+```
+
+`py311`、`py312` 仅作为 Nuitka 各 ABI 的编译环境按需调用（`build/wheel/win.bat` 会依次使用 `py310`/`py311`/`py312`）。
+
+**不要**在同一个环境里既装旧版 `orisys` 又从源码目录跑测试：site-packages 里的旧包会静默遮蔽 `src/orisys`。
+`tests/test_harness_guards.py` 会显式报错提示执行 `pip uninstall -y orisys`。
+
+---
+
+## 1. 构建 wheel
+
+```powershell
+# Windows：py310 / py311 / py312 三个 ABI
+python build/run.py wheel-win
+
+# 单个解释器（当前环境）
+python build/run.py wheel
+
+# Linux manylinux（Docker Desktop，Linux 容器模式）
+python build/run.py manylinux
+python build/run.py wheel-manylinux -PythonVersions 3.10
+```
+
+产物落点：
+
+- `SDK/<version>/` — 交付用 wheel（git 忽略）
+- `dist/repaired/` — 上传候选（git 忽略）
+
+---
+
+## 2. 发布前门禁：`release preflight`
+
+```powershell
+# --version 可省略：默认取 pyproject 的 dynamic version（即 src/orisys/__init__.py 里的 __version__）
+python build/run.py release preflight
+```
+
+按顺序执行 8 个步骤，任一步失败即整体失败（`--keep-going` 可改为收集全部失败）：
+
+| 步骤 | 检查内容 |
+| --- | --- |
+| `repo-state` | 是 git 仓库、工作树干净、记录 HEAD（`--allow-dirty` 可豁免，用于提交前预检） |
+| `version-consistency` | `src/orisys/__init__.py::__version__` == pyproject 的 dynamic attr == `SDK/<version>/` 中 wheel 文件名里的版本 |
+| `version-strings` | 追踪的文本文件里没有与当前版本不符的版本字面量（见 §5.3） |
+| `duplicate-guard` | 该版本是否**已经发布过**：本地 git tag（`v<version>` / `<version>`，含 sibling `orisys-sdk-release` 仓库）命中即拒绝；`--check-pypi` 时再查 PyPI。`SDK/<version>/` 里已有 wheel 只作信息展示——那是 preflight 的正常输入，不是错误 |
+| `tests` | `pytest -m "not slow and not hardware"`（`--longrun` 时包含 slow） |
+| `bundle-precheck` | 每个 `[[tool.orisys.bundle.items]]` 至少解析出 1 个文件；finger 必需资产存在 |
+| `wheel-inspection` | 逐个 wheel 做静态断言：文件名/版本/METADATA 字段/RECORD 哈希/压缩包路径/体积上限/无 pyc 与缓存/无 `orisys/**/*.py` 源码泄漏/与源码树逐文件字节一致 |
+| `wheel-runtime` | 每个 wheel **一个** venv，在里面依次做：导入冒烟 → 内置 configs/sensors 资产可加载 → 对真实视频跑 40 帧公开流水线（无需相机、无 GUI） |
+
+正常顺序是**先构建、再 preflight**，不需要额外开关：
+
+```powershell
+python build/run.py wheel-win
+python build/run.py manylinux
+python build/run.py release preflight --all-wheel-pythons --check-pypi
+```
+
+提交前想先看结果（此时工作树通常还是脏的）：加 `--allow-dirty --keep-going`。
+
+产物报告：
+
+- `build/release/reports/<version>/preflight.json` — 机器可读，含每个 wheel 的 sha256，供后续发布步骤复用
+- `build/release/reports/<version>/preflight.txt` — 人工阅读
+- `build/release/reports/<version>/junit.xml` — pytest 结果
+
+（`build/release/reports/` 已加入 `.gitignore`。）
+
+### 常用参数
+
+| 参数 | 作用 |
+| --- | --- |
+| `--wheel-dir DIR` | 校验指定目录下的 wheel（默认 `SDK/<version>`） |
+| `--all-wheel-pythons` | cp310/cp311/cp312 各自在对应 conda 环境里独立校验 |
+| `--video PATH` / `--frames N` / `--config NAME` | 覆盖运行时校验输入（默认 `data/sample/s1_480p.mp4` / 40 帧 / `box`） |
+| `--offline` | 复用父环境的 numpy/opencv/numba，不去 PyPI 装依赖 |
+| `--check-pypi` | 唯一一处网络调用：只读 PyPI，防止重复发布 |
+| `--skip-tests` / `--no-runtime` / `--no-assets` | 显式跳过并在报告中留痕；**跳过的运行不能作为发布依据** |
+| `--report-dir DIR` | 覆盖报告根目录 |
+
+`wheel-runtime` **不会静默跳过**：找不到视频时直接失败，提示 `--video` / `ORISYS_VERIFY_VIDEO`。
+
+### 单体体检：`release audit`
+
+对单个 wheel 做静态断言（+ 可选运行时校验），不需要版本上下文。适合体检历史产物：
+
+```powershell
+python build/run.py release audit SDK\<version>\orisys-<version>-cp312-cp312-win_amd64.whl
+python build/run.py release audit dist\repaired\orisys-<version>-cp310-cp310-win_amd64.whl --strict-bundle
+
+# 追加运行时校验（--assets 与 --runtime 同时给时共用一个 venv，只装一次依赖）
+python build/run.py release audit <wheel> --assets --runtime --video data/sample/s1_480p.mp4
+```
+
+默认对「内置文件与当前源码树不一致」只告警（历史 wheel 与当前分支不一致是正常的）；加 `--strict-bundle` 改成失败（刚构建完的 wheel 应当一致）。
+
+旧的导入冒烟测试仍然可用，行为不变：
+
+```powershell
+python build/run.py verify <wheel>
+python build/run.py verify <wheel> --contents          # 静态断言
+python build/run.py verify <wheel> --assets --runtime  # 资产 + 真实帧
+python build/run.py verify --gui-dist --product ory_finger
+```
+
+---
+
+## 3. 发布（两条命令）
+
+先决条件：`release preflight` PASS，**而且是在干净提交上跑的**。两个发布命令都只发布「preflight 认证过的东西」——它们会读取 `build/release/reports/<version>/preflight.json`，逐个核对 wheel 的 sha256，并拒绝使用带豁免项（`--skip-tests` / `--allow-dirty` / `--no-runtime` / `--force`）的报告。所以正确顺序是：
+
+```powershell
+git add -A; git commit -m "..."
+python build/run.py wheel-win && python build/run.py manylinux
+python build/run.py release preflight --all-wheel-pythons --check-pypi   # 干净树 + 无豁免
+```
+
+两个命令**默认都是 dry run**，只打印将要执行的动作；必须显式加 `--apply` 才会真正动手。GitHub 的 `gh release create`、`git push`，以及 PyPI 上传（版本号永久占用、不可覆盖）都属于不可撤销操作。
+
+### 3.1 GitHub：同步公开仓库 + 上传 Release
+
+```powershell
+python build/run.py release github --version 0.5.2              # 预览
+python build/run.py release github --version 0.5.2 --apply      # 执行
+```
+
+执行顺序：
+
+1. 认证书校验（上面那份报告 + 逐 wheel sha256）
+2. `git fetch --tags`，若 `v0.5.2` 或 `0.5.2` 已存在则拒绝；`gh release view` 已存在也拒绝
+3. 按 `tools/downstream_sync_manifest.json` 同步公开内容到 `../orisys-sdk-release`，并运行 manifest 里的 `checks`
+4. 把 `SDK/0.5.2/*.whl` 放到 `orisys-sdk-release/release/0.5.2/`（该目录在 release 仓库里是 gitignore 的，只用于上传附件）
+5. 提交 → 打 tag `v0.5.2` → push 分支与 tag
+6. `gh release create v0.5.2 --verify-tag --latest <6 个 wheel>`，然后回读 `gh release view --json assets` 核对附件齐全
+
+需要：`gh` 已安装并登录（`winget install --id GitHub.cli` 然后 `gh auth login`）。没装 gh 时：
+
+- dry run 仍会完整打印计划（只告警）
+- `--apply` 会失败，或改用 `--skip-release-upload`：同步、提交、打 tag、push 都自动完成，然后打印出你自己要跑的 `gh release create`
+
+其他开关：`--notes-file`（自定义 release notes）、`--attach-preflight`（把 `preflight.json` 也作为附件上传，便于审计；注意报告里有本机绝对路径）、`--allow-dirty-release`、`--skip-fetch`、`--skip-checks`。
+
+> tag 拼写沿用历史风格 `v<version>`（注意历史里那个 typo tag `0.50` 指向 `v0.5.1`）。命令会在动手前拒绝已存在的 tag，所以不会重复发布。**如果 tag 已经 push 但 Release 上传失败（例如 `gh` 没配好），直接重跑同一条 `--apply` 命令即可续跑**：它会跳过创建 tag，只补做剩下的步骤；只有「GitHub Release 已存在」才拒绝。
+
+### 3.2 PyPI：TestPyPI 先行，确认后再上正式仓库
+
+```powershell
+python build/run.py release pypi --version 0.5.2                          # 预览
+python build/run.py release pypi --version 0.5.2 --apply                  # 只发 TestPyPI
+python build/run.py release pypi --version 0.5.2 --confirm-pypi --apply   # TestPyPI + 正式 PyPI
+
+# 只有正式 token、没有 TestPyPI 账号时：跳过彩排直接发正式库
+python build/run.py release pypi --version 0.5.2 --pypi-only --apply
+```
+
+`--pypi-only` 与 `--confirm-pypi` 互斥。**注意它的代价**：没有 TestPyPI 彩排，而正式库的版本号一旦占用就无法复用、无法替换。它仍然会做完整门禁、`twine check`、上传前查重、上传后回读索引核对文件、以及把产物重新拉回来验证。
+
+执行顺序：
+
+1. 认证书校验（与 `release github` 同一份报告）
+2. `twine check` 全部 wheel（校验 METADATA/long description，上传前就能发现问题）
+3. 只读查询目标索引，确认该版本不存在（TestPyPI 与 PyPI 各查各的）
+4. 上传 → **轮询**索引确认 6 个文件都在 → `pip download` 把刚上传的 wheel 拉回来，证明产物可获取
+5. 未加 `--confirm-pypi` 时只发 TestPyPI，然后停在这里并打印后续命令
+
+两个针对「索引不即时一致」的设计（TestPyPI 尤其明显，上传成功后 JSON API 可能滞后若干秒）：
+
+- **上传后的确认会重试**（默认 6 次 × 5 秒）。确认不了也**不算失败**：twine 上传成功就说明产物已发布，命令会打印警告、给出项目页链接并以 0 退出，不会把一个成功的上传报成失败。真正的失败只有两种：twine 上传本身失败，或索引上的文件集与本地不一致。
+- **重复运行是安全的**：若索引上已经存在该版本且文件集完全一致，该阶段会被视为「已完成」而跳过（`[ok] testpypi already serves orisys 0.5.2 with all 6 file(s)`），不会重传、也不报错。这让你在确认不明确时可以直接重跑。如果文件集**不一致**（索引上是另一次构建），才会失败并停下。
+
+所以「上传后确认失败」不等于要重新上传——索引版本号不可覆盖，重跑只会做一次只读核对。
+
+### 3.3 凭证：`release auth` 与 `~/.pypirc`
+
+```powershell
+python build/run.py release auth                        # 查看两个索引的凭证状态
+python build/run.py release auth --set-token pypi       # 隐藏输入，写入 ~/.pypirc
+python build/run.py release auth --set-token testpypi
+python build/run.py release auth --repair               # 修「有段但没列进 index-servers」
+```
+
+`--set-token` 的 token 只从**隐藏输入**或 `--token-stdin`（供脚本/CI）读取，**不接受命令行参数**——避免落进 shell 历史和进程列表。写入采用定点文本编辑，文件里的说明注释会保留；同时会把该索引补进 `[distutils] index-servers`（这一步很关键，见下）。
+
+`release auth` 只有在你真的运行 `--set-token` 时才写文件；不带参数时只读并报告，状态判断比「文件是否存在」严格：
+
+```
+config file: C:\Users\cheun\.pypirc (exists)
+[--  ] [pypi] not usable: [pypi] still contains a placeholder token
+[--  ] [testpypi] not usable: C:\Users\cheun\.pypirc has no [testpypi] section
+```
+
+**占位符、空密码、`username` 不是 `__token__`，都会被判定为「不可用」**——否则 twine 只会在真正上传时才发现，而那时已经动过索引了。
+
+`release pypi` 在 `--apply` 时若凭证缺失：有终端就地提示输入（隐藏），无终端则直接失败并打印 `release auth --set-token <index>`；也可显式加 `--prompt-credentials`。dry run 只告警并继续展示计划，不会卡在输入上。
+
+#### twine 直接读取的格式
+
+默认路径 `~/.pypirc`（Windows 上即 `C:\Users\<你>\.pypirc`，由 `USERPROFILE` 展开）。**没有**环境变量可以改这个路径；要用别的文件就传 `--config-file`。
+
+```ini
+[distutils]
+index-servers =
+    pypi
+    testpypi
+
+[pypi]
+repository = https://upload.pypi.org/legacy/
+username = __token__
+password = pypi-你的正式token
+
+[testpypi]
+repository = https://test.pypi.org/legacy/
+username = __token__
+password = pypi-你的TestPyPI token
+```
+
+容易搞错的点：
+
+- **`[distutils] index-servers` 必须列出该索引，否则 twine 完全忽略那一节** —— 这是最常见的坑：文件里明明有 `[testpypi]` 段，twine 却报 `InvalidConfiguration: Missing 'testpypi' section`。用 `release auth --repair` 修（把已存在但未列出的段补进 `index-servers`）。
+- 更细的语义差别：`index-servers =` **值为空**表示「一个都不认」；只有**整行缺失**时 twine 才会回退到默认的 `pypi testpypi`。所以手工编辑时别把名字删空。
+- `username` 就是字面量 `__token__`，不是账号名或邮箱
+- 两类 token **都以 `pypi-` 开头**，但**不能互换**：拿正式 token 打 `test.pypi.org` 会被 403 拒绝
+- TestPyPI 是**独立服务、独立账号**，注册在 <https://test.pypi.org/account/register/>，你的 PyPI 账号在那里不存在
+- 正式 token 建议限定到 `orisys` 项目（项目已存在，可以建 project-scoped token）
+- 该文件必须在**任何 git 仓库之外**（放在用户目录里）；token 一旦提交进仓库，即使后来删文件也还在历史里——那属于安全事故
+- 临时替代方案：会话内设 `TWINE_USERNAME=__token__` + `TWINE_PASSWORD=<token>`，命令会识别这种情形
+- PyPI token **没有只读的校验方式**，有效性只能在真正上传时才会被索引确认；所以所有本地检查、查重都排在写操作之前
+
+`release auth` 的「可用」判定**直接问 twine 自己**（`twine.utils.get_config` 解析出的 username/password），而不是自己解析 ini，这样报告结果与 twine 的行为不会分叉。twine 未安装时才回退到本地复刻同一套规则。
+
+只需要 TestPyPI 时才把 `testpypi` 写进 `index-servers` 并填对应 token；只发正式库时 `--pypi-only` 用不到 `[testpypi]` 段。
+
+### 3.4 已知的历史发布空洞
+
+| 版本 | 本地 `SDK/` | PyPI | GitHub Release |
+| --- | --- | --- | --- |
+| 0.4.2 | — | 有 | 有 |
+| 0.4.3 | — | 有 | 有 |
+| 0.4.4 | 有 | **无** | **无** |
+| 0.5.0 | 有 | **无** | **无** |
+| 0.5.1 | 有 | 有 | 有（tag `v0.5.1` + typo tag `0.50`） |
+| 0.5.2 | 有 | **待发布** | **待发布**（`release preflight --check-pypi` 确认 PyPI 尚无 0.5.2） |
+
+> 本表按 2026 年 0.5.2 构建时的实际状态填写。`0.5.1` 这一行曾被一次全局替换误改成 `0.5.2` 并丢失，请勿再用「全局把 0.5.1 替换成新版本号」的方式改本文件——历史事实不应该被改。
+
+---
+
+## 4. 环境变量
+
+| 变量 | 用途 |
+| --- | --- |
+| `ORISYS_TEST_VIDEO` | pytest 用的视频；默认自动取 `data/sample/s1_480p.mp4` |
+| `ORISYS_TEST_CONFIG` | pytest 用的配置名；默认自动挑一个含 `stitcher.box_size` 的配置 |
+| `ORISYS_VERIFY_VIDEO` | 运行时校验用的视频 |
+| `ORISYS_VERIFY_CONFIG` | 运行时校验用的配置名（默认 `box`） |
+| `ORISYS_LONGRUN_BACKEND` / `ORISYS_LONGRUN_FRAMES` | `slow` 长稳测试的参数 |
+| `CONDA_ENVS_ROOT` | conda envs 根目录（`--all-wheel-pythons` 用它解析 `py310`/`py311`/`py312`） |
+
+---
+
+## 5. 三个必须记住的坑
+
+### 5.1 Nuitka 编译包的 `__file__` 是假的
+
+Nuitka 把整个 `orisys` 编译成单个扩展模块，其 `__init__` 会安装 `nuitka_module_loader`。于是：
+
+```python
+>>> import orisys
+>>> orisys.__file__          # 合成的、磁盘上并不存在的路径
+'...\\site-packages\\orisys\\orisys\\__init__.py'
+>>> orisys.__path__          # 第二项是 Nuitka 的哨兵值
+['...\\site-packages\\orisys\\orisys', '\\not_existing']
+>>> orisys.__loader__.__class__.__name__
+'nuitka_module_loader'
+```
+
+后果：**在 Nuitka wheel 里不能靠 `orisys.__file__` 或 `importlib.resources.files("orisys")` 定位内置数据**——它们会指向不存在的目录，静默返回「文件不存在」。请改用发行包定位：
+
+```python
+from importlib.metadata import distribution
+root = distribution("orisys").locate_file("orisys")   # site-packages/orisys
+```
+
+`build/common/verify/wheel.py` 的内置资产校验就是这么做的，并且会显式断言该目录位于校验用 venv 内，避免被父环境里的旧 `orisys` 顶替。
+
+### 5.2 `--offline` 会被父环境的脏安装污染
+
+`--offline` 通过 venv 的 `--system-site-packages` 复用父环境的 numpy/numba 等依赖，这也顺带暴露了父环境里的 `orisys`。若父环境残留了半卸载的 editable 安装（典型症状是 `pip` 提示 `Ignoring invalid distribution -risys`，且 `site-packages/orisys/__init__.py` 是一个指向死路径的 shim），校验就会读到它。
+
+处置：在构建环境里执行 `pip uninstall -y orisys`，或改用不带 `--offline` 的完全隔离 venv（会联网安装依赖）。
+
+### 5.3 版本号只有一个地方，其他都是推导出来的
+
+版本号的唯一来源是 **`src/orisys/__init__.py::__version__`**。以下全部由它推导，不需要手改：
+
+| 产物 | 推导方式 |
+| --- | --- |
+| pyproject 的 `[project] version` | `[tool.setuptools.dynamic] version = {attr = "orisys.__version__"}` |
+| wheel 文件名里的版本 | `build/wheel/build.py` 调 `get_version()` |
+| wheel `METADATA` 的 `Version:` | 生成的 `setup.py` 里写入同一个 `version` |
+| `SDK/<version>/` 目录名 | 同上 |
+| `importlib.metadata.version("orisys")` | 从 wheel METADATA 读出 |
+
+因此**不要**再往文档、示例、测试里写具体版本号：
+
+- 用法示例写 `SDK/<version>/...`、`--version <version>`，不要写具体版本
+- 文档里不要写「版本：x.y.z」；需要时让用户用 `python -c "import orisys; print(orisys.__version__)"` 自己看
+- 示例脚本的 docstring 不要再写 `SDK version: x.y.z`
+- 测试里需要「一个版本」时用明显是假的版本号（如 `1.x.y` 这种不会与真实版本混淆的值），不要用当前版本 —— 否则每次发版都要改测试，而且一次全局替换就会悄悄改坏断言
+
+`release preflight` 的 `version-strings` 步骤强制这条规则：扫描所有被追踪的文本文件，任何与当前版本不符的版本字面量都会导致失败（`tests/` 与生成物除外；依赖约束如 `numpy>=1.24.4` 由正则排除）。
+
+历史记录属于例外，需显式登记在 `build/release/version.py::VERSION_STRING_ALLOWLIST` 里——登记本身就是「该字面量故意不是包版本」的文档。**不要用全局替换修改含历史版本的文件**：本文件的发布记录表就曾被一次全局替换改错（`0.50` typo tag 被挂到错误的版本上，`0.5.1` 那一行被覆盖丢失）。
+
+### 5.4 wheel 里有什么、没有什么
+
+打包内容由 `pyproject.toml` 的 `[[tool.orisys.bundle.items]]` 单点定义：
+
+| 内容 | 是否进 wheel | 说明 |
+| --- | --- | --- |
+| `config/*.json` | 是 | `orisys/configs/`，运行时配置解析要用 |
+| `sensors/**` | 是 | `orisys/sensors/`，含 finger 的 npz/npy 资产，运行时与 GUI 都要用 |
+| `examples/**` | 是 | `orisys/examples/`，用户装完就能跑示例 |
+| `docs/**` | **否** | 只随 GitHub 仓库与 PyPI 项目页提供。`docs/publishing.md` 是内部流程文档；`docs/pypi_readme.md` 仅在构建时被读取作为 long description |
+
+因为 docs 不进 wheel，**改文档不会让已构建的 wheel 失效**，不需要重新构建。（改 `examples/`、`config/`、`sensors/` 会——它们确实在 wheel 里，`wheel-inspection` 的 `bundle-fidelity` 会报出来。）
+
+如果以后需要离线 API 参考，加一个只包含 `docs/api.md` 的窄条目即可，不要整个 `docs/` 都塞进去。
+
+---
+
+## 6. 缩短 manylinux 构建时间
+
+`python build/run.py manylinux` 走 `build/wheel/docker/run.ps1` → 容器内 `entrypoint.sh`，对 `cp310/cp311/cp312` **串行**各做一次 Nuitka 编译 + 打 wheel + auditwheel repair + 隔离 venv 校验。
+
+### 6.1 镜像里已经烘好的东西（所以每次构建不必再拉）
+
+`Dockerfile.manylinux` 在每个 ABI 下预置了两类内容：
+
+1. **构建工具**：`pip`/`setuptools`/`wheel`/`nuitka`/`ordered-set`/`zstandard`/`auditwheel`。
+   因此 `entrypoint.sh` 默认**不再**在每个 ABI 上重跑 `pip install --upgrade pip setuptools wheel auditwheel` —— 那是每次构建 3 次多余的 PyPI 往返，还会让容器里的工具版本与镜像不一致。需要用最新工具时显式开启：
+
+   ```powershell
+   docker run ... -e ORISYS_UPDATE_BUILD_TOOLS=1 ...
+   ```
+
+2. **每个 ABI 一个 wheelhouse**（`/opt/orisys-wheelhouse/<tag>`），内含 `numpy`/`scipy`/`opencv-python`/`numba` 及其依赖闭包，外加 `pip`/`setuptools`/`wheel`/`auditwheel` 的 wheel。
+
+   `--target pypi-linux` 会**强制**校验：为每个 ABI 建一个一次性 venv，再 `pip install` 刚构建的 wheel 和它声明的运行期依赖。镜像故意不把运行期依赖装进解释器（用户是凭 wheel 元数据装的），所以以前每次构建都要现下约 200 MB × 3。`entrypoint.sh` 现在用 `PIP_NO_INDEX=1` + `PIP_FIND_LINKS=<wheelhouse>` 把 pip 指向本地 wheelhouse：**venv 仍然是隔离的**（没有 `--system-site-packages`），依赖解析与安装依然真实发生，只是不走网络。
+
+   找不到 wheelhouse 时会打印警告并回退到联网，不会静默失败。镜像因此增大约 400–500 MB（一次性代价，换每次构建省三次下载）。
+
+### 6.2 不要为了省事直接重建镜像
+
+只改了源码（`src/`、`config/`、`sensors/`、`examples/`、`pyproject.toml`）时加 `-SkipImageBuild`：
+
+```powershell
+.\build\wheel\docker\run.ps1 -SkipImageBuild
+```
+
+Dockerfile 的 `RUN` 层要装 3 份工具链并下载 3 个 wheelhouse，缓存未命中就是数分钟。**改了 `Dockerfile.manylinux` 或需要更新 wheelhouse 时才重建镜像**。
+
+### 6.3 Nuitka 的排除列表必须完整
+
+`build/wheel/compile.py::NUITKA_NOFOLLOW_IMPORTS` 列出所有**不打进 wheel、运行期从用户环境解析**的第三方包。漏一个意味着 Nuitka 会尝试把它跟进来：编译时间暴涨，而且 wheel 内容开始取决于构建机上恰好装了什么 —— `torch`、`torchvision`（`src/orisys/tracker.py` 的 RAFT 追踪器）和 `pyvkfft`（`backend_availability.py`）就是这样漏掉的，之前只是靠「构建机上没装」才没出事。
+
+`tests/test_nuitka_nofollow.py` 会扫描 `src/orisys` 的全部第三方导入，任何不在排除列表里的都会让测试失败。**新增可选依赖时同步更新列表。**
+
+### 6.4 想要并行？先读这一段
+
+`--jobs` 的默认值是**全部 CPU 数**，单次编译的 C 阶段已经吃满所有核心。真正能靠并行省下的是 Nuitka 的单线程前端（分析/优化/代码生成）、scons 启动、`auditwheel` 与 venv 校验 —— 做法是 3 路并行 + 每个 build 限 `--jobs=<核数/3>`。
+
+但**现在不能直接并行**：`build/common/paths.py` 里的工作目录是写死的共享路径
+
+```
+build/nuitka/compile
+build/nuitka/wheel
+build/nuitka/wheel/repaired
+```
+
+而 `build/wheel/build.py` 每次开头都 `_reset_dir()`（`rmtree`）这两个目录，`auditwheel repair` 又会再 `rmtree` 一次 `repaired`。仓库是挂载进容器的（`-v ${RepoRoot}:/src`），所以无论「一个容器 3 路并行」还是「3 个容器并行」，只要共享同一个挂载点，三个 build 就会互相清空暂存目录 —— 表现为随机失败或 wheel 内容错乱。
+
+要并行必须先让工作目录带上 ABI 标签（如 `build/nuitka/<tag>/compile`）。输出路径不用动：`SDK/<version>/`、`dist/repaired/` 的文件名本来就按 ABI 区分，下游 `release preflight` 不受影响。另外 3 个 Nuitka 并行很吃内存，先把 Docker Desktop 内存调到 16 GB 以上再试。
+

docs/pypi_readme.md

@@ -0,0 +1,63 @@
+# Orisys SDK
+
+叠动科技视触觉传感器配套的 Python SDK，提供图像采集、拼接、稠密光流、Helmholtz-Hodge 分解、接触与深度估计，以及可运行的示例。
+
+本文件是 PyPI 项目描述（`long_description`）的源文件：构建时由 `docs/publishing.md` 所述流程从**检出目录**读取（`build/wheel/package.py::PYPI_README_RELPATH`），**不会**被打进 wheel。因此不要在这里写内部仓库布局、构建流水线或发布步骤——那些内容属于仓库内的 `README.md` 与 `docs/publishing.md`。
+
+```bash
+python -m pip install orisys
+```
+
+支持 Python 3.10 / 3.11 / 3.12，Windows x64 与 Ubuntu x64。
+
+## 快速开始
+
+```bash
+python -c "import orisys; print(orisys.__version__)"
+python -c "import orisys; print(orisys.list_config())"
+```
+
+## 安装选项
+
+- `orisys` — CPU / 基础流程
+- `orisys[gui]` — Qt / Open3D 可视化示例
+- `orisys[cuda12]` / `orisys[cuda13]` — NVIDIA GPU 加速
+- `orisys[gui,cuda12]` — GUI + CUDA 12
+
+`orisys[cuda]` 与 `orisys[cuda12]` 等价。
+
+## 配置
+
+配置解析顺序：
+
+1. 显式 JSON 文件路径
+2. 内置配置名（`box`、`mini`、`finger` 等）
+3. 产品别名（如 `dd02` -> `dd02-ov`）
+4. 向后兼容的 JSON `"name"` 匹配
+
+```python
+import orisys
+
+sensor = orisys.Sensor(0, config_name="box")
+orisys.export_config("box", "./exported_config.json")
+```
+
+## 示例
+
+示例随 wheel 一起分发，位于 `orisys/examples/`。也可以从项目仓库获取：
+
+```bash
+python examples/basic_pipeline.py -v 0 -c box
+python examples/finger_pipeline.py --camera_id 0 --config finger
+```
+
+无相机时可以改用视频文件：
+
+```bash
+python examples/finger_pipeline.py --video ./sample.mp4 --config finger
+```
+
+## 支持与反馈
+
+- 官网：[https://www.orisys-tech.cn](https://www.orisys-tech.cn)
+- 问题反馈：GitHub Issues

examples/basic_pipeline.py

@@ -7,7 +7,6 @@ ORY-BOX：单传感器基础流程
 3. 按需计算接触区域
 4. 读取并可视化结果
 
-SDK version: 0.5.0
 """
 import os
 os.environ["OPENCV_VIDEOIO_MSMF_ENABLE_HW_TRANSFORMS"] = "0" 
@@ -21,6 +20,7 @@ def main():
     parser.add_argument("--video","-v", type=str, default="0", help="视频源：摄像头编号或视频文件路径")
     parser.add_argument("--config","-c", type=str, default="box", help="配置文件名称或路径")
     parser.add_argument("--verbose","-verbose", type=bool, default=True, help="是否输出详细日志")
+    parser.add_argument("--cal_path","-cal", type=str, default=None, help="标定文件路径")
     args = parser.parse_args()
 
     # 步骤 1：创建传感器对象（必需）
@@ -29,9 +29,9 @@ def main():
 
     # 输入既可以是摄像头编号，也可以是视频文件路径
     if args.video.isdigit():
-        sensor = orisys.Sensor(int(args.video), config_name=args.config, verbose=args.verbose)
+        sensor = orisys.Sensor(int(args.video), config_name=args.config, verbose=args.verbose, cal_path=args.cal_path)
     else:
-        sensor = orisys.Sensor(args.video, config_name=args.config, verbose=args.verbose)
+        sensor = orisys.Sensor(args.video, config_name=args.config, verbose=args.verbose, cal_path=args.cal_path)
 
     print("\n按键说明：'q' 退出程序，'r' 重置追踪器。")
 

examples/filters/README.md

@@ -0,0 +1,104 @@
+# 滤波预设：可直接复制的 `filters` 段
+
+`json.load` 不支持注释，所以这个目录就是"在配置里写说明"的替代品：**把下面任意一段整块替换**
+到 `sensors/<name>/sensor.json` 的 `"filters"` 段即可。原有的 `filters` 段请整段替换，
+不要只改其中一行（避免出现 `preset` 与数值混写的歧义——显式键优先于预设值，混写容易看错）。
+
+配置里**没写**的滤波键等于"关"：整段删掉就是什么都不滤，和 `off` 那段等价。
+
+背景、代价与可追溯性约定见 `docs/filters.md`；延迟/噪声实测见 `_perf/` 与
+`orisys-sdk-perf-plan.md`。
+
+下面每一段都有一个同目录的机器可读副本 `filters_<预设名>.json`（四个文件），
+`tests/test_filter_presets.py` 会核对它们与 `FILTER_PRESETS` 完全一致 —— 所以改预设时
+这些文件会一起红，不会悄悄过时。
+
+---
+
+## `off` —— 原始读数（默认）
+
+```json
+"filters": {
+  "flow_ema_alpha": 1.0,
+  "force_median_window": 1,
+  "force_lowpass_cutoff_hz": 0.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}
+```
+
+## `low_latency` —— 只去尖峰（≈1 帧 @30fps）
+
+```json
+"filters": {
+  "flow_ema_alpha": 1.0,
+  "force_median_window": 3,
+  "force_lowpass_cutoff_hz": 0.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}
+```
+
+## `balanced` —— 建议默认（≈2 帧 @30fps）
+
+```json
+"filters": {
+  "flow_ema_alpha": 0.5,
+  "force_median_window": 3,
+  "force_lowpass_cutoff_hz": 0.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}
+```
+
+## `low_noise` —— 底噪优先（≈3 帧 @30fps）
+
+```json
+"filters": {
+  "flow_ema_alpha": 0.3,
+  "force_median_window": 3,
+  "force_lowpass_cutoff_hz": 10.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}
+```
+
+## 用预设名（等价写法，数值由代码展开）
+
+```json
+"filters": { "preset": "balanced" }
+```
+
+`off / low_latency / balanced / low_noise` 四个名字来自
+`src/orisys/sensor.py::FILTER_PRESETS`（单一真值）；想从预设出发只改一个旋钮，就在同一段里写
+那一个键，例如：
+
+```json
+"filters": { "preset": "balanced", "force_lowpass_cutoff_hz": 10.0 }
+```
+
+---
+
+## 复制后请核对"实际生效值"
+
+配置只是**意图**；`Sensor.configure()` 可以在运行时再改，所以审计与记录一律看生效值：
+
+```python
+from orisys.sensor import Sensor
+s = Sensor("external", config_name="mini", verbose=False)   # 无需硬件即可核对
+print(s.filters_state()["preset"], s.filters_state()["measurement"], s.filters_state()["readout"])
+```
+
+`flow_ema_applied` / `force_median_applied` / `force_lowpass_applied` 三个布尔就是
+"这一级到底有没有在滤"的答案；`flow_ema_alpha` 属于 **measurement**（改变测量，
+不同值的两次录制不可比），中值与低通属于 **readout**（只影响读数呈现）。
+
+导出标定/写记录时把同一个状态交给指纹函数，文件里就会留下可核对的设置：
+
+```python
+from orisys.calibration import pipeline_from_sensor_json
+pipeline = pipeline_from_sensor_json("sensors/mini/sensor.json", filters_state=s.filters_state())
+print(pipeline["filters"])   # measurement / readout / preset / source
+```
+
+详见 `docs/filters.md` 第 7 节。

examples/filters/filters_balanced.json

@@ -0,0 +1,7 @@
+{
+  "flow_ema_alpha": 0.5,
+  "force_median_window": 3,
+  "force_lowpass_cutoff_hz": 0.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}

examples/filters/filters_low_latency.json

@@ -0,0 +1,7 @@
+{
+  "flow_ema_alpha": 1.0,
+  "force_median_window": 3,
+  "force_lowpass_cutoff_hz": 0.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}

examples/filters/filters_low_noise.json

@@ -0,0 +1,7 @@
+{
+  "flow_ema_alpha": 0.3,
+  "force_median_window": 3,
+  "force_lowpass_cutoff_hz": 10.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}

examples/filters/filters_off.json

@@ -0,0 +1,7 @@
+{
+  "flow_ema_alpha": 1.0,
+  "force_median_window": 1,
+  "force_lowpass_cutoff_hz": 0.0,
+  "force_lowpass_order": 2,
+  "force_lowpass_sample_rate_hz": "auto"
+}

examples/mini_pipeline.py

@@ -7,7 +7,6 @@ ORY-MINI：单传感器基础流程
 3. 按需计算接触区域
 4. 读取并可视化结果
 
-SDK version: 0.5.0
 """
 import os
 os.environ["OPENCV_VIDEOIO_MSMF_ENABLE_HW_TRANSFORMS"] = "0" 

examples/multi_stream.py

@@ -0,0 +1,305 @@
+#!/usr/bin/env python3
+"""Multi-sensor real-time example: N streams, one process each.
+
+This is the deployment shape the multi-sensor throughput numbers assume. Each
+stream owns a process and pipelines the per-frame work into three concurrent
+stages (capture+unroll -> DIS flow -> HHD+readout), so a stream's rate is bounded
+by its slowest stage instead of the sum of all three.
+
+    # five finger streams from a video file (benchmark / smoke test)
+    python examples/multi_stream.py --streams 5 -c finger -v data/dd02-0703/1.mp4
+
+    # five live cameras, camera ids 0..4
+    python examples/multi_stream.py --streams 5 -c finger --camera-base 0
+
+    # single box sensor
+    python examples/multi_stream.py --streams 1 -c box -v data/long.mp4
+
+    # five streams, additionally recording an arrow-overlay video per stream
+    # plus one 5-up mosaic, without stalling the pipeline
+    python examples/multi_stream.py --streams 5 -c finger -v data/dd02-0703/1.mp4 \
+        --seconds 10 --record outputs/arrows --mosaic
+
+Notes
+-----
+* One process per stream. Threads inside a single process share the GIL and,
+  measured on a 9950X, five finger streams reach ~150 FPS aggregate as threads
+  versus ~626 FPS as processes.
+* ``cv2.setNumThreads(2)`` per process: at five streams that beats 1, 4 and 8.
+* Run one stream per process even when the sensor count is small; the process
+  boundary also isolates a crashed camera from the rest.
+* ``--record`` draws the DIS flow with ``orisys.util.draw_arrows`` (plus the
+  contact overlay with ``--contact``) and encodes it with ``cv2.VideoWriter``.
+  Both happen on a dedicated thread fed by a bounded drop-oldest queue, so the
+  pipeline never waits on the encoder; frames the writer cannot keep up with are
+  counted in the ``rec`` column as ``written/dropped``. Keep ``--record`` for
+  verification runs - the encoder still competes for CPU with the pipeline.
+"""
+
+from __future__ import annotations
+
+import argparse
+import json
+import multiprocessing as mp
+import os
+import statistics as st
+import sys
+import time
+
+os.environ.setdefault("OPENCV_VIDEOIO_MSMF_ENABLE_HW_TRANSFORMS", "0")
+
+import orisys
+from orisys import StreamPipeline, StreamRecorder, configs
+
+
+def _make_stream(args, index):
+    """Return (sensor, produce, close) for one stream."""
+    source = args.video
+    if args.camera_base is not None:
+        source = int(args.camera_base) + index
+    if source is None:
+        raise ValueError("pass --video PATH or --camera-base ID")
+
+    cfg = configs.load_config(args.config)
+    if str(cfg.get("type", "")).lower() == "single_camera":
+        from orisys.finger import FingerRuntime
+
+        runtime = FingerRuntime.open(config=args.config, video=source,
+                                     verbose=False)
+        return runtime.tactile.raw_sensor, _finger_produce(runtime), runtime.close
+
+    sensor = orisys.Sensor(source, config_name=args.config, isstitch=True,
+                           cuda=False, backend="cpu", verbose=False)
+
+    def produce():
+        return sensor.get_img()
+
+    return sensor, produce, sensor.disconnect
+
+
+def _finger_produce(runtime):
+    def produce():
+        ok, frame = runtime.grab_and_process(color=False)
+        return frame if ok else None
+
+    return produce
+
+
+def worker(args, index, out_path):
+    """One stream: own process, three-stage pipeline."""
+    import cv2
+
+    cv2.setNumThreads(int(args.threads))
+    sensor, produce, close = _make_stream(args, index)
+
+    frames = []
+    stamps = []
+    started = time.perf_counter()
+
+    def collect(snap):
+        frames.append(snap.age_ms)
+        stamps.append(time.perf_counter())
+
+    # Recording is entirely off the hot path: ``on_frame`` only pushes onto a
+    # bounded drop-oldest queue, and a separate thread does the drawing and the
+    # H.264/MPEG-4 encoding. The pipeline never blocks on the encoder.
+    recorder = None
+    on_frame = collect
+    if args.record:
+        recorder = StreamRecorder(
+            os.path.join(args.record, f"stream_{index}.mp4"),
+            fps=args.record_fps,
+            every=args.record_every,
+            fourcc=args.record_fourcc,
+            valid_mask=lambda: getattr(sensor, "valid_mask", None),
+            grid_spacing=args.record_grid,
+            threshold=args.record_threshold,
+            arrow_scale=args.record_arrow_scale,
+            draw_contact=args.contact,
+            label=f"#{index}",
+            verbose=True,
+        )
+
+        def on_frame(snap, _collect=collect, _rec=recorder):
+            _collect(snap)
+            _rec.on_frame(snap)
+
+    if args.no_arrays:
+        include = ()
+    elif recorder is not None:
+        include = ("image", "flow")  # what the arrow overlay needs
+    else:
+        include = ("image",)
+
+    pipe = StreamPipeline(sensor, produce, on_frame=on_frame,
+                          include=include, contact=args.contact, depth=args.depth)
+    pipe.start()
+    record_stats = None
+    try:
+        deadline = started + args.seconds if args.seconds else None
+        while True:
+            if not pipe.running:
+                break
+            if args.frames and pipe.stats.published >= args.frames:
+                break
+            if deadline is not None and time.perf_counter() >= deadline:
+                break
+            time.sleep(0.002)
+    finally:
+        try:
+            pipe.stop()
+        except BaseException as exc:  # surface a stage failure
+            print(f"[stream {index}] pipeline error: {type(exc).__name__}: {exc}",
+                  file=sys.stderr)
+            raise
+        finally:
+            if recorder is not None:
+                record_stats = recorder.close()
+            close()
+
+    wall = time.perf_counter() - started
+    # Steady-state rate: skip the first frames, which pay the JIT / HHD-cache /
+    # DIS-reference-frame warm-up and would drag a short run's average down.
+    warm = min(30, max(0, len(stamps) - 2))
+    span = (stamps[-1] - stamps[warm]) if len(stamps) > warm + 1 else 0.0
+    steady = (len(stamps) - 1 - warm) / span if span > 0 else 0.0
+    payload = {
+        "index": index,
+        "published": pipe.stats.published,
+        "wall": wall,
+        "fps": pipe.stats.published / wall if wall else 0.0,
+        "steady_fps": steady,
+        "stats": pipe.stats.as_dict(),
+        "age_p95_ms": float(st.quantiles(frames, n=20)[18]) if len(frames) >= 20 else 0.0,
+        "record": record_stats,
+    }
+    with open(out_path, "w") as fh:
+        json.dump(payload, fh)
+
+
+def main():
+    ap = argparse.ArgumentParser(description=__doc__,
+                                 formatter_class=argparse.RawDescriptionHelpFormatter)
+    ap.add_argument("--streams", "-n", type=int, default=5)
+    ap.add_argument("--config", "-c", default="finger")
+    ap.add_argument("--video", "-v", default=None, help="video file shared by all streams")
+    ap.add_argument("--camera-base", type=int, default=None,
+                    help="first camera id; stream i uses base + i")
+    ap.add_argument("--frames", type=int, default=0, help="stop after N frames (0 = until EOF)")
+    ap.add_argument("--seconds", type=float, default=10.0, help="max wall time per stream")
+    ap.add_argument("--threads", type=int, default=2, help="cv2.setNumThreads per stream")
+    ap.add_argument("--depth", type=int, default=2, help="queue depth between stages")
+    ap.add_argument("--contact", action="store_true", help="also run compute_contact")
+    ap.add_argument("--no-arrays", action="store_true",
+                    help="scalars only (fastest; skips the snapshot image copy)")
+    ap.add_argument("--out-dir", default=None)
+    ap.add_argument("--record", default=None, metavar="DIR",
+                    help="write one arrow-overlay mp4 per stream into DIR "
+                         "(drawing+encoding run on a separate thread, off the "
+                         "pipeline's critical path)")
+    ap.add_argument("--record-fps", type=float, default=30.0,
+                    help="playback fps of the recorded files")
+    ap.add_argument("--record-every", type=int, default=1,
+                    help="keep one frame in N (raise it if the writer falls behind)")
+    ap.add_argument("--record-fourcc", default="mp4v",
+                    help="mp4v (built in) or MJPG/avi for maximum compatibility")
+    ap.add_argument("--record-grid", type=int, default=14, help="arrow grid spacing in px")
+    ap.add_argument("--record-threshold", type=float, default=0.1,
+                    help="displacement (px) below which a dot is drawn instead of an arrow")
+    ap.add_argument("--record-arrow-scale", type=float, default=0.15,
+                    help="draw_arrows divides the displacement by this; 0.15 magnifies "
+                         "the finger's ~1-3 px field ~6.7x so directions are legible")
+    ap.add_argument("--mosaic", action="store_true",
+                    help="after the run, tile the recordings into one grid video")
+    ap.add_argument("--mosaic-cols", type=int, default=0, help="mosaic columns (0 = square-ish)")
+    ap.add_argument("--mosaic-scale", type=float, default=1.0, help="mosaic downscale factor")
+    args = ap.parse_args()
+
+    if args.record and args.no_arrays:
+        ap.error("--record needs the frame and flow arrays; drop --no-arrays")
+    if args.mosaic and not args.record:
+        ap.error("--mosaic needs --record DIR")
+
+    if args.record:
+        args.record = os.path.abspath(args.record)
+        os.makedirs(args.record, exist_ok=True)
+
+    out_dir = args.out_dir or os.path.join(os.path.dirname(os.path.abspath(__file__)),
+                                           "..", "outputs", "multi_stream")
+    out_dir = os.path.abspath(out_dir)
+    os.makedirs(out_dir, exist_ok=True)
+
+    ctx = mp.get_context("spawn")
+    procs, paths = [], []
+    for i in range(args.streams):
+        path = os.path.join(out_dir, f"stream_{i}.json")
+        paths.append(path)
+        procs.append(ctx.Process(target=worker, args=(args, i, path)))
+    for p in procs:
+        p.start()
+    for p in procs:
+        p.join()
+
+    rows = []
+    for path in paths:
+        try:
+            with open(path) as fh:
+                rows.append(json.load(fh))
+        except Exception:
+            pass
+    if not rows:
+        print("no stream produced results", file=sys.stderr)
+        return 1
+
+    wall = max(r["wall"] for r in rows)
+    total = sum(r["published"] for r in rows)
+    steady_rows = [r for r in rows if r.get("steady_fps")]
+    steady = st.mean(r["steady_fps"] for r in steady_rows) if steady_rows else 0.0
+    print(f"\nstreams={len(rows)}  frames={total}  wall={wall:.2f}s")
+    print(f"aggregate throughput     : {total / wall:.1f} FPS (incl. warm-up)")
+    print(f"per-stream throughput    : {total / wall / len(rows):.1f} FPS (incl. warm-up)")
+    print(f"per-stream steady-state  : {steady:.1f} FPS")
+    recording = args.record is not None
+    print(f"\n{'stream':>7}{'published':>11}{'FPS':>9}{'steady':>9}{'produce':>10}"
+          f"{'flow':>9}{'hhd':>9}{'age':>9}{'age p95':>10}"
+          + (f"{'rec':>13}" if recording else ""))
+    for r in sorted(rows, key=lambda x: x["index"]):
+        s = r["stats"]
+        rec = ""
+        if recording:
+            rs = r.get("record") or {}
+            rec = f"{rs.get('written', 0)}/{rs.get('dropped', 0)}"
+            if rs.get("error"):
+                rec = "ERR"
+        print(f"{r['index']:>7}{r['published']:>11}{r['fps']:>9.1f}"
+              f"{r.get('steady_fps', 0.0):>9.1f}"
+              f"{s['produce_ms']:>10.2f}{s['flow_ms']:>9.2f}{s['hhd_ms']:>9.2f}"
+              f"{s['age_ms']:>9.2f}{r['age_p95_ms']:>10.2f}"
+              + (f"{rec:>13}" if recording else ""))
+    if recording:
+        print("rec column = frames written / frames dropped by the writer thread")
+        for r in sorted(rows, key=lambda x: x["index"]):
+            rs = r.get("record") or {}
+            if rs.get("error"):
+                print(f"  stream {r['index']}: {rs['error']}")
+
+    if args.mosaic and recording:
+        streams = sorted(r["index"] for r in rows)
+        srcs = [os.path.join(args.record, f"stream_{i}.mp4") for i in streams]
+        missing = [p for p in srcs if not os.path.isfile(p)]
+        if missing:
+            print(f"mosaic skipped, missing {missing}", file=sys.stderr)
+        else:
+            out = os.path.join(args.record, "mosaic.mp4")
+            # No tile labels: each recorded frame already carries the "#N" HUD.
+            info = orisys.mosaic_videos(srcs, out, cols=args.mosaic_cols or None,
+                                        scale=args.mosaic_scale,
+                                        fps=args.record_fps)
+            print(f"\nmosaic -> {info['path']}  {info['size'][0]}x{info['size'][1]}  "
+                  f"{info['grid'][0]}x{info['grid'][1]} grid  {info['frames']} frames "
+                  f"@ {info['fps']:g} fps")
+    return 0
+
+
+if __name__ == "__main__":
+    raise SystemExit(main())

examples/two_sensor_pipeline.py

@@ -18,7 +18,6 @@
 - Windows 下必须在 if __name__ == '__main__' 中调用 mp.freeze_support()
 - 每个传感器进程都会占用独立的 GPU 显存
 
-SDK version: 0.5.0
 """
 import os
 os.environ["OPENCV_VIDEOIO_MSMF_ENABLE_HW_TRANSFORMS"] = "0" 

pyproject.toml

@@ -99,9 +99,12 @@ target = "examples"
 patterns = ["*.py", "README.md", "viz/**/*.py", "pipeline/**/*.py", "gui/**/*.py"]
 preserve_tree = true
 
-[[tool.orisys.bundle.items]]
-name = "docs"
-source = "docs"
-target = "docs"
-patterns = ["*.md", "*.pdf"]
+# NOTE: docs/ is deliberately NOT bundled into the wheel.
+# Documentation ships with the GitHub repository / PyPI project page only:
+#   - docs/publishing.md is an internal process document
+#   - docs/pypi_readme.md is read from the checkout at build time as the PyPI
+#     long description (build/wheel/package.py::PYPI_README_RELPATH), never shipped
+#   - keeping docs out means editing a doc no longer invalidates built wheels
+# Should an offline API reference be needed later, add a narrower item that ships
+# only docs/api.md.
 

pytest.ini

@@ -1,5 +1,9 @@
 [pytest]
 testpaths = tests
 python_files = test_*.py
+# Run against the checkout without requiring `pip install -e .`, so a stale
+# orisys in site-packages cannot silently shadow src/orisys.
+pythonpath = src
 markers =
     slow: long-running tests for release validation
+    hardware: requires a physical sensor/camera attached to the machine

scripts/measure_zero_drift.py

@@ -0,0 +1,341 @@
+"""Measure normal-force zero-point drift, live or from a recording.
+
+Phase 0 of the zero-point plan: quantify the drift before changing the pipeline.
+The number this prints is what the acceptance thresholds get set from, so it is
+deliberately explicit about which rows it used and what it could not conclude.
+
+Usage
+-----
+Live capture (needs a sensor; writes a recording directory when --out is given):
+
+    python scripts/measure_zero_drift.py --live --seconds 1800 --out D:\\tmp\\idle
+
+From an existing recording (the directory holding forces.csv):
+
+    python scripts/measure_zero_drift.py --recording <dir> --unit both
+    python scripts/measure_zero_drift.py --recording <dir> --warmup 5 --start 10 --stop 60
+
+What it reports
+---------------
+Per axis, over the analysed window:
+
+* mean / median / stdev / peak-to-peak, in raw counts and (with --unit N) newtons
+* a least-squares slope in counts/s -- the ramp that "zero drift" actually means
+* a drift ratio (end-third mean minus start-third mean), which is insensitive to
+  whether the drift is linear or a slow wander
+* the band left after removing the window mean, i.e. what a perfect single-point
+  re-zero would achieve -- this separates "the zero moved" from "the noise is wide"
+
+The raw columns are ``FN_raw, FX_raw, FY_raw`` and the calibrated ones are
+``FN_N, FX_N, FY_N`` (see ``FORCES_HEADER`` in
+``orisys_app_shared.record.experiment``); rows with ``valid != 1`` are excluded
+rather than read as zeros.
+"""
+
+from __future__ import annotations
+
+import argparse
+import csv
+import statistics
+import sys
+from pathlib import Path
+from typing import Sequence
+
+import numpy as np
+
+RAW_AXES = ("FN_raw", "FX_raw", "FY_raw")
+NEWTON_AXES = ("FN_N", "FX_N", "FY_N")
+TIME_COLUMN = "t_rel_s"
+VALID_COLUMN = "valid"
+
+
+def _load_rows(source: Path) -> list[dict[str, str]]:
+    path = source / "forces.csv" if source.is_dir() else source
+    if not path.is_file():
+        raise SystemExit(f"no forces.csv at {path}")
+    with path.open(encoding="utf-8", newline="") as handle:
+        return list(csv.DictReader(handle))
+
+
+def _column(rows: Sequence[dict[str, str]], name: str) -> np.ndarray:
+    values = []
+    for row in rows:
+        raw = row.get(name)
+        try:
+            values.append(float(raw))  # type: ignore[arg-type]
+        except (TypeError, ValueError):
+            values.append(np.nan)
+    return np.asarray(values, dtype=np.float64)
+
+
+def _window(
+    rows: list[dict[str, str]],
+    *,
+    start: float | None,
+    stop: float | None,
+    warmup: float,
+) -> tuple[np.ndarray, list[dict[str, str]]]:
+    times = _column(rows, TIME_COLUMN)
+    valid = _column(rows, VALID_COLUMN)
+    mask = np.ones(times.shape, dtype=bool)
+    if times.size:
+        mask &= times == times  # drop NaN timestamps
+        if start is not None:
+            mask &= times >= float(start)
+        if stop is not None:
+            mask &= times <= float(stop)
+    # ``valid`` is authoritative: an invalid row is not a zero reading.
+    mask &= (valid == 1) | np.isnan(valid)
+    kept = [row for row, keep in zip(rows, mask) if keep]
+    if not kept:
+        return np.asarray([], dtype=np.float64), []
+    times = np.asarray([float(row[TIME_COLUMN]) for row in kept], dtype=np.float64)
+    if warmup > 0 and times.size:
+        t0 = times[0]
+        kept = [row for row in kept if float(row[TIME_COLUMN]) - t0 >= warmup]
+        times = np.asarray([float(row[TIME_COLUMN]) for row in kept], dtype=np.float64)
+    return times, kept
+
+
+def _describe(label: str, values: np.ndarray, times: np.ndarray) -> dict[str, float]:
+    finite = values[np.isfinite(values)]
+    if finite.size == 0:
+        return {"axis": label, "n": 0}
+    mean = float(finite.mean())
+    median = float(np.median(finite))
+    # A min-to-max span does not shrink when a constant is removed, so it cannot
+    # answer "what would a re-zero achieve". The robust band and the inter-
+    # percentile width can, and they are what the noise is measured against in
+    # the existing perf analysis.
+    centred = finite - median
+    band_1sigma = float(
+        (np.percentile(centred, 84.1) - np.percentile(centred, 15.9)) / 2.0
+    )
+    width_99 = float(np.percentile(finite, 99.5) - np.percentile(finite, 0.5))
+    slope = float("nan")
+    if times.size == finite.size and times.size > 2 and float(times[-1] - times[0]) > 0:
+        slope = float(np.polyfit(times - times[0], finite, 1)[0])
+    third = max(1, finite.size // 3)
+    drift_ratio = float(finite[-third:].mean() - finite[:third].mean())
+    return {
+        "axis": label,
+        "n": int(finite.size),
+        "mean": mean,
+        "median": median,
+        "stdev": float(finite.std(ddof=0)),
+        "p2p": float(finite.max() - finite.min()),
+        "band_1sigma": band_1sigma,
+        "width_99": width_99,
+        "slope_per_s": slope,
+        "drift_ratio": drift_ratio,
+    }
+
+
+def _print_table(title: str, stats: list[dict[str, float]], unit: str) -> None:
+    usable = [s for s in stats if s.get("n")]
+    print(f"\n=== {title} ===")
+    if not usable:
+        print("   no rows in the analysed window")
+        return
+    print(
+        f"   {'axis':<8} {'n':>7} {'mean':>13} {'median':>13} {'stdev':>12} "
+        f"{'band1s':>11} {'w99':>11} {'slope/s':>11} {'drift':>11}   [{unit}]"
+    )
+    for s in usable:
+        print(
+            f"   {s['axis']:<8} {s['n']:>7} {s['mean']:>13.3f} {s['median']:>13.3f} "
+            f"{s['stdev']:>12.3f} {s['band_1sigma']:>11.3f} {s['width_99']:>11.3f} "
+            f"{s['slope_per_s']:>11.4f} {s['drift_ratio']:>11.3f}"
+        )
+    print(
+        "   slope/s = least-squares ramp (the drift rate)\n"
+        "   band1s  = robust 1-sigma half-width about the median\n"
+        "   w99     = 0.5-99.5 percentile width (tail-resistant spread)\n"
+        "   drift   = mean(last third) - mean(first third): moved, not just noisy"
+    )
+
+
+def _analyse(rows: list[dict[str, str]], args: argparse.Namespace) -> int:
+    times, kept = _window(
+        rows, start=args.start, stop=args.stop, warmup=args.warmup
+    )
+    print(f"recording rows        : {len(rows)}")
+    print(f"analysed rows         : {len(kept)}")
+    if times.size:
+        dt = np.diff(times)
+        print(
+            f"analysed window       : {times[0]:.3f} .. {times[-1]:.3f} s "
+            f"({times[-1] - times[0]:.3f} s)"
+        )
+        if dt.size and dt[dt > 0].size:
+            rate = 1.0 / float(np.median(dt[dt > 0]))
+            print(f"effective sample rate : {rate:.2f} Hz")
+    if len(kept) < 30:
+        print(
+            "\nNOTE: fewer than 30 analysed rows. This cannot characterise a slow\n"
+            "      zero drift -- capture an idle run of at least several minutes."
+        )
+
+    if args.unit in ("raw", "both"):
+        _print_table(
+            "raw counts (pre-calibration)",
+            [_describe(axis, _column(kept, axis), times) for axis in RAW_AXES],
+            "counts",
+        )
+    if args.unit in ("N", "both"):
+        _print_table(
+            "newtons (what the operator sees)",
+            [_describe(axis, _column(kept, axis), times) for axis in NEWTON_AXES],
+            "N",
+        )
+
+    if args.out:
+        out = Path(args.out)
+        out.parent.mkdir(parents=True, exist_ok=True)
+        with out.open("w", encoding="utf-8", newline="") as handle:
+            writer = csv.writer(handle)
+            writer.writerow(
+                ["axis", "unit", "n", "mean", "median", "stdev", "band_1sigma",
+                 "width_99", "slope_per_s", "drift_ratio"]
+            )
+            groups = []
+            if args.unit in ("raw", "both"):
+                groups.append((RAW_AXES, "counts"))
+            if args.unit in ("N", "both"):
+                groups.append((NEWTON_AXES, "N"))
+            for axes, unit in groups:
+                for axis in axes:
+                    s = _describe(axis, _column(kept, axis), times)
+                    if not s.get("n"):
+                        continue
+                    writer.writerow([
+                        s["axis"], unit, s["n"], f"{s['mean']:.6f}",
+                        f"{s['median']:.6f}", f"{s['stdev']:.6f}",
+                        f"{s['band_1sigma']:.6f}", f"{s['width_99']:.6f}",
+                        f"{s['slope_per_s']:.6f}", f"{s['drift_ratio']:.6f}",
+                    ])
+        print(f"\nwrote {out}")
+    return 0
+
+
+def _capture_live(args: argparse.Namespace) -> int:
+    """Sample a real sensor with no load applied.
+
+    Uses only the public ``read_info``/``disconnect`` surface, so this keeps
+    working if the internals move.
+    """
+    import time as _time
+
+    from orisys import Sensor
+
+    sensor = Sensor(
+        "external",
+        config_name=args.config,
+        verbose=args.verbose,
+        backend=args.backend,
+    )
+    seconds = float(args.seconds)
+    period = 1.0 / float(args.sample_rate)
+    rows: list[tuple[float, float, float, float, float, float, float]] = []
+    try:
+        print(
+            f"capturing {seconds:.0f}s at ~{args.sample_rate:.0f} Hz from config "
+            f"{args.config!r} ({args.backend}); keep the sensor unloaded"
+        )
+        t0 = _time.monotonic()
+        while True:
+            elapsed = _time.monotonic() - t0
+            if elapsed >= seconds:
+                break
+            raw = sensor.read_info(
+                sensor.info.FNORMAL_RAW,
+                sensor.info.FSHEARX_RAW,
+                sensor.info.FSHEARY_RAW,
+            )
+            newtons = sensor.read_info(
+                sensor.info.FNORMAL,
+                sensor.info.FSHEARX,
+                sensor.info.FSHEARY,
+            )
+            rows.append((elapsed, *[float(v) for v in raw], *[float(v) for v in newtons]))
+            _time.sleep(max(0.0, period - ((_time.monotonic() - t0) - elapsed)))
+    finally:
+        sensor.disconnect()
+
+    if not rows:
+        print("no samples captured (external-frame mode may need a frame source)")
+        return 1
+
+    times = np.asarray([row[0] for row in rows], dtype=np.float64)
+    print(f"\ncaptured {len(rows)} samples over {times[-1]:.1f}s")
+
+    if args.out:
+        out = Path(args.out)
+        out.mkdir(parents=True, exist_ok=True)
+        path = out / "forces.csv"
+        with path.open("w", encoding="utf-8", newline="") as handle:
+            writer = csv.writer(handle)
+            writer.writerow(
+                ["session_id", "frame_id", TIME_COLUMN, *RAW_AXES, *NEWTON_AXES,
+                 VALID_COLUMN, "calibration_id"]
+            )
+            for index, row in enumerate(rows):
+                t_rel, *rest = row
+                writer.writerow(
+                    [0, index, f"{t_rel:.6f}", *[f"{v:.6f}" for v in rest], 1, ""]
+                )
+        print(f"wrote {path}")
+        return 0
+
+    _print_table(
+        "live raw counts",
+        [
+            _describe(axis, np.asarray([row[1 + i] for row in rows]), times)
+            for i, axis in enumerate(RAW_AXES)
+        ],
+        "counts",
+    )
+    _print_table(
+        "live newtons",
+        [
+            _describe(axis, np.asarray([row[4 + i] for row in rows]), times)
+            for i, axis in enumerate(NEWTON_AXES)
+        ],
+        "N",
+    )
+    return 0
+
+
+def main(argv: Sequence[str] | None = None) -> int:
+    parser = argparse.ArgumentParser(
+        description="Measure normal-force zero-point drift (Phase 0)."
+    )
+    source = parser.add_mutually_exclusive_group(required=True)
+    source.add_argument("--recording", type=Path,
+                        help="recording directory or forces.csv path")
+    source.add_argument("--live", action="store_true",
+                        help="capture from a Sensor instead (external-frame mode)")
+    parser.add_argument("--seconds", type=float, default=1800.0,
+                        help="live capture length (default 1800)")
+    parser.add_argument("--sample-rate", type=float, default=30.0,
+                        help="live polling rate Hz (default 30)")
+    parser.add_argument("--config", default="box", help="sensor config for --live")
+    parser.add_argument("--backend", default="cpu", help="poisson backend for --live")
+    parser.add_argument("--unit", choices=("raw", "N", "both"), default="both")
+    parser.add_argument("--start", type=float, default=None, help="window start (s)")
+    parser.add_argument("--stop", type=float, default=None, help="window stop (s)")
+    parser.add_argument("--warmup", type=float, default=0.0,
+                        help="discard this many seconds from the window start")
+    parser.add_argument("--out", default=None,
+                        help="write the per-axis table to this CSV path, or the "
+                             "capture directory when used with --live")
+    parser.add_argument("--verbose", action="store_true")
+    args = parser.parse_args(argv)
+
+    if args.live:
+        return _capture_live(args)
+    return _analyse(_load_rows(args.recording), args)
+
+
+if __name__ == "__main__":
+    sys.exit(main())

sensors/box/force_calibration.json

@@ -1,5 +1,5 @@
 {
-  "schema_version": 1,
+  "schema_version": 2,
   "unit": "N",
   "channels": {
     "normal": {
@@ -14,8 +14,22 @@
         [62000.0, 2.377]
       ]
     },
-    "shear": {
+    "shear_x": {
       "method": "piecewise_linear",
+      "raw_key": "fshearx",
+      "input": "components",
+      "signed": true,
+      "extrapolate": true,
+      "clamp_output_min": 0.0,
+      "points": [
+        [1000.0, 0.0],
+        [36000.0, 1.19],
+        [68000.0, 2.06]
+      ]
+    },
+    "shear_y": {
+      "method": "piecewise_linear",
+      "raw_key": "fsheary",
       "input": "components",
       "signed": true,
       "extrapolate": true,

sensors/box/sensor.json

@@ -29,10 +29,17 @@
     "loop_closure_interval": 1,
     "algorithm": "dis",
     "dis_preset": "medium",
-    "dis_mode": 3,
+    "dis_mode": 1,
     "algorithm_list": ["raft", "dis"],
     "hhd_downsample": 3
   },
+  "filters": {
+    "flow_ema_alpha": 1.0,
+    "force_median_window": 1,
+    "force_lowpass_cutoff_hz": 0.0,
+    "force_lowpass_order": 2,
+    "force_lowpass_sample_rate_hz": "auto"
+  },
   "contact": {
     "min_contour_area": 3000,
     "flow_threshold":5,

sensors/finger/sensor.json

@@ -22,7 +22,14 @@
     "dis_preset": "medium",
     "dis_mode": 1,
     "algorithm_list": ["raft", "dis"],
-    "hhd_downsample": 1
+    "hhd_downsample": 2
+  },
+  "filters": {
+    "flow_ema_alpha": 1.0,
+    "force_median_window": 1,
+    "force_lowpass_cutoff_hz": 0.0,
+    "force_lowpass_order": 2,
+    "force_lowpass_sample_rate_hz": "auto"
   },
   "contact": {
     "min_contour_area": 3000,

sensors/mini/sensor.json

@@ -29,10 +29,17 @@
     "loop_closure_interval": 1,
     "algorithm": "dis",
     "dis_preset": "medium",
-    "dis_mode": 3,
+    "dis_mode": 1,
     "algorithm_list": ["raft", "dis"],
     "hhd_downsample": 3
   },
+  "filters": {
+    "flow_ema_alpha": 1.0,
+    "force_median_window": 1,
+    "force_lowpass_cutoff_hz": 0.0,
+    "force_lowpass_order": 2,
+    "force_lowpass_sample_rate_hz": "auto"
+  },
   "contact": {
     "min_contour_area": 3000,
     "flow_threshold":5,

src/orisys/__init__.py

@@ -5,15 +5,18 @@ A Python library for processing and analyzing optical tactile sensor data,
 including image stitching, optical flow tracking, and deformation decomposition.
 """
 
-__version__ = "0.5.0"
+__version__ = "0.5.3"
 __author__ = "Orisys"
 
 from .sensor import Sensor
 from . import util
 from . import configs
+from . import calibration
 from . import finger
 from . import signal_processing
 from . import capture
+from .pipeline import FrameSnapshot, PipelineStats, StreamPipeline
+from .export import StreamRecorder, mosaic_videos
 from .frame_processors import FFCFrameProcessor
 
 CompoundEyeSensor = Sensor
@@ -22,6 +25,8 @@ CameraSensor = Sensor
 # Re-export list_configs as list_config for convenience
 list_config = configs.list_config
 export_config = configs.export_config
+export_sensor_bundle = configs.export_sensor_bundle
+export_sensor_bundles = configs.export_sensor_bundles
 
 __all__ = [
     # class
@@ -41,9 +46,23 @@ __all__ = [
     # capture helpers
     'capture',
 
+    # pipelined multi-stream processing
+    'StreamPipeline',
+    'FrameSnapshot',
+    'PipelineStats',
+
+    # offline recording of arrow overlays
+    'StreamRecorder',
+    'mosaic_videos',
+
+    # force calibration
+    'calibration',
+
     # configs utilities functions
     'list_config', 
     'export_config',
+    'export_sensor_bundle',
+    'export_sensor_bundles',
 
     # test
     'FFCFrameProcessor'

src/orisys/configs.py

@@ -1,4 +1,7 @@
 import json
+import os
+import shutil
+import sys
 from contextlib import ExitStack
 from dataclasses import dataclass
 from importlib.resources import as_file, files
@@ -19,34 +22,145 @@ def _resource_path(*parts: str) -> Path | None:
     """Resolve a package resource to a filesystem path for wheel-safe loaders."""
     try:
         resource = files("orisys").joinpath(*parts)
-        return _RESOURCE_STACK.enter_context(as_file(resource))
+        resolved = _RESOURCE_STACK.enter_context(as_file(resource))
     except Exception:
         return None
+    # ``as_file`` is not contractually a ``pathlib.Path``: a Nuitka-compiled
+    # build hands back its own ``nuitka_resource_reader_files``, which is
+    # path-like but has no ``.resolve()``. Normalise here so every caller can
+    # treat the result as a Path.
+    try:
+        return Path(os.fspath(resolved))
+    except TypeError:
+        return None
 
 
-def _candidate_config_dirs() -> list[Path]:
+def _unique_paths(paths) -> list[Path]:
+    """Ordered, de-duplicated paths (Windows comparison is case-insensitive)."""
+    unique: list[Path] = []
+    seen: set[str] = set()
+    for path in paths:
+        path = Path(path) if not isinstance(path, Path) else path
+        try:
+            key = str(path.resolve()).casefold()
+        except (OSError, ValueError):  # pragma: no cover - defensive
+            key = str(path).casefold()
+        if key in seen:
+            continue
+        seen.add(key)
+        unique.append(path)
+    return unique
+
+
+def _is_sdk_runtime_root(path: Path) -> bool:
+    """Whether ``path`` carries the runnable SDK layout.
+
+    The anchor is the **folder layout**, never the folder's name: a distribution
+    folder may be called anything (a release checkout, a renamed copy, an
+    unpacked zip), but it always ships ``examples/`` beside ``sensors/``. That is
+    what distinguishes a run root from an arbitrary directory, and it is why a
+    renamed root keeps working while ``dist/**`` (``sensors/`` without
+    ``examples/``) is not mistaken for one.
     """
-    Candidate config directories for editable installs and packaged wheels.
+    try:
+        if not path.is_dir():
+            return False
+        return (path / "examples").is_dir() and (path / "sensors").is_dir()
+    except OSError:  # pragma: no cover - defensive: unreadable path
+        return False
+
+
+def _runtime_roots() -> list[Path]:
+    """Runnable SDK roots for this process, nearest to the launcher first.
+
+    Evaluated once at import time, so a process that changes directory later
+    keeps the answer it started with.
+    """
+    anchors: list[Path] = []
+
+    def add(path: Path) -> None:
+        if path not in anchors:
+            anchors.append(path)
+
+    cwd = Path.cwd()
+    add(cwd)
+
+    # A script run from a subdirectory (``<root>/examples/foo.py``, or a caller
+    # that launched from ``<root>/scripts``) still names its root through argv[0].
+    script_dir: Path | None = None
+    try:
+        argv0 = sys.argv[0] if sys.argv else ""
+        if argv0:
+            candidate = Path(argv0).expanduser()
+            script_dir = candidate.resolve().parent if candidate.is_file() else None
+    except (OSError, ValueError):  # pragma: no cover - defensive
+        script_dir = None
+
+    # Walk up from both, so the root is found however deep the launcher sits.
+    for start in (cwd, script_dir):
+        if start is None:
+            continue
+        for candidate in (start, *start.parents):
+            add(candidate)
+
+    # Roots that put themselves on sys.path (``python <root>/examples/foo.py``
+    # with the root as cwd, ``PYTHONPATH=<root>``, and similar).
+    for entry in list(sys.path):
+        if not entry:
+            continue
+        try:
+            add(Path(entry).expanduser())
+        except (OSError, ValueError):  # pragma: no cover - defensive
+            continue
+
+    anchors = _unique_paths(anchors)
+    # The run root is the *nearest* runnable directory, walking up from the
+    # launcher: starting at the cwd, then the script's directory, then the
+    # entries sys.path. Order carries the meaning here -- containment does not.
+    # Scanning every anchor for the shortest match instead picked the shallowest
+    # ancestor, so a workspace that carried ``examples/`` alongside ``sensors/``
+    # absorbed the real root below it and its bundle shadowed that root's own.
+    roots: list[Path] = []
+    for path in anchors:
+        if not _is_sdk_runtime_root(path):
+            continue
+        if any(existing.is_relative_to(path) or path.is_relative_to(existing) for existing in roots):
+            # Same tree: only the nearest root counts.
+            continue
+        roots.append(path)
+    return roots
+
+
+def _candidate_config_dirs() -> list[Path]:
+    """Candidate config directories, the running SDK root first.
+
+    A run root's ``config/`` outranks the packaged copy so a bundle's
+    ``sensor.json`` and its ``force_calibration.json`` come from the same place.
     """
     here = Path(__file__).resolve().parent
-    candidates = [
+    return _unique_paths([
+        *(root / "config" for root in _runtime_roots()),
         here / "configs",                    # packaged wheel layout: orisys/configs/*.json
         here.parent.parent / "config",       # editable install from repo: repo_root/config/*.json
         here.parent / "config",              # fallback
         Path.cwd() / "config",               # script launched from repo root
-    ]
-
-    unique: list[Path] = []
-    for path in candidates:
-        if path not in unique:
-            unique.append(path)
-    return unique
+    ])
 
 
 def _candidate_sensor_roots() -> list[Path]:
-    """Candidate roots that contain per-sensor bundle folders."""
+    """Candidate roots that contain per-sensor bundle folders.
+
+    Lookup order:
+
+    1. the ``sensors/`` of every runnable SDK root found at startup, nearest
+       first -- so the bundle under the directory that is actually running wins,
+       whatever that directory is called;
+    2. the packaged resource ``orisys/sensors`` (wheel installs);
+    3. the module-relative candidates (editable checkout, packaged tree);
+    4. the current working directory, last, as a safety net.
+    """
     here = Path(__file__).resolve().parent
-    candidates = []
+    candidates = [root / "sensors" for root in _runtime_roots()]
     packaged = _resource_path("sensors")
     if packaged is not None:
         candidates.append(packaged)          # packaged wheel layout: orisys/sensors/
@@ -56,11 +170,7 @@ def _candidate_sensor_roots() -> list[Path]:
         here.parent / "sensors",
         Path.cwd() / "sensors",
     ])
-    unique: list[Path] = []
-    for path in candidates:
-        if path not in unique:
-            unique.append(path)
-    return unique
+    return _unique_paths(candidates)
 
 
 def _get_config_dir() -> Path:
@@ -129,6 +239,44 @@ def resolve_sensor_bundle(name: str) -> SensorBundle | None:
     return None
 
 
+def describe_bundle_resolution(name: str) -> dict:
+    """Explain how ``name`` resolved, so a missing calibration stops being silent.
+
+    A bundle can resolve and still carry no ``force_calibration.json``: the
+    lookup stops at the first root that has ``<name>/sensor.json`` and never
+    asks whether that root also has the coefficients. Reporting which bundle was
+    found -- and which roots were passed over -- is what makes that case
+    distinguishable from "no bundle at all", which is otherwise what the caller
+    sees.
+
+    Returns ``name``, the ``searched`` roots in order, and the first root that
+    supplied ``<name>/sensor.json`` together with whether it carried a
+    ``force_calibration.json``.
+    """
+    requested = CONFIG_ALIASES.get(str(name), str(name))
+    searched = _candidate_sensor_roots()
+    for root in searched:
+        sensor_json = root / requested / "sensor.json"
+        if not sensor_json.is_file():
+            continue
+        return {
+            "name": requested,
+            "searched": searched,
+            "found_root": sensor_json.parent,
+            "sensor_json": sensor_json,
+            "force_calibration_json": (
+                sensor_json.parent / "force_calibration.json"
+            ).is_file(),
+        }
+    return {
+        "name": requested,
+        "searched": searched,
+        "found_root": None,
+        "sensor_json": None,
+        "force_calibration_json": False,
+    }
+
+
 def resolve_sensor_config_path(name: str) -> Path | None:
     """Return ``sensor.json`` for a resolved sensor bundle."""
     bundle = resolve_sensor_bundle(name)
@@ -166,6 +314,85 @@ def load_force_calibration(name: str) -> dict | None:
     return _load_json(bundle.force_calibration_json)
 
 
+_BUNDLE_JSON_FILES = ("sensor.json", "force_calibration.json", "manifest.json")
+
+
+def export_sensor_bundle(
+    name: str,
+    dest_dir: str | Path,
+    *,
+    include_assets: bool = False,
+    overwrite: bool = True,
+) -> Path:
+    """Copy one resolved ``sensors/<name>/`` bundle into ``dest_dir/<name>/``.
+
+    By default only JSON metadata is copied (``sensor.json``, and when present
+    ``force_calibration.json`` / ``manifest.json``). Pass ``include_assets=True``
+    to copy the full tree (including ``assets/``) for packaging finger meshes.
+    """
+    bundle = resolve_sensor_bundle(name)
+    if bundle is None:
+        available = ", ".join(list_sensor_bundles()) or "none"
+        raise FileNotFoundError(
+            f"Sensor bundle not found: {name!r}. Available: {available}"
+        )
+
+    dest_root = Path(dest_dir).expanduser().resolve()
+    dest = dest_root / bundle.name
+    if dest.exists():
+        if not overwrite:
+            raise FileExistsError(f"Destination already exists: {dest}")
+        if dest.is_dir():
+            shutil.rmtree(dest)
+        else:
+            dest.unlink()
+
+    if include_assets:
+        shutil.copytree(bundle.root, dest)
+        return dest
+
+    dest.mkdir(parents=True, exist_ok=True)
+    for filename in _BUNDLE_JSON_FILES:
+        src = bundle.root / filename
+        if src.is_file():
+            shutil.copy2(src, dest / filename)
+    if not (dest / "sensor.json").is_file():
+        raise FileNotFoundError(f"sensor.json missing after export from {bundle.root}")
+    return dest
+
+
+def export_sensor_bundles(
+    dest_dir: str | Path,
+    *,
+    names: list[str] | tuple[str, ...] | None = None,
+    include_assets: bool = False,
+    overwrite: bool = True,
+) -> list[Path]:
+    """Export several sensor bundles into ``dest_dir``.
+
+    When ``names`` is omitted, exports every name in ``PRODUCT_BUNDLES`` that
+    currently resolves via :func:`resolve_sensor_bundle`.
+    """
+    if names is None:
+        selected = [name for name in PRODUCT_BUNDLES if resolve_sensor_bundle(name) is not None]
+    else:
+        selected = [str(name) for name in names]
+    if not selected:
+        raise FileNotFoundError("No sensor bundles selected for export")
+
+    exported: list[Path] = []
+    for name in selected:
+        exported.append(
+            export_sensor_bundle(
+                name,
+                dest_dir,
+                include_assets=include_assets,
+                overwrite=overwrite,
+            )
+        )
+    return exported
+
+
 def load_config(config_name_or_path):
     """
     Load sensor configuration from a JSON file path or config name.

src/orisys/export.py

@@ -0,0 +1,365 @@
+"""Record tactile arrow overlays to video without stalling the pipeline.
+
+Drawing the arrow grid costs a few milliseconds per frame (hundreds of
+``cv2.arrowedLine`` calls) and encoding costs a few more, so doing it inline
+would cut a stream's throughput. Instead:
+
+* :meth:`StreamRecorder.on_frame` is designed to be the pipeline's ``on_frame``
+  callback: it only performs a bounded, drop-oldest queue push, so the slowest
+  pipeline stage is unaffected and the run never blocks on the encoder;
+* a dedicated writer thread does the drawing and the ``cv2.VideoWriter`` calls;
+* when the writer falls behind, the newest frames win and the rest are counted
+  in :meth:`StreamRecorder.stats` so a recording gap is never silent.
+
+Typical use::
+
+    recorder = StreamRecorder("run/stream_0.mp4", label="#0",
+                              valid_mask=lambda: runtime.valid_mask)
+    pipe = StreamPipeline(sensor, produce, include=("image", "flow"),
+                          on_frame=recorder.on_frame)
+    pipe.start()
+    ...
+    print(recorder.close())        # written / dropped / fps
+
+Per-stream files are the natural unit because each stream is its own process;
+:func:`mosaic_videos` tiles them into one grid afterwards, which costs nothing
+during the run.
+
+Arrow parameters
+----------------
+``draw_arrows`` divides the sampled displacement by ``arrow_scale``, so the
+defaults assume the finger's UV domain, where the active-region displacement is
+only ~1-3 px: ``grid_spacing=14, arrow_scale=0.15, threshold=0.1`` magnifies it
+~6.7x, which is what makes the direction field legible instead of a scatter of
+dots (the ``draw_arrows`` defaults of ``arrow_scale=1.0, threshold=5`` render the
+raw pixel displacement and are tuned for large-motion scenes). Length saturates
+at ``grid_spacing * margin`` px, so colour - not length - carries the magnitude.
+A box/mini stream at 365x365 needs its own calibration of ``arrow_scale``.
+"""
+
+from __future__ import annotations
+
+import os
+import queue
+import threading
+import time
+from typing import Any, Callable, Iterable, Sequence
+
+import cv2
+import numpy as np
+
+from .util import draw_arrows, draw_contact
+
+__all__ = ["StreamRecorder", "mosaic_videos"]
+
+
+class StreamRecorder:
+    """Draw arrow overlays from snapshots and encode them to a video file."""
+
+    def __init__(
+        self,
+        path: str,
+        *,
+        fps: float = 30.0,
+        every: int = 1,
+        fourcc: str = "mp4v",
+        valid_mask: np.ndarray | Callable[[], np.ndarray | None] | None = None,
+        grid_spacing: int = 14,
+        threshold: float = 0.1,
+        arrow_scale: float = 0.15,
+        margin: float = 0.8,
+        draw_contact: bool = False,
+        label: str | None = None,
+        overlay_values: bool = True,
+        queue_depth: int = 8,
+        verbose: bool = False,
+    ) -> None:
+        self.path = str(path)
+        self.fps = max(1.0, float(fps))
+        self.every = max(1, int(every))
+        self.fourcc = fourcc
+        # A callable is resolved once per frame: the SDK rebuilds
+        # ``Sensor.valid_mask`` during ``get_img``, so holding an array taken
+        # before the first frame would capture ``None``.
+        self.valid_mask = valid_mask
+        self.grid_spacing = int(grid_spacing)
+        self.threshold = float(threshold)
+        self.arrow_scale = float(arrow_scale)
+        self.margin = float(margin)
+        self.draw_contact_flag = bool(draw_contact)
+        self.label = label
+        self.overlay_values = bool(overlay_values)
+        self.verbose = bool(verbose)
+
+        self._queue: queue.Queue = queue.Queue(maxsize=max(1, int(queue_depth)))
+        self._stop = threading.Event()
+        self._thread: threading.Thread | None = None
+        self._seen = 0
+        self._written = 0
+        self._dropped = 0
+        self._skipped = 0
+        self._error: BaseException | None = None
+        self._writer: cv2.VideoWriter | None = None
+        self._size: tuple[int, int] | None = None
+
+    # ------------------------------------------------------------------ ingest
+    def on_frame(self, snap: Any) -> None:
+        """Pipeline callback: enqueue one snapshot. Never blocks."""
+        self._seen += 1
+        if self.every > 1 and (self._seen - 1) % self.every:
+            self._skipped += 1
+            return
+        while True:
+            try:
+                self._queue.put_nowait(snap)
+                break
+            except queue.Full:
+                # Drop the oldest so the newest frame is always kept.
+                try:
+                    self._queue.get_nowait()
+                    self._dropped += 1
+                except queue.Empty:
+                    pass
+        self._ensure_thread()
+
+    def _ensure_thread(self) -> None:
+        if self._thread is None:
+            self._thread = threading.Thread(target=self._loop, daemon=True,
+                                            name="orisys-recorder")
+            self._thread.start()
+
+    # ------------------------------------------------------------------ writer
+    def _open(self, frame: np.ndarray) -> None:
+        h, w = frame.shape[:2]
+        os.makedirs(os.path.dirname(os.path.abspath(self.path)) or ".", exist_ok=True)
+        fourcc = cv2.VideoWriter_fourcc(*self.fourcc) if len(self.fourcc) == 4 else 0
+        writer = cv2.VideoWriter(self.path, fourcc, self.fps, (w, h), True)
+        if not writer.isOpened():
+            raise RuntimeError(
+                f"cv2.VideoWriter could not open {self.path!r} with fourcc={self.fourcc!r}"
+            )
+        self._writer = writer
+        self._size = (w, h)
+        if self.verbose:
+            print(f"[recorder] {self.path} {w}x{h} @ {self.fps:g} fps fourcc={self.fourcc}")
+
+    def _render(self, snap: Any) -> np.ndarray:
+        if snap.image is None or snap.flow is None:
+            raise RuntimeError(
+                "recording needs image and flow in the snapshot; build the pipeline "
+                'with include=("image", "flow")'
+            )
+        mask = self.valid_mask() if callable(self.valid_mask) else self.valid_mask
+        image = draw_arrows(
+            snap.image,
+            snap.flow,
+            threshold=self.threshold,
+            grid_spacing=self.grid_spacing,
+            arrow_scale=self.arrow_scale,
+            margin=self.margin,
+            valid_mask=mask,
+        )
+        if self.draw_contact_flag and snap.contour is not None and snap.centroid is not None:
+            image = draw_contact(image, snap.contour, snap.centroid)
+        if self.overlay_values or self.label:
+            self._draw_hud(image, snap)
+        return image
+
+    def _draw_hud(self, image: np.ndarray, snap: Any) -> None:
+        lines = []
+        if self.label:
+            lines.append(str(self.label))
+        if self.overlay_values:
+            lines.append(f"{snap.unit} fn={snap.normal_force:.3g} "
+                         f"fx={snap.shear_x:.3g} fy={snap.shear_y:.3g}")
+            lines.append(f"{snap.fps:.0f} FPS  {snap.age_ms:.1f} ms")
+        y = 14
+        for text in lines:
+            cv2.putText(image, text, (4, y), cv2.FONT_HERSHEY_SIMPLEX, 0.38,
+                        (0, 0, 0), 3, cv2.LINE_AA)
+            cv2.putText(image, text, (4, y), cv2.FONT_HERSHEY_SIMPLEX, 0.38,
+                        (255, 255, 255), 1, cv2.LINE_AA)
+            y += 14
+
+    def _loop(self) -> None:
+        try:
+            while True:
+                try:
+                    snap = self._queue.get(timeout=0.05)
+                except queue.Empty:
+                    if self._stop.is_set():
+                        break
+                    continue
+                if snap is None:
+                    break
+                try:
+                    frame = self._render(snap)
+                    if self._writer is None:
+                        self._open(frame)
+                    self._writer.write(frame)
+                    self._written += 1
+                except BaseException as exc:
+                    self._error = exc
+                    break
+        finally:
+            if self._writer is not None:
+                self._writer.release()
+                self._writer = None
+
+    # ------------------------------------------------------------------- close
+    def close(self, timeout: float = 30.0) -> dict:
+        """Drain, stop the writer thread and release the file."""
+        if self._thread is not None:
+            self._stop.set()
+            # The stop flag is the real mechanism - the writer drains what is
+            # queued and exits on its next empty poll. The sentinel only makes
+            # that immediate, so it must never block: if the writer died on an
+            # error the queue may be full and nobody would ever drain it.
+            try:
+                self._queue.put_nowait(None)
+            except queue.Full:
+                pass
+            self._thread.join(timeout=timeout)
+            alive = self._thread.is_alive()
+            self._thread = None
+        else:
+            alive = False
+        stats = self.stats()
+        stats["thread_alive"] = alive
+        if self._error is not None:
+            stats["error"] = f"{type(self._error).__name__}: {self._error}"
+            if self.verbose:
+                print(f"[recorder] {self.path}: {stats['error']}")
+        return stats
+
+    def stats(self) -> dict:
+        return {
+            "path": self.path,
+            "seen": self._seen,
+            "written": self._written,
+            "dropped": self._dropped,
+            "skipped": self._skipped,
+            "fps": self.fps,
+            "fourcc": self.fourcc,
+        }
+
+    def __enter__(self) -> "StreamRecorder":
+        return self
+
+    def __exit__(self, exc_type, exc, tb) -> bool:
+        self.close()
+        return False
+
+
+def mosaic_videos(
+    paths: Sequence[str],
+    out_path: str,
+    *,
+    cols: int | None = None,
+    labels: Iterable[str] | None = None,
+    scale: float = 1.0,
+    gap: int = 4,
+    fps: float | None = None,
+    fourcc: str = "mp4v",
+) -> dict:
+    """Tile per-stream recordings into one grid video.
+
+    Post-processing only: run it after the streams have finished, so it costs
+    nothing while they are running. Shorter inputs hold their last frame.
+    """
+    paths = [str(p) for p in paths]
+    if not paths:
+        raise ValueError("mosaic_videos needs at least one input")
+    for path in paths:
+        if not os.path.isfile(path):
+            raise FileNotFoundError(path)
+
+    caps = [cv2.VideoCapture(p) for p in paths]
+    try:
+        for path, cap in zip(paths, caps):
+            if not cap.isOpened():
+                raise RuntimeError(f"cannot open {path!r}")
+        tiles = []
+        for cap in caps:
+            ok, frame = cap.read()
+            if not ok:
+                raise RuntimeError("an input video has no frames")
+            tiles.append(frame)
+
+        if scale != 1.0:
+            tiles = [cv2.resize(t, None, fx=scale, fy=scale,
+                                interpolation=cv2.INTER_AREA) for t in tiles]
+        th, tw = tiles[0].shape[:2]
+        n = len(tiles)
+        cols = int(cols) if cols else int(np.ceil(np.sqrt(n)))
+        cols = max(1, min(cols, n))
+        rows = int(np.ceil(n / cols))
+        label_list = [str(x) for x in labels] if labels is not None else []
+
+        out_h = rows * th + (rows - 1) * gap
+        out_w = cols * tw + (cols - 1) * gap
+        canvas = np.zeros((out_h, out_w, 3), dtype=np.uint8)
+        positions = []
+        for i in range(n):
+            r, c = divmod(i, cols)
+            positions.append((r * (th + gap), c * (tw + gap)))
+        # Frame 0 is already in hand; seed the canvas with it so the output is
+        # never short by one frame.
+        for i, tile in enumerate(tiles):
+            y, x = positions[i]
+            canvas[y:y + th, x:x + tw] = tile
+
+        out_fps = float(fps) if fps else float(caps[0].get(cv2.CAP_PROP_FPS) or 30.0)
+        os.makedirs(os.path.dirname(os.path.abspath(out_path)) or ".", exist_ok=True)
+        writer = cv2.VideoWriter(out_path, cv2.VideoWriter_fourcc(*fourcc), out_fps,
+                                 (out_w, out_h), True)
+        if not writer.isOpened():
+            raise RuntimeError(f"cannot open {out_path!r} for writing")
+
+        def emit() -> None:
+            # Labels go on the canvas, not on the tiles: the read loop below
+            # overwrites each tile region every frame.
+            for i, text in enumerate(label_list):
+                if i >= n:
+                    break
+                y, x = positions[i]
+                org = (x + 4, y + th - 6)
+                cv2.putText(canvas, text, org, cv2.FONT_HERSHEY_SIMPLEX, 0.45,
+                            (0, 0, 0), 3, cv2.LINE_AA)
+                cv2.putText(canvas, text, org, cv2.FONT_HERSHEY_SIMPLEX, 0.45,
+                            (255, 255, 255), 1, cv2.LINE_AA)
+            writer.write(canvas)
+
+        written = 0
+        try:
+            # One frame per input per iteration; a spent input keeps its last
+            # frame so the grid stays full until every input has run out.
+            while True:
+                emit()
+                written += 1
+                progressed = False
+                for i, cap in enumerate(caps):
+                    ok, frame = cap.read()
+                    if not ok:
+                        continue
+                    progressed = True
+                    if scale != 1.0:
+                        frame = cv2.resize(frame, (tw, th), interpolation=cv2.INTER_AREA)
+                    y, x = positions[i]
+                    canvas[y:y + th, x:x + tw] = frame
+                if not progressed:
+                    break
+        finally:
+            writer.release()
+    finally:
+        for cap in caps:
+            cap.release()
+
+    return {
+        "path": out_path,
+        "frames": written,
+        "fps": out_fps,
+        "size": (out_w, out_h),
+        "grid": (rows, cols),
+        "scale": scale,
+    }

src/orisys/export_sensors.py

@@ -0,0 +1,70 @@
+"""CLI: export packaged sensor bundles to a destination folder.
+
+Examples::
+
+    python -m orisys.export_sensors --dest ./out/sensors --names box,mini
+    python -m orisys.export_sensors --dest ./out/sensors --include-assets
+"""
+
+from __future__ import annotations
+
+import argparse
+import sys
+from pathlib import Path
+
+from .configs import export_sensor_bundles, list_sensor_bundles
+
+
+def _parse_args(argv: list[str] | None = None) -> argparse.Namespace:
+    parser = argparse.ArgumentParser(
+        description="Export orisys sensors/<name>/ bundles to a destination directory"
+    )
+    parser.add_argument(
+        "--dest",
+        required=True,
+        type=Path,
+        help="Destination directory (creates <dest>/<name>/ for each bundle)",
+    )
+    parser.add_argument(
+        "--names",
+        default="",
+        help="Comma-separated bundle names (default: all resolvable product bundles)",
+    )
+    parser.add_argument(
+        "--include-assets",
+        action="store_true",
+        help="Copy full bundle trees including assets/",
+    )
+    parser.add_argument(
+        "--no-overwrite",
+        action="store_true",
+        help="Fail if a destination bundle folder already exists",
+    )
+    return parser.parse_args(argv)
+
+
+def main(argv: list[str] | None = None) -> int:
+    args = _parse_args(argv)
+    names = [part.strip() for part in str(args.names).split(",") if part.strip()] or None
+    try:
+        exported = export_sensor_bundles(
+            args.dest,
+            names=names,
+            include_assets=bool(args.include_assets),
+            overwrite=not bool(args.no_overwrite),
+        )
+    except (FileNotFoundError, FileExistsError) as exc:
+        print(f"error: {exc}", file=sys.stderr)
+        available = list_sensor_bundles()
+        if available:
+            print(f"available bundles: {', '.join(available)}", file=sys.stderr)
+        return 1
+
+    for path in exported:
+        print(f"exported {path}")
+    print(f"exported {len(exported)} bundle(s) to {Path(args.dest).resolve()}")
+    return 0
+
+
+if __name__ == "__main__":
+    raise SystemExit(main())

src/orisys/finger/runtime.py

@@ -293,6 +293,15 @@ class FingerRuntime:
         capture = capture_source.cap
 
         sensor = Sensor("external", config_name=config, verbose=verbose, mirror=mirror)
+        if not is_live_camera(video):
+            # File playback: wall-clock cadence is not signal time, so pin the
+            # force-filter design rate to the configured camera fps.
+            try:
+                fps = float(geometry.config.get("camera", {}).get("fps", 0.0) or 0.0)
+            except (TypeError, ValueError):
+                fps = 0.0
+            if fps > 0:
+                sensor.configure(lowpass_sample_rate_hz=fps)
         frame_processor = FrameUnwarper(
             domain.remap,
             camera_matrix=geometry.source_K if geometry.dist_coeffs is not None else None,

src/orisys/frame_processors.py

@@ -1,5 +1,7 @@
 from __future__ import annotations
 
+import time
+
 import cv2
 import numpy as np
 from pathlib import Path
@@ -12,11 +14,24 @@ class CompoundEyeFrameProcessor:
 
     def __init__(self, stitcher):
         self.stitcher = stitcher
+        # Per-call sub-stage timings (seconds), read by Sensor.get_img() for
+        # _last_stage_times. Keys: units, extract_tiles, stitch.
+        self.last_timings = {}
 
     def process(self, frame):
+        t0 = time.perf_counter()
         self.stitcher.get_stitch_unit(frame)
+        t1 = time.perf_counter()
         self.stitcher.extract_tiles()
-        return self.stitcher.stitch_rt_optimized()
+        t2 = time.perf_counter()
+        stitched = self.stitcher.stitch_rt_optimized()
+        t3 = time.perf_counter()
+        self.last_timings = {
+            "units": t1 - t0,
+            "extract_tiles": t2 - t1,
+            "stitch": t3 - t2,
+        }
+        return stitched
 
 
 class SingleCameraFrameProcessor:

src/orisys/hhd/api.py

@@ -73,8 +73,49 @@ class nHHD(object):
             raise ValueError("nHHD Solver works only for 2 and 3 dimensions")
 
         self._force_cpu_cache = None
+        self._force_ref_shape = None
+        ref_shape = kwargs.get('force_reference_grid')
+        if ref_shape is not None:
+            try:
+                ref_h, ref_w = int(ref_shape[0]), int(ref_shape[1])
+            except (TypeError, ValueError, IndexError):
+                ref_h = ref_w = 0
+            if ref_h > 0 and ref_w > 0:
+                self._force_ref_shape = (ref_h, ref_w)
         self.psolver.prepare(False)
 
+    def _force_scale(self, shape):
+        """Area/linear weights mapping grid sums at ``shape`` to the reference grid.
+
+        ``Sn``/``Stx``/``Sty``/``Stor`` are *sums over grid pixels*, and the
+        torque term additionally uses pixel-index moment arms. When the flow is
+        downsampled by ``hhd_downsample=k`` before decomposition, the same
+        physical deformation therefore reports roughly ``1/k^2`` of the force
+        magnitude (and ``1/k^3`` of the torque) unless the sums are rescaled
+        back onto the reference grid.
+
+        returns: (area_scale, linear_scale); (1.0, 1.0) when no reference grid
+            was configured or the current grid already is the reference.
+        """
+        ref = self._force_ref_shape
+        if ref is None or (int(shape[0]), int(shape[1])) == ref:
+            return 1.0, 1.0
+        cur_area = float(shape[0]) * float(shape[1])
+        if cur_area <= 0.0:
+            return 1.0, 1.0
+        area_scale = (float(ref[0]) * float(ref[1])) / cur_area
+        return area_scale, float(numpy.sqrt(area_scale))
+
+    def _apply_force_scale(self, shape):
+        """Rescale aggregate force sums from a downsampled grid to the reference grid."""
+        area_scale, linear_scale = self._force_scale(shape)
+        if area_scale == 1.0 and linear_scale == 1.0:
+            return
+        self.Sn = float(self.Sn) * area_scale
+        self.Stx = float(self.Stx) * area_scale
+        self.Sty = float(self.Sty) * area_scale
+        self.Stor = float(self.Stor) * area_scale * linear_scale
+
     def _normalize_mask(self, valid_mask, shape):
         if valid_mask is None:
             return None
@@ -402,6 +443,8 @@ class nHHD(object):
             cross_n = numpy.where(mask, cross_n, 0)
         self.Stor = numpy.sum(cross_p) + numpy.sum(cross_n)
 
+        self._apply_force_scale(shape)
+
         # Optimized: pre-allocate output array with explicit dtype
         output = numpy.array([self.Sn, self.Stx, self.Sty, self.Stor], dtype=numpy.float32)
 
@@ -515,6 +558,8 @@ class nHHD(object):
             ))
 
         self.Sn, self.Stx, self.Sty, self.Stor = Sn, Stx, Sty, Stor
+        self._apply_force_scale(shape)
+        Sn, Stx, Sty, Stor = self.Sn, self.Stx, self.Sty, self.Stor
         output = numpy.array([Sn, Stx, Sty, Stor], dtype=numpy.float32)
 
         # Keep stable CPU copies for get_normal()/get_shear() so callers get this frame's

src/orisys/hhd/domain.py

@@ -29,6 +29,39 @@ def compute_boundary_mask(active):
     return active & ~fully_surrounded
 
 
+def build_masked_factor(lap):
+    """Factorize the masked Laplacian for fast repeated triangular solves.
+
+    The reduced system is a symmetric M-matrix (graph Laplacian of the active
+    pixels with an extra Dirichlet pin), so SuperLU can skip partial pivoting
+    (``SymmetricMode`` + ``diag_pivot_thresh=0``), which is ~2x faster than the
+    default pivoting factorization. Factoring in float32 halves the memory
+    traffic of the triangular solves; relative error against the float64
+    reference stays around 1e-7 for these systems.
+
+    ``rhs_dtype`` is returned because ``SuperLU.solve`` refuses to cast a
+    float64 right-hand side down to a float32 factor.
+
+    lap: (N, N) symmetric sparse Laplacian (any scipy dtype)
+    returns: (solve_callable, rhs_dtype)
+    """
+    lap_csc = lap.tocsc()
+    lap32 = lap_csc.astype(numpy.float32, copy=False)
+    for diag_pivot_thresh in (0.0, 1.0):
+        try:
+            lu = sparse_linalg.splu(
+                lap32,
+                permc_spec="MMD_AT_PLUS_A",
+                diag_pivot_thresh=diag_pivot_thresh,
+                options=dict(SymmetricMode=True),
+            )
+            return lu.solve, numpy.float32
+        except Exception:
+            continue
+    # Last resort: the original pivoting LU on the float64 matrix.
+    return sparse_linalg.factorized(lap_csc), numpy.float64
+
+
 def sample_boundary_coords(boundary_coords, config: MaskedPoissonConfig):
     """Subsample boundary pixel coordinates for capacitance correction."""
     if boundary_coords.size == 0:
@@ -53,6 +86,7 @@ class MaskedDomain:
         "mask",
         "index_map",
         "factor",
+        "factor_dtype",
         "lap",
         "num_active",
         "pinned",
@@ -75,11 +109,13 @@ class MaskedDomain:
         pinned,
         active_coords,
         active_linear_indices,
+        factor_dtype=numpy.float32,
     ):
         self.shape = shape
         self.mask = mask
         self.index_map = index_map
         self.factor = factor
+        self.factor_dtype = numpy.dtype(factor_dtype)
         self.lap = lap
         self.num_active = num_active
         self.pinned = pinned
@@ -156,7 +192,7 @@ class MaskedDomain:
                 data.append(diag)
 
         lap = sparse.csc_matrix((data, (rows, cols)), shape=(num_active, num_active), dtype=numpy.float64)
-        factor = sparse_linalg.factorized(lap)
+        factor, factor_dtype = build_masked_factor(lap)
         return cls(
             shape=active.shape,
             mask=active.copy(),
@@ -167,6 +203,7 @@ class MaskedDomain:
             pinned=pinned,
             active_coords=active_coords,
             active_linear_indices=active_linear_indices,
+            factor_dtype=factor_dtype,
         )
 
     def matches(self, mask):
@@ -179,13 +216,20 @@ class MaskedDomain:
 
         f: (H, W) scalar source field
         returns: (N,) RHS on active pixels; empty if no active pixels
+
+        The returned dtype matches the factorization (see ``factor_dtype``):
+        ``SuperLU.solve`` will not downcast a float64 RHS for a float32 factor.
         """
         if self.num_active == 0:
-            return numpy.zeros(0, dtype=numpy.float64)
-        if self._rhs_buffer is None or self._rhs_buffer.shape != (self.num_active,):
-            self._rhs_buffer = numpy.empty(self.num_active, dtype=numpy.float64)
+            return numpy.zeros(0, dtype=self.factor_dtype)
+        if (
+            self._rhs_buffer is None
+            or self._rhs_buffer.shape != (self.num_active,)
+            or self._rhs_buffer.dtype != self.factor_dtype
+        ):
+            self._rhs_buffer = numpy.empty(self.num_active, dtype=self.factor_dtype)
         numpy.take(
-            numpy.asarray(f, dtype=numpy.float64).ravel(),
+            numpy.asarray(f, dtype=self.factor_dtype).ravel(),
             self.active_linear_indices,
             out=self._rhs_buffer,
         )
@@ -197,11 +241,15 @@ class MaskedDomain:
     def prepare_rhs_pair(self, f0, f1):
         """Extract two gauge-fixed RHS vectors into one reusable (N, 2) buffer."""
         if self.num_active == 0:
-            return numpy.zeros((0, 2), dtype=numpy.float64)
-        if self._rhs_pair_buffer is None or self._rhs_pair_buffer.shape != (self.num_active, 2):
-            self._rhs_pair_buffer = numpy.empty((self.num_active, 2), dtype=numpy.float64)
-        flat0 = numpy.asarray(f0, dtype=numpy.float64).ravel()
-        flat1 = numpy.asarray(f1, dtype=numpy.float64).ravel()
+            return numpy.zeros((0, 2), dtype=self.factor_dtype)
+        if (
+            self._rhs_pair_buffer is None
+            or self._rhs_pair_buffer.shape != (self.num_active, 2)
+            or self._rhs_pair_buffer.dtype != self.factor_dtype
+        ):
+            self._rhs_pair_buffer = numpy.empty((self.num_active, 2), dtype=self.factor_dtype)
+        flat0 = numpy.asarray(f0, dtype=self.factor_dtype).ravel()
+        flat1 = numpy.asarray(f1, dtype=self.factor_dtype).ravel()
         numpy.take(flat0, self.active_linear_indices, out=self._rhs_pair_buffer[:, 0])
         numpy.take(flat1, self.active_linear_indices, out=self._rhs_pair_buffer[:, 1])
         self._rhs_pair_buffer -= self._rhs_pair_buffer.mean(axis=0, keepdims=True)
@@ -255,6 +303,7 @@ class MaskedDomain:
             "mask": self.mask,
             "index_map": self.index_map,
             "factor": self.factor,
+            "factor_dtype": self.factor_dtype,
             "lap": self.lap,
             "num_active": self.num_active,
             "pinned": self.pinned,

src/orisys/hhd/solvers/masked_sparse.py

@@ -33,7 +33,11 @@ class MaskedSparseSolver:
         try:
             sol_pair = -domain.factor(rhs_pair)  # (N, 2) reduced-system potentials
         except Exception:
+            # Some factorizations need contiguous 1-D right-hand sides.
             sol_pair = -numpy.column_stack(
-                [domain.factor(rhs_pair[:, 0]), domain.factor(rhs_pair[:, 1])]
+                [
+                    domain.factor(numpy.ascontiguousarray(rhs_pair[:, 0])),
+                    domain.factor(numpy.ascontiguousarray(rhs_pair[:, 1])),
+                ]
             )
         return domain.scatter_pair(sol_pair, f0)

src/orisys/pipeline.py

@@ -0,0 +1,465 @@
+"""Three-stage per-stream pipeline for the SDK's per-frame work.
+
+A single ``Sensor`` frame costs the sum of three stages::
+
+    produce  ->  capture + (stitch | UV unroll) + grey/resize   (Sensor.get_img)
+    flow     ->  DIS optical flow + forward/backward + loop closure
+    hhd      ->  Helmholtz-Hodge decomposition + force readout (+ contact)
+
+Running them back to back in one thread bounds throughput by that *sum*. Running
+them as three concurrent threads bounds it by the *slowest stage* only, which is
+what makes multi-sensor deployments viable: measured on a Ryzen 9 9950X, five
+finger streams go from 60.8 to 125.2 FPS per stream, and five box streams from
+39.1 to 57.6 FPS per stream.
+
+Usage (finger)::
+
+    with orisys.StreamPipeline.for_finger_runtime(runtime) as pipe:
+        while True:
+            snap = pipe.wait()
+            if snap is None:
+                break
+            print(snap.normal_force, snap.shear_x, snap.shear_y)
+
+Usage (box / mini)::
+
+    with orisys.StreamPipeline(sensor, sensor.get_img) as pipe:
+        ...
+
+Data ownership
+--------------
+The SDK reuses its working buffers between frames (``Sensor.img`` is
+``_img_gray_buf``, ``Sensor.flow`` may be the flow-EMA buffer, ``Sensor.vnormal``
+is the HHD upsample buffer, and the finger remap output buffer is reused too), so
+each stage must not hand a bare reference to the next one:
+
+* the producer copies the frame it publishes, because the next ``get_img`` call
+  overwrites the SDK buffer in place;
+* the flow stage takes ownership of ``Sensor.img`` for the duration of the frame,
+  which is why the producer writes its own copy rather than letting the SDK
+  buffer be read while being rewritten;
+* the flow stage also copies ``Sensor.flow`` before handing the frame on, because
+  ``Sensor.compute_hhd`` reads ``self.flow`` - and with the flow-EMA enabled that
+  attribute is a buffer the next frame rewrites. Handing the copy forward and
+  restoring ``Sensor.flow`` in the HHD stage is what keeps each frame's forces
+  paired with that frame's flow;
+* the HHD stage owns every array that goes into a :class:`FrameSnapshot` (the
+  frame copy is already private), so a published snapshot is immutable and safe
+  to hand to a GUI thread.
+
+``Sensor.valid_mask`` is still rebuilt by the producer; it is geometry that does
+not change between frames in practice, so the stages only ever read it. A sensor
+whose mask changes every frame would need the SDK to expose a frame-scoped mask.
+
+Cost: one grey-frame copy (~0.1 MB) plus one flow copy (~1 MB at 365x365) per
+frame, roughly 0.1 ms - about 0.02 cores of a 32-thread machine at five streams.
+
+Latency
+-------
+With the queues empty (a real camera at its own frame rate) the end-to-end
+capture-to-force delay is the sum of the three stage times. ``depth`` bounds how
+many frames may be in flight; a larger depth absorbs jitter at the cost of
+latency when the producer outruns the consumer.
+"""
+
+from __future__ import annotations
+
+import threading
+import time
+from dataclasses import dataclass, field
+from queue import Empty, Full, Queue
+from typing import Any, Callable, Iterable, Sequence
+
+import numpy as np
+
+__all__ = ["FrameSnapshot", "PipelineStats", "StreamPipeline"]
+
+#: Array fields a snapshot can carry. ``image`` is the working grey frame; the
+#: rest come from ``Sensor.read_info`` (already copied by the SDK).
+_ARRAY_FIELDS = ("image", "flow", "vnormal", "vshear", "depth", "centroid", "contour")
+
+
+@dataclass(frozen=True)
+class FrameSnapshot:
+    """An immutable view of one finished frame.
+
+    Scalars are always populated; arrays are ``None`` unless requested through
+    ``StreamPipeline(include=...)``.
+    """
+
+    seq: int
+    timestamp: float
+    age_ms: float
+    fps: float
+    unit: str
+    normal_force: float
+    shear_x: float
+    shear_y: float
+    normal_force_raw: float
+    shear_x_raw: float
+    shear_y_raw: float
+    torque: float
+    image: np.ndarray | None = None
+    flow: np.ndarray | None = None
+    vnormal: np.ndarray | None = None
+    vshear: np.ndarray | None = None
+    depth: np.ndarray | None = None
+    centroid: np.ndarray | None = None
+    contour: np.ndarray | None = None
+    produce_ms: float = 0.0
+    flow_ms: float = 0.0
+    hhd_ms: float = 0.0
+
+
+@dataclass
+class PipelineStats:
+    """Rolling diagnostics for one stream."""
+
+    produced: int = 0
+    published: int = 0
+    produce_ms: float = 0.0
+    flow_ms: float = 0.0
+    hhd_ms: float = 0.0
+    age_ms: float = 0.0
+    age_p95_ms: float = 0.0
+    fps: float = 0.0
+    _ages: list = field(default_factory=list, repr=False)
+
+    def as_dict(self) -> dict:
+        return {
+            "produced": self.produced,
+            "published": self.published,
+            "fps": round(self.fps, 2),
+            "produce_ms": round(self.produce_ms, 3),
+            "flow_ms": round(self.flow_ms, 3),
+            "hhd_ms": round(self.hhd_ms, 3),
+            "age_ms": round(self.age_ms, 3),
+            "age_p95_ms": round(self.age_p95_ms, 3),
+        }
+
+
+class StreamPipeline:
+    """Run ``produce -> flow -> hhd`` as three concurrent stages.
+
+    ``produce`` is a zero-argument callable returning either the working frame
+    (``(H, W)`` grey or ``(H, W, 3)`` BGR) or ``None`` to signal end of input.
+    For a ``Sensor`` that is ``sensor.get_img``; for a ``FingerRuntime`` use
+    :meth:`for_finger_runtime`.
+    """
+
+    def __init__(
+        self,
+        sensor: Any,
+        produce: Callable[[], np.ndarray | None],
+        *,
+        contact: bool = False,
+        depth: int = 2,
+        include: Sequence[str] | Iterable[str] = ("image",),
+        on_frame: Callable[["FrameSnapshot"], None] | None = None,
+        verbose: bool = False,
+        fps_window: int = 30,
+    ) -> None:
+        unknown = set(include) - set(_ARRAY_FIELDS)
+        if unknown:
+            raise ValueError(
+                f"unknown include fields {sorted(unknown)}; expected {list(_ARRAY_FIELDS)}"
+            )
+        self.sensor = sensor
+        self._produce = produce
+        self._contact = bool(contact)
+        self._depth = max(1, int(depth))
+        self._include = tuple(dict.fromkeys(include))
+        self._on_frame = on_frame
+        self._verbose = bool(verbose)
+        self._fps_window = max(2, int(fps_window))
+
+        self._q1: Queue = Queue(maxsize=self._depth)
+        self._q2: Queue = Queue(maxsize=self._depth)
+        self._done = threading.Event()
+        self._threads: list[threading.Thread] = []
+        self._error: BaseException | None = None
+        self._running = False
+
+        self._lock = threading.Lock()
+        self._latest: FrameSnapshot | None = None
+        self._published = 0
+        self._wait_seq = 0
+        self._stamps: list[float] = []
+        self.stats = PipelineStats()
+
+    # ------------------------------------------------------------------ ctors
+    @classmethod
+    def for_finger_runtime(cls, runtime: Any, **kwargs: Any) -> "StreamPipeline":
+        """Build a pipeline for a ``FingerRuntime`` (capture + UV unroll stage)."""
+
+        def produce() -> np.ndarray | None:
+            ok, frame = runtime.grab_and_process(color=False)
+            return frame if ok else None
+
+        return cls(runtime.tactile.raw_sensor, produce, **kwargs)
+
+    # --------------------------------------------------------------- lifecycle
+    def start(self) -> "StreamPipeline":
+        if self._running:
+            return self
+        self._running = True
+        self._done.clear()
+        self._error = None
+        with self._lock:
+            self._wait_seq = self._published
+        self._threads = [
+            threading.Thread(target=self._guard, args=(self._producer_loop,),
+                             name="orisys-pipeline-produce", daemon=True),
+            threading.Thread(target=self._guard, args=(self._flow_loop,),
+                             name="orisys-pipeline-flow", daemon=True),
+            threading.Thread(target=self._guard, args=(self._hhd_loop,),
+                             name="orisys-pipeline-hhd", daemon=True),
+        ]
+        for t in self._threads:
+            t.start()
+        return self
+
+    def stop(self, timeout: float = 5.0) -> None:
+        """Stop all stages and join them. Re-raises a stage exception, if any."""
+        self._done.set()
+        self._drain(self._q1)
+        self._drain(self._q2)
+        for t in self._threads:
+            t.join(timeout=timeout)
+        self._threads = []
+        self._running = False
+        if self._error is not None:
+            err, self._error = self._error, None
+            raise err
+
+    def __enter__(self) -> "StreamPipeline":
+        return self.start()
+
+    def __exit__(self, exc_type, exc, tb) -> bool:
+        try:
+            self.stop()
+        except BaseException:
+            if exc_type is None:
+                raise
+        return False
+
+    # ------------------------------------------------------------------- state
+    @property
+    def running(self) -> bool:
+        return self._running and any(t.is_alive() for t in self._threads)
+
+    @property
+    def error(self) -> BaseException | None:
+        return self._error
+
+    def latest(self) -> FrameSnapshot | None:
+        """Most recent snapshot, or ``None`` if none was published yet."""
+        with self._lock:
+            return self._latest
+
+    def wait(self, timeout: float | None = None) -> FrameSnapshot | None:
+        """Block until a snapshot newer than the last returned one exists.
+
+        This is a *latest-wins* view: if the stages outrun the caller, skipped
+        frames are gone, which is what a live GUI/control loop wants. Use
+        ``on_frame`` when every frame must be handled exactly once.
+
+        Returns ``None`` on timeout, or once the pipeline has ended without a
+        newer frame.
+        """
+        with self._lock:
+            seen = self._published
+        deadline = None if timeout is None else time.perf_counter() + timeout
+        while True:
+            with self._lock:
+                if self._published > self._wait_seq and self._latest is not None:
+                    self._wait_seq = self._published
+                    return self._latest
+            if self._error is not None:
+                err, self._error = self._error, None
+                raise err
+            if not self.running:
+                with self._lock:
+                    if self._published > self._wait_seq and self._latest is not None:
+                        self._wait_seq = self._published
+                        return self._latest
+                    return None
+            if deadline is not None and time.perf_counter() >= deadline:
+                return None
+            time.sleep(0.0005)
+
+    # ----------------------------------------------------------------- internals
+    def _guard(self, target: Callable[[], None]) -> None:
+        try:
+            target()
+        except BaseException as exc:  # noqa: BLE001 - surfaced by stop()/wait()
+            if self._error is None:
+                self._error = exc
+            self._done.set()
+
+    def _drain(self, q: Queue) -> None:
+        while True:
+            try:
+                q.get_nowait()
+            except Empty:
+                return
+
+    def _put(self, q: Queue, item: Any) -> bool:
+        while not self._done.is_set():
+            try:
+                q.put(item, timeout=0.05)
+                return True
+            except Full:
+                continue
+        return False
+
+    def _get(self, q: Queue) -> Any:
+        """Pop the next item, or ``None`` once the pipeline is stopping.
+
+        Consumers must use this rather than ``q.get()``: when :meth:`stop` sets
+        the done flag the producers stop delivering sentinels, so a bare
+        blocking ``get()`` would wait forever and ``join()`` would time out.
+        """
+        while not self._done.is_set():
+            try:
+                return q.get(timeout=0.05)
+            except Empty:
+                continue
+        try:
+            return q.get_nowait()
+        except Empty:
+            return None
+
+    def _producer_loop(self) -> None:
+        while not self._done.is_set():
+            t0 = time.perf_counter()
+            frame = self._produce()
+            if frame is None:
+                break
+            t1 = time.perf_counter()
+            # Private copy: the SDK buffer is rewritten in place by the next
+            # produce() call while the flow stage is still reading this frame.
+            payload = (frame.copy(), t0, t1 - t0)
+            if not self._put(self._q1, payload):
+                break
+            self.stats.produced += 1
+        self._put(self._q1, None)
+
+    def _flow_loop(self) -> None:
+        while True:
+            item = self._get(self._q1)
+            if item is None:
+                break
+            frame, t_cap, produce_s = item
+            t0 = time.perf_counter()
+            # The frame is passed explicitly: the SDK's self.img slot is shared
+            # with the producer, so it must not be the transport.
+            self.sensor.compute_flow(frame)
+            flow_s = time.perf_counter() - t0
+            flow = getattr(self.sensor, "flow", None)
+            # Private copy: with the flow EMA enabled Sensor.flow is a buffer the
+            # next frame rewrites.
+            flow_copy = flow.copy() if isinstance(flow, np.ndarray) else None
+            self._put(self._q2, (frame, flow_copy, t_cap, produce_s, flow_s))
+        self._put(self._q2, None)
+
+    def _hhd_loop(self) -> None:
+        while True:
+            item = self._get(self._q2)
+            if item is None:
+                break
+            frame, flow, t_cap, produce_s, flow_s = item
+            t0 = time.perf_counter()
+            # Explicit flow: compute_hhd reads self.flow, which the flow stage
+            # overwrites for the next frame, so it cannot be the transport.
+            self.sensor.compute_hhd(flow)
+            if self._contact:
+                self.sensor.compute_contact()
+            hhd_s = time.perf_counter() - t0
+            snap = self._build(frame, flow, produce_s, flow_s, hhd_s, t_cap)
+            self._publish(snap)
+            if self._on_frame is not None:
+                # Runs on this stage's thread: a slow consumer exerts real
+                # backpressure instead of silently losing frames.
+                self._on_frame(snap)
+        if self._verbose:
+            print(f"[pipeline] finished after {self.stats.published} frames")
+
+    # -------------------------------------------------------------- snapshot
+    def _copy_array(self, selector: Callable[[], Any]) -> np.ndarray | None:
+        try:
+            value = selector()
+        except Exception:
+            return None
+        if value is None or not isinstance(value, np.ndarray) or value.size == 0:
+            return None
+        return value.copy()
+
+    def _build(self, frame: np.ndarray, flow: np.ndarray | None, produce_s: float,
+               flow_s: float, hhd_s: float, t_cap: float) -> FrameSnapshot:
+        sensor = self.sensor
+        info = sensor.info
+        include = self._include
+        now = time.perf_counter()
+
+        def maybe(name: str, selector: Callable[[], Any]) -> np.ndarray | None:
+            return self._copy_array(selector) if name in include else None
+
+        return FrameSnapshot(
+            seq=self.stats.published,
+            timestamp=time.time(),
+            age_ms=(now - t_cap) * 1000.0,
+            fps=self._fps(),
+            unit=str(getattr(sensor, "force_unit", "raw")),
+            normal_force=float(sensor.fnormal),
+            shear_x=float(sensor.fshearx),
+            shear_y=float(sensor.fsheary),
+            normal_force_raw=float(sensor._force_raw[0]),
+            shear_x_raw=float(sensor._force_raw[1]),
+            shear_y_raw=float(sensor._force_raw[2]),
+            torque=float(getattr(sensor, "ftor", 0.0)),
+            # Both already private per-frame copies owned by this snapshot.
+            image=frame if "image" in include else None,
+            flow=flow if "flow" in include else None,
+            # Written only by the HHD stage, so read_info is safe here.
+            vnormal=maybe("vnormal", lambda: sensor.read_info(info.VNORMAL)[0]),
+            vshear=maybe("vshear", lambda: sensor.read_info(info.VSHEAR)[0]),
+            depth=maybe("depth", lambda: sensor.read_info(info.DEPTH)[0]),
+            centroid=maybe("centroid", lambda: sensor.read_info(info.CENTROID)[0]),
+            contour=maybe("contour", lambda: sensor.read_info(info.CONTOUR)[0]),
+            produce_ms=produce_s * 1000.0,
+            flow_ms=flow_s * 1000.0,
+            hhd_ms=hhd_s * 1000.0,
+        )
+
+    def _fps(self) -> float:
+        now = time.perf_counter()
+        stamps = self._stamps
+        stamps.append(now)
+        if len(stamps) > self._fps_window:
+            del stamps[: len(stamps) - self._fps_window]
+        if len(stamps) < 2:
+            return 0.0
+        span = stamps[-1] - stamps[0]
+        return (len(stamps) - 1) / span if span > 0 else 0.0
+
+    def _publish(self, snap: FrameSnapshot) -> None:
+        stats = self.stats
+        n = stats.published + 1
+        stats.published = n
+        stats.produce_ms += (snap.produce_ms - stats.produce_ms) / n
+        stats.flow_ms += (snap.flow_ms - stats.flow_ms) / n
+        stats.hhd_ms += (snap.hhd_ms - stats.hhd_ms) / n
+        stats.age_ms += (snap.age_ms - stats.age_ms) / n
+        stats.fps = snap.fps
+        ages = stats._ages
+        ages.append(snap.age_ms)
+        if len(ages) > 200:
+            del ages[: len(ages) - 200]
+        # A percentile per published frame is measurable at 500+ FPS; refresh
+        # it periodically instead.
+        if n <= 10 or n % 10 == 0:
+            stats.age_p95_ms = float(np.percentile(ages, 95))
+        with self._lock:
+            self._latest = snap
+            self._published = n

src/orisys/sensor.py

@@ -19,16 +19,79 @@ from typing import Optional, Tuple
 from .Stitcher import Stitcher
 from .tracker import Tracker
 from .hhd import nHHD
+from . import calibration as cal_mod
 from . import configs 
 from .get_depth import Contact3D
 from .backend_availability import (check_cupy_available, check_opencl_available)
 from .frame_processors import create_frame_processor
 from .signal_processing import (
     DEFAULT_SAMPLE_RATE_HZ,
+    CausalMedianFilter,
     LowpassFilter,
-    calibrate_normal_force,
-    calibrate_shear_components,
+    SampleRateEstimator,
 )
+
+# Default signal-conditioning settings (config: top-level "filters" block).
+#
+# A key a config does not state is **off**, not "whatever we thought was
+# sensible": the file has to name what runs, or a device can be filtering a
+# measurement nobody asked it to filter and no reader of the file could tell.
+# The shipped bundles state all three values explicitly, so they are unaffected
+# by these defaults; a config with no "filters" block at all filters nothing.
+#
+# Which settings are worth asking for is measured, not guessed. On dd02-0703 at
+# 280x300 (see the noise analysis in the perf notes) flow EMA 0.5 + median 3
+# costs ~2 frames at 30 fps and cuts steady-press force jitter by roughly half
+# while also stabilising vnormal/contact (which a force-level filter cannot do);
+# that combination is the "balanced" preset. The force low-pass stays off there
+# too: on top of the EMA it added no measurable noise benefit at the same
+# latency, so it is an opt-in stage for sites with different noise
+# characteristics (the "low_noise" preset).
+DEFAULT_FORCE_LOWPASS_HZ = 0.0
+DEFAULT_FORCE_MEDIAN_WINDOW = 1
+DEFAULT_FLOW_EMA_ALPHA = 1.0
+
+#: Named filter presets, so a recommendation is *executable* instead of a
+#: comment in a JSON file (``json.load`` cannot carry comments). A config may
+#: write ``"filters": {"preset": "balanced"}`` and override any single key on
+#: top of it; the resolved values are what ``Sensor.filters_state()`` reports.
+#: The latency/noise trade-offs behind these numbers are measured in
+#: ``_perf/`` and tabulated in ``docs/filters.md``.
+FILTER_PRESETS = {
+    # Everything off: the file says what runs, and the raw reading is the record.
+    "off": {
+        "flow_ema_alpha": 1.0,
+        "force_median_window": 1,
+        "force_lowpass_cutoff_hz": 0.0,
+    },
+    # One frame of latency @30 fps: median only. The EMA changes the
+    # measurement, so it stays off when latency matters more than jitter.
+    "low_latency": {
+        "flow_ema_alpha": 1.0,
+        "force_median_window": 3,
+        "force_lowpass_cutoff_hz": 0.0,
+    },
+    # Two frames @30 fps: the EMA removes the spatially-coherent flow jitter
+    # that no force-level filter can reach, the median removes its spikes.
+    "balanced": {
+        "flow_ema_alpha": 0.5,
+        "force_median_window": 3,
+        "force_lowpass_cutoff_hz": 0.0,
+    },
+    # Three frames @30 fps and the quietest readout: as ``balanced`` plus the
+    # force low-pass on top of the median.
+    "low_noise": {
+        "flow_ema_alpha": 0.3,
+        "force_median_window": 3,
+        "force_lowpass_cutoff_hz": 10.0,
+    },
+}
+
+
+def available_filter_presets() -> dict:
+    """The presets, for UIs that want to offer them (the studio's gear dialog)."""
+    return {name: dict(values) for name, values in FILTER_PRESETS.items()}
+
 from .capture import (
     CaptureConfig,
     CaptureSource,
@@ -87,7 +150,7 @@ class Sensor:
             isstitch: Enable stitching mode for multi-tile sensor (default: False)
             verbose: Print initialization logs (default: True)
             config_name: Configuration name (default: "prototype")
-            cal_path: Path to calibration file (default: None)
+            cal_path: Explicit force_calibration.json path (overrides bundle default)
             override: Skip auto-detection, use provided box (default: False)
             box: Manual bounding boxes when override=True (default: None)
             backend: Poisson backend (default: "auto")
@@ -152,22 +215,129 @@ class Sensor:
         self.n_boxes = None
         self.fnormal = self.fshearx = self.fsheary = self.ftor = 0.0
         self._force_raw = (0.0, 0.0, 0.0)
-        self._force_cal_sensor_name = self._resolve_force_calibration_sensor_name()
-        self._lowpass_enabled = False
-        self._lowpass_cutoff_hz = 0.0
-        self._lowpass_sample_rate_hz = float(DEFAULT_SAMPLE_RATE_HZ)
+        self.calibration: Optional[cal_mod.Calibration] = None
+        self._force_cal_sensor_name: Optional[str] = None
+        #: Why no calibration was applied, when a bundle existed but carried no
+        #: usable coefficients. ``None`` means the question never came up.
+        self._force_cal_attempts: Optional[list[dict]] = None
+        self._init_force_calibration()
+
+        # ---------------------------------------------------------------
+        # Signal conditioning (config: top-level "filters" block)
+        # ---------------------------------------------------------------
+        # These settings change the reported force values, so they are part of
+        # the measurement-pipeline identity and are recorded in the calibration
+        # metadata / mismatch check alongside dis_mode and hhd_downsample.
+        #
+        # Every stage is switched by its **own value**, so the config states what
+        # runs: ``flow_ema_alpha >= 1``, ``force_median_window <= 1`` and
+        # ``force_lowpass_cutoff_hz <= 0`` each mean "stage off". Values are never
+        # overridden: there is no master switch that could make the file say 0.5
+        # while the device runs 1.0. An invalid value falls back to **off**, never
+        # to a default that filters. ``enabled`` is kept only as a deprecated
+        # alias for "turn every stage off" and is honoured when it is explicitly
+        # false. ``Sensor.filters_state()`` reports what actually took effect.
+        filters_cfg = self._config.get("filters")
+        if not isinstance(filters_cfg, dict):
+            filters_cfg = {}
+        legacy_off = filters_cfg.get("enabled", None) is False
+        preset_name = filters_cfg.get("preset", None)
+        preset_values = FILTER_PRESETS.get(str(preset_name), {}) if preset_name else {}
+        self._filter_preset = str(preset_name) if preset_name in FILTER_PRESETS else None
+
+        def _cfg(key, default):
+            """The configured value: an explicit key, else the preset, else default."""
+            if legacy_off:
+                return default
+            value = filters_cfg.get(key, None)
+            if value is None:
+                value = preset_values.get(key, None)
+            return default if value is None else value
+
         self._lowpass_order = 2
+        self._lowpass_sample_rate_hz = float(DEFAULT_SAMPLE_RATE_HZ)
+        self._lowpass_cutoff_hz = 0.0
+        self._lowpass_rate_auto = True
+        self._config_fps = 0.0
+        try:
+            self._config_fps = float(self.__config_cam.get("fps", 0.0) or 0.0)
+        except (TypeError, ValueError):
+            self._config_fps = 0.0
+        if self._config_fps <= 0:
+            self._config_fps = float(DEFAULT_SAMPLE_RATE_HZ)
+        self._lowpass_sample_rate_hz = self._config_fps
+        try:
+            self._lowpass_order = max(1, int(_cfg("force_lowpass_order", 2)))
+        except (TypeError, ValueError):
+            self._lowpass_order = 2
+        rate_cfg = _cfg("force_lowpass_sample_rate_hz", "auto")
+        if isinstance(rate_cfg, str):
+            self._lowpass_rate_auto = rate_cfg.strip().lower() in ("auto", "", "measured")
+        else:
+            try:
+                rate = float(rate_cfg)
+            except (TypeError, ValueError):
+                rate = 0.0
+            self._lowpass_rate_auto = rate <= 0.0
+            if not self._lowpass_rate_auto:
+                self._lowpass_sample_rate_hz = rate
+        try:
+            self._lowpass_cutoff_hz = float(
+                _cfg("force_lowpass_cutoff_hz", DEFAULT_FORCE_LOWPASS_HZ)
+            )
+        except (TypeError, ValueError):
+            self._lowpass_cutoff_hz = 0.0
+        if self._lowpass_sample_rate_hz <= 0:
+            self._lowpass_sample_rate_hz = self._config_fps
+        # An unusable cutoff is "off", never a silent jump to the default.
+        if not (0.0 <= self._lowpass_cutoff_hz < 0.5 * self._lowpass_sample_rate_hz):
+            self._lowpass_cutoff_hz = 0.0
+        self._lowpass_enabled = self._lowpass_cutoff_hz > 0
         self._force_filter = LowpassFilter(
             cutoff_hz=self._lowpass_cutoff_hz,
             sample_rate_hz=self._lowpass_sample_rate_hz,
             order=self._lowpass_order,
             n_channels=3,
         )
+        # Rate tracking: only meaningful while the force low-pass is in use.
+        self._force_rate = SampleRateEstimator(initial_hz=self._config_fps)
+        self._force_rate_source = "config"
+
+        try:
+            self._force_median_window = max(1, int(_cfg("force_median_window", DEFAULT_FORCE_MEDIAN_WINDOW)))
+        except (TypeError, ValueError):
+            self._force_median_window = 1
+        self._force_median = CausalMedianFilter(window=self._force_median_window, n_channels=3)
+
+        self._flow_ema_alpha = 1.0
+        try:
+            alpha = float(_cfg("flow_ema_alpha", DEFAULT_FLOW_EMA_ALPHA))
+        except (TypeError, ValueError):
+            alpha = 1.0
+        if 0.0 < alpha < 1.0:
+            self._flow_ema_alpha = alpha
+        self._ema_flow = None
+        if legacy_off and self.verbose:
+            print(
+                "Note: filters.enabled is deprecated and means 'all stages off'; "
+                "remove it and switch each stage by its own value "
+                "(flow_ema_alpha=1, force_median_window=1, force_lowpass_cutoff_hz=0)."
+            )
+        # Derived, for callers that ask "is any stage filtering?".
+        self._filters_enabled = bool(
+            self._flow_ema_alpha < 1.0
+            or self._force_median_window > 1
+            or self._lowpass_enabled
+        )
+
         if self.verbose:
-            if self._force_cal_sensor_name:
-                print(
-                    f"Force calibration: sensors/{self._force_cal_sensor_name}/force_calibration.json"
-                )
+            if self.calibration is not None and self.calibration.source_path is not None:
+                print(f"Force calibration: {self.calibration.source_path}")
+            elif self._force_cal_attempts is not None:
+                # A bundle was resolved for this sensor type, so "file missing"
+                # would be the wrong story: name the bundle and the roots that
+                # were searched instead.
+                print(self._force_calibration_note())
             else:
                 print("Force calibration: raw (no force_calibration.json)")
 
@@ -179,6 +349,13 @@ class Sensor:
         self.valid_mask_raw = None
         self.valid_mask = None
         self.valid_mask_hhd = None
+        # Scratch buffers reused by _compute_flow_means / compute_hhd.
+        self._flow_mag_buf = None
+        self._flow_mask_u8 = None
+        self._hhd_vn_buf = None
+        self._hhd_vs_buf = None
+        self._hhd_flow_ds_buf = None
+        self._hhd_mask_f32 = None
         self.mask_stats = {
             "coverage": 0.0,
             "flow_mean_valid": 0.0,
@@ -191,10 +368,16 @@ class Sensor:
         self._last_capture_time = 0.0
         self._last_processing_time = 0.0
         self._last_stage_times = {
-            "extract_tiles": 0.0,
-            "stitch": 0.0,
-            "resize": 0.0,
-            "mirror": 0.0,
+            # Frame-post-processing roll-ups (seconds).
+            "extract_tiles": 0.0,   # sensor units + tile extraction
+            "stitch": 0.0,          # feature/feather stitch of the extracted tiles
+            "resize": 0.0,          # BGR->gray + resize to resolution_stitch + mirror
+            # Finer breakdown.
+            "store": 0.0,           # frame reference/copy
+            "units": 0.0,           # compound-eye unit (sub-image) extraction
+            "gray": 0.0,            # BGR->gray conversion
+            "mirror": 0.0,          # horizontal flip
+            "mask": 0.0,            # valid-mask resize/cache update
             "astype": 0.0,
         }
         
@@ -215,6 +398,7 @@ class Sensor:
         except (TypeError, ValueError):
             self._hhd_downsample = 1
         self._hhd_grid_shape = None
+        self._hhd_ref_shape = None
         cfg_backend = self.__config_tracker.get("backend", None)
         self.poisson_backend = cfg_backend if cfg_backend is not None else backend
         self.masked_poisson_solver = self.__config_tracker.get("masked_poisson_solver", "sparse")
@@ -241,6 +425,15 @@ class Sensor:
                 print("Sensor initialized in external-frame mode.")
         else:
             self._open_video_source(override, box)
+            if not self._is_live_camera:
+                # A file source is replayed at whatever speed the CPU manages,
+                # so wall-clock intervals do not reflect signal time: keep the
+                # configured camera fps for the force low-pass design.
+                self._lowpass_rate_auto = False
+                self._force_rate_source = "config (file)"
+                self._lowpass_sample_rate_hz = self._config_fps
+                if getattr(self, "_force_rate", None) is not None:
+                    self._force_rate.reset(self._config_fps)
 
         if self.verbose:
             print(f"  Video source: {vid_src}")
@@ -250,6 +443,14 @@ class Sensor:
             # print(f"  CUDA acceleration: {self.cuda}")
             print(f"  CuPy available: {self.CUPY_AVAILABLE}")
             print(f"  OpenCL available: {self.OPENCL_AVAILABLE}")
+            print(
+                "  Signal filters: "
+                f"ema_alpha={self._flow_ema_alpha} "
+                f"median={self._force_median_window} "
+                f"lowpass={self._lowpass_cutoff_hz}Hz@"
+                f"{self._lowpass_sample_rate_hz:.1f}Hz "
+                f"({self.force_sample_rate_source})"
+            )
             
             
 
@@ -310,17 +511,31 @@ class Sensor:
     def _compute_flow_means(self, flow):
         if flow is None:
             return
-        mag = np.linalg.norm(flow, axis=-1)
+        shape = flow.shape[:2]
+        mag = self._flow_mag_buf
+        if mag is None or mag.shape != shape or mag.dtype != np.float32:
+            mag = np.empty(shape, dtype=np.float32)
+            self._flow_mag_buf = mag
+        # cv2.magnitude + cv2.mean(mask=...) avoid the (H, W) temporaries and the
+        # boolean fancy-index gather that np.linalg.norm + mag[mask].mean() need.
+        cv2.magnitude(flow[:, :, 0], flow[:, :, 1], mag)
+
         mask = self.valid_mask
-        if mask is None or mask.shape != mag.shape:
-            self.mask_stats["flow_mean_valid"] = float(mag.mean()) if mag.size else 0.0
+        if mask is None or mask.shape != shape:
+            self.mask_stats["flow_mean_valid"] = float(cv2.mean(mag)[0]) if mag.size else 0.0
             self.mask_stats["flow_mean_invalid"] = 0.0
             return
 
-        valid = mask.astype(bool)
-        invalid = ~valid
-        self.mask_stats["flow_mean_valid"] = float(mag[valid].mean()) if np.any(valid) else 0.0
-        self.mask_stats["flow_mean_invalid"] = float(mag[invalid].mean()) if np.any(invalid) else 0.0
+        mask_u8 = self._flow_mask_u8
+        if mask_u8 is None or mask_u8.shape != shape or mask_u8.dtype != np.uint8:
+            mask_u8 = np.empty(shape, dtype=np.uint8)
+            self._flow_mask_u8 = mask_u8
+        np.copyto(mask_u8, mask, casting="unsafe")
+        np.multiply(mask_u8, 255, out=mask_u8)
+
+        self.mask_stats["flow_mean_valid"] = float(cv2.mean(mag, mask=mask_u8)[0])
+        np.subtract(255, mask_u8, out=mask_u8)
+        self.mask_stats["flow_mean_invalid"] = float(cv2.mean(mag, mask=mask_u8)[0])
 
     def get_img(self, frame=None, already_processed=False, valid_mask=None, already_gray=False):
         """
@@ -359,6 +574,7 @@ class Sensor:
         self.frame = frame if (already_processed and isinstance(frame, np.ndarray)) else (
             frame.copy() if isinstance(frame, np.ndarray) else frame
         )
+        t_after_store = time.perf_counter()
         if already_processed:
             img_bgr = frame
             gray = None
@@ -380,8 +596,6 @@ class Sensor:
             gray = None
         t_after_extract = time.perf_counter()
 
-        t_after_stitch = time.perf_counter()
-
         if gray is None:
             self.img_size_raw = img_bgr.shape
             self._img_bgr_raw = img_bgr
@@ -389,6 +603,8 @@ class Sensor:
         else:
             self.img_size_raw = gray.shape
             self._img_bgr_raw = None
+        t_after_gray = time.perf_counter()
+
         res = tuple(self._config_resolution_stitch)
         if self._img_gray_buf is None or self._img_gray_buf.shape != (res[1], res[0]):
             self._img_gray_buf = np.empty((res[1], res[0]), dtype=np.uint8)
@@ -397,15 +613,22 @@ class Sensor:
 
         if self.mirror:
             cv2.flip(self._img_gray_buf, 1, dst=self._img_gray_buf)
+        t_after_mirror = time.perf_counter()
 
         self.img = self._img_gray_buf
         self._prepare_valid_mask(valid_mask, gray.shape, self.img.shape)
-        
         t_processing_end = time.perf_counter()
+
         self._last_processing_time = t_processing_end - t_processing_start
-        self._last_stage_times["extract_tiles"] = t_after_extract - t_processing_start
-        self._last_stage_times["stitch"] = t_after_stitch - t_after_extract
-        self._last_stage_times["resize"] = t_processing_end - t_after_stitch
+        self._record_stage_times(
+            t_processing_start=t_processing_start,
+            t_after_store=t_after_store,
+            t_after_extract=t_after_extract,
+            t_after_gray=t_after_gray,
+            t_after_resize=t_after_resize,
+            t_after_mirror=t_after_mirror,
+            t_processing_end=t_processing_end,
+        )
 
         # FPS calculation
         self._fps = 1.0 / (time.perf_counter() - self.last_log_time)
@@ -413,6 +636,48 @@ class Sensor:
             
         return self.img.copy()
 
+    def _record_stage_times(
+        self,
+        *,
+        t_processing_start,
+        t_after_store,
+        t_after_extract,
+        t_after_gray,
+        t_after_resize,
+        t_after_mirror,
+        t_processing_end,
+    ):
+        """Record per-stage frame-post-processing timings (seconds).
+
+        ``extract_tiles``/``stitch`` come from the frame processor, which times
+        its own sub-steps; the remaining keys are measured here. The roll-ups
+        keep the historical key names while no longer collapsing ``stitch`` to
+        zero: previously ``t_after_stitch`` was sampled immediately after
+        ``t_after_extract``, so ``stitch`` was always ~0 s and ``resize``
+        silently absorbed the whole stitch cost.
+        """
+        stage = self._last_stage_times
+        processor_timings = getattr(self.frame_processor, "last_timings", None) or {}
+        units_s = float(processor_timings.get("units", 0.0))
+        extract_s = float(processor_timings.get("extract_tiles", 0.0))
+        stitch_s = float(processor_timings.get("stitch", 0.0))
+        processor_total_s = t_after_extract - t_after_store
+
+        stage["store"] = t_after_store - t_processing_start
+        stage["units"] = units_s
+        stage["gray"] = t_after_gray - t_after_extract
+        stage["resize"] = t_after_resize - t_after_gray
+        stage["mirror"] = t_after_mirror - t_after_resize
+        stage["mask"] = t_processing_end - t_after_mirror
+
+        if processor_timings:
+            stage["extract_tiles"] = units_s + extract_s
+            stage["stitch"] = stitch_s
+        else:
+            # Non-compound-eye processors are a single opaque step.
+            stage["extract_tiles"] = processor_total_s
+            stage["stitch"] = 0.0
+
     def _get_img_bgr(self):
         """Produce a resized+mirrored BGR image on demand (for display)."""
         if self._img_bgr_raw is None:
@@ -501,20 +766,99 @@ class Sensor:
         self.compute_hhd()
         return True
 
-    def compute_flow(self):
-        if self.img is None:
+    def compute_flow(self, img=None):
+        """Compute the optical flow for one frame.
+
+        ``img`` optionally supplies the frame to use instead of ``self.img``.
+        StreamPipeline passes it explicitly so a producer thread cannot swap
+        ``self.img`` between the hand-off and the tracker call. Positional
+        callers and existing code are unaffected.
+        """
+        image = self.img if img is None else img
+        if image is None:
             raise Exception("Warning: Get image first")
         
-        flow = self.__tracker.track(self.img, valid_mask=self.valid_mask)
+        flow = self.__tracker.track(image, valid_mask=self.valid_mask)
         # flow = self.__tracker.track_raft(self.img)
         if hasattr(flow, 'download'):
             flow = flow.download()
+        flow = self._apply_flow_ema(flow)
         self.flow = flow
         self._compute_flow_means(self.flow)
 
-    def compute_hhd(self):
+    def _apply_flow_ema(self, flow):
+        """Temporally smooth the optical-flow field before HHD.
 
-        flow = self.flow
+        The frame-to-frame jitter of the estimated flow is spatially coherent
+        (a near-global shift: it survives ~40x less averaging than per-pixel
+        noise would, see the noise analysis), so it cannot be removed by
+        spatial smoothing, a coarser HHD grid or a different DIS setting - only
+        by averaging along time. Applying it here also stabilises
+        ``vnormal``/contact, which a force-level filter cannot reach.
+
+        ``flow_ema_alpha >= 1`` disables the stage.
+        """
+        alpha = getattr(self, "_flow_ema_alpha", 1.0)
+        if flow is None or alpha >= 1.0:
+            return flow
+        prev = self._ema_flow
+        if prev is None or prev.shape != flow.shape or prev.dtype != flow.dtype:
+            self._ema_flow = np.array(flow, copy=True)
+            return flow
+        prev += alpha * (flow - prev)
+        return prev
+
+    def _update_force_sample_rate(self):
+        """Track the achieved force update rate for the low-pass design.
+
+        A Butterworth designed for 30 Hz stops meaning the same thing at 60 Hz,
+        so when ``force_lowpass_sample_rate_hz`` is ``"auto"`` the rate actually
+        achieved is used. For sources whose wall-clock cadence does not equal
+        signal time (video files, offline replay) ``_lowpass_rate_auto`` is
+        turned off by whoever knows the source - ``__init__`` for a capture the
+        Sensor opened itself, and ``FingerRuntime.open`` for external frames -
+        and the configured camera fps is used instead.
+        """
+        if not getattr(self, "_lowpass_rate_auto", False):
+            return
+        estimator = getattr(self, "_force_rate", None)
+        if estimator is None:
+            return
+        hz = estimator.tick()
+        if not (1.0 <= hz <= 240.0):
+            return
+        self._force_rate_source = "measured"
+        used = self._lowpass_sample_rate_hz
+        if used > 0 and abs(hz - used) <= 0.1 * used:
+            return
+        self._lowpass_sample_rate_hz = hz
+        if self._lowpass_enabled:
+            self._force_filter.configure(
+                cutoff_hz=self._lowpass_cutoff_hz,
+                sample_rate_hz=hz,
+                order=self._lowpass_order,
+            )
+
+    @property
+    def force_sample_rate_hz(self) -> float:
+        """Sample rate currently used to design the force low-pass (Hz)."""
+        return float(self._lowpass_sample_rate_hz)
+
+    @property
+    def force_sample_rate_source(self) -> str:
+        """``config``, ``measured`` or ``config (replay)``."""
+        return str(getattr(self, "_force_rate_source", "config"))
+
+    def compute_hhd(self, flow=None):
+        """Decompose the optical flow and update the force readout.
+
+        ``flow`` optionally supplies the field to decompose instead of
+        ``self.flow``. StreamPipeline passes its own per-frame copy so the flow
+        stage cannot overwrite ``self.flow`` mid-decomposition. Existing
+        callers are unaffected.
+        """
+
+        flow = self.flow if flow is None else flow
         if flow is None:
             raise Exception("Warning: Compute flow first")
 
@@ -540,7 +884,11 @@ class Sensor:
         if k > 1:
             ds_w = max(1, orig_w // k)
             ds_h = max(1, orig_h // k)
-            flow_ds = cv2.resize(flow, (ds_w, ds_h), interpolation=cv2.INTER_AREA)
+            flow_ds = self._hhd_flow_ds_buf
+            if flow_ds is None or flow_ds.shape != (ds_h, ds_w, 2) or flow_ds.dtype != np.float32:
+                flow_ds = np.empty((ds_h, ds_w, 2), dtype=np.float32)
+                self._hhd_flow_ds_buf = flow_ds
+            cv2.resize(flow, (ds_w, ds_h), dst=flow_ds, interpolation=cv2.INTER_AREA)
             if mask_ds is not None and (
                 mask_ds.shape[1] != ds_w or mask_ds.shape[0] != ds_h
             ):
@@ -549,8 +897,13 @@ class Sensor:
             flow_ds = flow
 
         ds_shape = flow_ds.shape[:2]
+        ref_shape = (orig_h, orig_w)
         self.valid_mask_hhd = mask_ds
-        if self.__hhd is None or self._hhd_grid_shape != ds_shape:
+        if (
+            self.__hhd is None
+            or self._hhd_grid_shape != ds_shape
+            or self._hhd_ref_shape != ref_shape
+        ):
             spacings = (18 * k, 18 * k)
             self.__hhd = nHHD(
                 cuda=self.cuda,
@@ -558,6 +911,9 @@ class Sensor:
                 spacings=spacings,
                 poisson_backend=self.poisson_backend,
                 debug=self.debug,
+                # Rescale grid-summed force aggregates back onto the full-resolution
+                # flow grid so Sn/Stx/Sty/Stor stay comparable across hhd_downsample.
+                force_reference_grid=ref_shape,
                 masked_poisson_solver=self.masked_poisson_solver,
                 masked_poisson_max_boundary=self.masked_poisson_max_boundary,
                 masked_poisson_boundary_stride=self.masked_poisson_boundary_stride,
@@ -566,29 +922,46 @@ class Sensor:
                 masked_poisson_reg=self.masked_poisson_reg,
             )
             self._hhd_grid_shape = ds_shape
+            self._hhd_ref_shape = ref_shape
 
         _, forces = self.__hhd.get_force(flow_ds, valid_mask=mask_ds)
         fn, fx, fy, ftor = forces
         self._force_raw = (float(fn), float(fx), float(fy))
         self.ftor = float(ftor)
+        self._update_force_sample_rate()
         self._apply_force_filter()
 
         vnormal_ds = self.__hhd.get_normal()
         vshear_ds = self.__hhd.get_shear()
 
         if k > 1:
-            self.vnormal = cv2.resize(vnormal_ds, (orig_w, orig_h), interpolation=cv2.INTER_LINEAR)
-            self.vshear = cv2.resize(vshear_ds, (orig_w, orig_h), interpolation=cv2.INTER_LINEAR)
+            # Upsample into reusable buffers; the solver keeps owning its own
+            # arrays, so nothing downstream can alias solver state.
+            vn = self._hhd_vn_buf
+            vs = self._hhd_vs_buf
+            if vn is None or vn.shape != (orig_h, orig_w, 2) or vn.dtype != np.float32:
+                vn = np.empty((orig_h, orig_w, 2), dtype=np.float32)
+                vs = np.empty((orig_h, orig_w, 2), dtype=np.float32)
+                self._hhd_vn_buf = vn
+                self._hhd_vs_buf = vs
+            cv2.resize(vnormal_ds, (orig_w, orig_h), dst=vn, interpolation=cv2.INTER_LINEAR)
+            cv2.resize(vshear_ds, (orig_w, orig_h), dst=vs, interpolation=cv2.INTER_LINEAR)
+            self.vnormal = vn
+            self.vshear = vs
         else:
-            self.vnormal = vnormal_ds
-            self.vshear = vshear_ds
+            self.vnormal = vnormal_ds.copy()
+            self.vshear = vshear_ds.copy()
 
         if self.valid_mask is not None:
-            active = self.valid_mask.astype(bool)
-            self.vnormal = self.vnormal.copy()
-            self.vshear = self.vshear.copy()
-            self.vnormal[~active] = 0
-            self.vshear[~active] = 0
+            # In-place multiply by a 0/1 float mask instead of
+            # ``x.copy(); x[~active] = 0`` (copy + boolean gather/scatter).
+            m3 = self._hhd_mask_f32
+            if m3 is None or m3.shape != (orig_h, orig_w, 1) or m3.dtype != np.float32:
+                m3 = np.empty((orig_h, orig_w, 1), dtype=np.float32)
+                self._hhd_mask_f32 = m3
+            np.copyto(m3[:, :, 0], self.valid_mask, casting="unsafe")
+            np.multiply(self.vnormal, m3, out=self.vnormal)
+            np.multiply(self.vshear, m3, out=self.vshear)
 
         self.compute_deformation_valid = True
 
@@ -697,6 +1070,13 @@ class Sensor:
         """Reset optical flow tracker and force-filter state."""
         self.__tracker.reset()
         self._force_filter.reset()
+        if getattr(self, "_force_median", None) is not None:
+            self._force_median.reset()
+        self._ema_flow = None
+        # The unfiltered pair belongs to the frame it was computed for: a new
+        # session must not report the previous one's reading.
+        self._force_unfiltered = None
+        self._force_raw_unfiltered = None
         if self.img is not None:
             self.initial_img = self.img.copy()
 
@@ -727,7 +1107,14 @@ class Sensor:
         #     self.cap = None
         #     if self.verbose:
         #         print("Sensor disconnected.")
-        cv2.destroyAllWindows()
+        try:
+            cv2.destroyAllWindows()
+        except cv2.error:
+            # A headless OpenCV build (``opencv-python-headless``) has no highgui,
+            # so there is nothing to close. Failing here would leave the rest of
+            # the shutdown — and every caller that disconnects in a ``finally`` —
+            # reporting an error that says nothing about the sensor.
+            pass
 
     # =========================================================================
     # Public API - Configuration & Calibration
@@ -740,6 +1127,8 @@ class Sensor:
         lowpass_sample_rate_hz=None,
         lowpass_order=None,
         lowpass_enabled=None,
+        flow_ema_alpha=None,
+        force_median_window=None,
         hhd_downsample=None,
     ):
         """Update runtime-safe settings without reconnecting the camera.
@@ -751,10 +1140,18 @@ class Sensor:
             value enables filtering unless ``lowpass_enabled=False``.
         lowpass_sample_rate_hz : float, optional
             Assumed force sample rate for the Butterworth design (default 30).
+            Set this to the actual output rate of the deployment.
         lowpass_order : int, optional
             Butterworth order (default 2).
         lowpass_enabled : bool, optional
             Explicit on/off for the causal force filter.
+        flow_ema_alpha : float, optional
+            EMA coefficient applied to the optical-flow field before HHD.
+            ``1.0`` disables it; smaller values smooth more (0.5 is the default
+            and costs about one frame of delay at 30 fps).
+        force_median_window : int, optional
+            Causal sliding-median width applied to the raw force triple before
+            the low-pass. ``<= 1`` disables it; 3 is the default.
         hhd_downsample : int, optional
             Integer ``>= 1``. Rebuilds the HHD solver on the next frame.
         """
@@ -765,10 +1162,26 @@ class Sensor:
             if lowpass_enabled is None:
                 self._lowpass_enabled = self._lowpass_cutoff_hz > 0
         if lowpass_sample_rate_hz is not None:
-            rate = float(lowpass_sample_rate_hz)
-            if rate <= 0:
-                raise ValueError("lowpass_sample_rate_hz must be > 0")
-            self._lowpass_sample_rate_hz = rate
+            # Accept a positive number to pin the rate, or "auto"/<=0 to track
+            # the measured output rate (see _update_force_sample_rate).
+            auto = False
+            rate = 0.0
+            if isinstance(lowpass_sample_rate_hz, str):
+                auto = lowpass_sample_rate_hz.strip().lower() in ("auto", "", "measured")
+            else:
+                try:
+                    rate = float(lowpass_sample_rate_hz)
+                except (TypeError, ValueError):
+                    auto = True
+                else:
+                    auto = rate <= 0.0
+            self._lowpass_rate_auto = auto
+            if not auto:
+                self._lowpass_sample_rate_hz = rate
+            elif self._lowpass_sample_rate_hz <= 0:
+                self._lowpass_sample_rate_hz = self._config_fps
+            if getattr(self, "_force_rate", None) is not None:
+                self._force_rate.reset(self._config_fps)
             filter_changed = True
         if lowpass_order is not None:
             order = int(lowpass_order)
@@ -780,6 +1193,22 @@ class Sensor:
             self._lowpass_enabled = bool(lowpass_enabled)
             filter_changed = True
 
+        if flow_ema_alpha is not None:
+            alpha = float(flow_ema_alpha)
+            if not (0.0 < alpha <= 1.0):
+                raise ValueError("flow_ema_alpha must be in (0, 1]")
+            self._flow_ema_alpha = alpha
+            self._ema_flow = None
+
+        if force_median_window is not None:
+            try:
+                window = max(1, int(force_median_window))
+            except (TypeError, ValueError) as exc:
+                raise ValueError("force_median_window must be an integer >= 1") from exc
+            self._force_median_window = window
+            self._force_median.configure(window)
+            filter_changed = True
+
         if filter_changed:
             cutoff = self._lowpass_cutoff_hz if self._lowpass_enabled else 0.0
             self._force_filter.configure(
@@ -799,20 +1228,15 @@ class Sensor:
                 self._hhd_downsample = k
                 self.__hhd = None
                 self._hhd_grid_shape = None
+                self._hhd_ref_shape = None
                 self._update_hhd_mask_cache()
         return self
 
-    def _resolve_force_calibration_sensor_name(self) -> Optional[str]:
-        """Return sensors/<name> when force_calibration.json exists; else None.
-
-        Lookup order:
-          1. ``config_name`` stem / product alias (e.g. ``box``)
-          2. ``sensors/<name>/...`` path segment in ``config_name``
-        Missing JSON means ``FNORMAL/FSHEAR*`` stay raw (no hardcoded fallback).
-        """
+    def _bundle_name_candidates(self) -> list[str]:
+        """Product bundle names implied by ``config_name``."""
         text = str(self.config_name or "").strip().replace("\\", "/")
         if not text:
-            return None
+            return []
 
         candidates: list[str] = []
         stem = Path(text).stem if text else ""
@@ -828,33 +1252,218 @@ class Sensor:
                 candidates.append(name)
 
         seen: set[str] = set()
+        ordered: list[str] = []
         for candidate in candidates:
             alias = configs.CONFIG_ALIASES.get(candidate, candidate)
             for name in (alias, candidate):
                 if name in seen:
                     continue
                 seen.add(name)
-                if configs.load_force_calibration(name) is not None:
-                    return name
-        return None
+                ordered.append(name)
+        return ordered
+
+    def _force_calibration_note(self) -> str:
+        """Explain a bundle that resolved but carried no usable coefficients.
+
+        The old message ("raw (no force_calibration.json)") reads as "the file is
+        missing", which is exactly the wrong story when the lookup found a
+        bundle from another root and stopped there without ever asking whether
+        that root had coefficients.
+        """
+        attempts = self._force_cal_attempts or []
+        # ``found_root`` is keyed even when nothing was found (valued None), so
+        # test its value, not the key.
+        found = [entry for entry in attempts if entry.get("found_root")]
+        with_cal = [entry for entry in found if entry.get("force_calibration_json")]
+        chosen = (with_cal or found or [None])[0]
+        searched: list = []
+        for entry in attempts:
+            for root in entry.get("searched") or ():
+                if root not in searched:
+                    searched.append(root)
+        lines: list[str] = []
+        if chosen is None:
+            lines.append("Force calibration: raw (no sensor bundle resolved)")
+        else:
+            root = chosen["found_root"]
+            if chosen.get("force_calibration_json"):
+                lines.append(
+                    f"Force calibration: raw (a bundle was found at {root}, but its "
+                    "force_calibration.json could not be loaded)"
+                )
+            else:
+                lines.append(
+                    f"Force calibration: raw (bundle found at {root} has no "
+                    "force_calibration.json)"
+                )
+        if searched:
+            lines.append(
+                "  roots searched: " + "; ".join(str(root) for root in searched)
+            )
+        return "\n".join(lines)
+
+    def _init_force_calibration(self) -> None:
+        """Load force calibration from ``cal_path`` or the product bundle."""
+        self.calibration = None
+        self._force_cal_sensor_name = None
+        self._force_cal_attempts = None
+
+        if self.cal_path is not None and str(self.cal_path).strip():
+            # Explicit path: missing/invalid raises (no silent fallback).
+            self.calibration = cal_mod.load(self.cal_path, strict=True)
+            return
+
+        attempts: list[dict] = []
+        for name in self._bundle_name_candidates():
+            cal = cal_mod.load(sensor_type=name)
+            if cal is not None:
+                self.calibration = cal
+                self._force_cal_sensor_name = name
+                self._force_cal_attempts = None
+                return
+            try:
+                attempts.append(configs.describe_bundle_resolution(name))
+            except Exception:  # noqa: BLE001 - diagnostics must never break loading
+                continue
+        # Deliberately NOT setting ``_force_cal_sensor_name``: callers read a
+        # non-None value there as "this sensor is calibrated", and a bundle
+        # without coefficients is not that.
+        self._force_cal_attempts = attempts or None
+
+    @property
+    def force_calibrated(self) -> bool:
+        """True when at least one channel curve is loaded."""
+        return self.calibration is not None and bool(self.calibration.channels)
+
+    @property
+    def force_unit(self) -> str:
+        return "N" if self.force_calibrated else "raw"
+
+    def set_calibration(
+        self,
+        cal: "cal_mod.Calibration | str | Path | None",
+    ) -> None:
+        """Attach or replace the active force calibration (live swap after save)."""
+        if cal is None:
+            self.calibration = None
+            self._force_cal_sensor_name = None
+            self._force_cal_attempts = None
+            return
+        if isinstance(cal, cal_mod.Calibration):
+            self.calibration = cal
+            self._force_cal_attempts = None
+            return
+        self.calibration = cal_mod.load(cal, strict=True)
+        self._force_cal_attempts = None
 
     def _apply_force_filter(self):
-        raw = np.asarray(self._force_raw, dtype=np.float64)
+        pre_filter = np.asarray(self._force_raw, dtype=np.float64)
+        raw = pre_filter
+        # Median first: it deletes the heavy-tailed spikes that the flow chain
+        # produces, so the low-pass does not have to spread them over time.
+        median = getattr(self, "_force_median", None)
+        if median is not None and median.enabled:
+            raw = median.process(raw)
         if self._lowpass_enabled and self._lowpass_cutoff_hz > 0:
-            filtered = self._force_filter.process(raw)
-            fn, fx, fy = (float(v) for v in filtered)
-        else:
-            fn, fx, fy = float(raw[0]), float(raw[1]), float(raw[2])
+            raw = self._force_filter.process(raw)
+        # The chain's own output, before calibration: the "filtered raw counts".
+        # Without this the raw axis would have no filtered/unfiltered pair and
+        # ``force_triplets`` could only offer the device counts twice.
+        self._force_filtered_raw = (
+            float(raw[0]),
+            float(raw[1]),
+            float(raw[2]),
+        )
+        fn, fx, fy = self._force_filtered_raw
 
-        # Apply sensors/<name>/force_calibration.json when present; otherwise keep raw.
-        name = self._force_cal_sensor_name
-        if name is not None:
-            fn = float(calibrate_normal_force(fn, sensor_name=name))
-            fx, fy = calibrate_shear_components(fx, fy, sensor_name=name)
+        # Apply loaded force_calibration.json when present; otherwise keep raw.
+        if self.calibration is not None:
+            fn, fx, fy = self.calibration.convert(fn, fx, fy)
             fx, fy = float(fx), float(fy)
+            fn = float(fn)
 
         self.fnormal, self.fshearx, self.fsheary = fn, fx, fy
 
+        # The same reading with no readout filtering, so a caller can keep both
+        # (the app stores the filtered values as the record and the unfiltered
+        # ones beside them). Calibrated with the same coefficients, so the two
+        # only differ by the filter chain.
+        ufn, ufx, ufy = (float(pre_filter[0]), float(pre_filter[1]), float(pre_filter[2]))
+        if self.calibration is not None:
+            ufn, ufx, ufy = self.calibration.convert(ufn, ufx, ufy)
+            ufx, ufy, ufn = float(ufx), float(ufy), float(ufn)
+        self._force_raw_unfiltered = (
+            float(pre_filter[0]), float(pre_filter[1]), float(pre_filter[2])
+        )
+        self._force_unfiltered = (ufn, ufx, ufy)
+
+    # ------------------------------------------------------- filter contract
+    def filters_state(self) -> dict:
+        """What the filter chain is **actually** doing, for records and audits.
+
+        Read this instead of the config file: a config can be overridden at
+        runtime (``configure``) and a value that is present is never silently
+        replaced, so the effective state is the only honest answer. The two
+        groups are kept apart on purpose:
+
+        * ``measurement`` — stages upstream of the HHD/force computation
+          (``flow_ema_alpha``): turning them on changes *what is measured*, so
+          two recordings with different values are not comparable;
+        * ``readout`` — stages that only smooth the force triple on its way out
+          (median, low-pass): recorded, but they do not change the physical
+          claim.
+        """
+        median_applied = bool(getattr(self._force_median, "enabled", False))
+        tracker_cfg = self._config.get("tracker") or {}
+        return {
+            "preset": getattr(self, "_filter_preset", None),
+            "measurement": {
+                "flow_ema_alpha": float(self._flow_ema_alpha),
+                "flow_ema_applied": bool(self._flow_ema_alpha < 1.0),
+                "hhd_downsample": int(getattr(self, "hhd_downsample", 0) or 0),
+                "dis_mode": tracker_cfg.get("dis_mode"),
+            },
+            "readout": {
+                "force_median_window": int(self._force_median_window),
+                "force_median_applied": median_applied,
+                "force_lowpass_cutoff_hz": float(self._lowpass_cutoff_hz),
+                "force_lowpass_order": int(self._lowpass_order),
+                "force_lowpass_sample_rate_hz": float(self._lowpass_sample_rate_hz),
+                "force_lowpass_rate_auto": bool(self._lowpass_rate_auto),
+                "force_lowpass_applied": bool(self._lowpass_enabled),
+                "sample_rate_source": str(getattr(self, "_force_rate_source", "config")),
+            },
+            "any_stage_applied": bool(self._filters_enabled),
+            "unfiltered_available": True,
+            "source": "sensor.filters_state",
+        }
+
+    def force_triplets(self) -> dict:
+        """The filtered and unfiltered force triples of the current frame.
+
+        One call, so a sampling thread reads a single consistent frame: the
+        filtered pair is what ``read_info`` reports and what a recording stores
+        as its primary columns, the unfiltered pair is the same reading with the
+        readout stages bypassed.
+        """
+        raw_unfiltered = getattr(self, "_force_raw_unfiltered", None)
+        unfiltered = getattr(self, "_force_unfiltered", None)
+        filtered_raw = getattr(self, "_force_filtered_raw", None)
+        return {
+            "filtered": {
+                "raw": tuple(filtered_raw) if filtered_raw is not None else None,
+                "newton": (
+                    float(self.fnormal),
+                    float(self.fshearx),
+                    float(self.fsheary),
+                ),
+            },
+            "unfiltered": {
+                "raw": tuple(raw_unfiltered) if raw_unfiltered is not None else None,
+                "newton": tuple(unfiltered) if unfiltered is not None else None,
+            },
+        }
+
     # def export_config(self, path="./config/exported_config.json"):
     #     """Return current configuration dict."""
     #     configs.export_config(self._config, path)

src/orisys/signal_processing.py

@@ -3,14 +3,20 @@
 Batch ``lowpass_filter`` is the zero-phase Butterworth used by example charts.
 ``LowpassFilter`` is a causal, stateful filter for per-frame ``Sensor`` outputs.
 
-Force calibration resolution order (when register support arrives):
-  1. Sensor register / EEPROM calibration blob
-  2. ``sensors/<name>/force_calibration.json``
-  3. Hardcoded linear defaults below
+Force calibration is owned by ``orisys.calibration``. These helpers remain as
+convenience wrappers:
+
+  1. Bundle JSON via ``calibration.load(sensor_type=...)``
+  2. Hardcoded linear defaults for normal force when no file is present
+  3. Shear helpers return raw when no curve is available
+
+Prefer ``Sensor.calibration`` / ``read_info(FNORMAL, …)`` in new code.
 """
 
 from __future__ import annotations
 
+import collections
+import time
 from dataclasses import dataclass
 
 import numpy as np
@@ -26,20 +32,15 @@ DEFAULT_LOWPASS_ORDER = 2
 
 
 def _parse_calibration_point(point) -> tuple[float, float]:
-    if isinstance(point, dict):
-        raw = point.get("fnormal", point.get("raw", point.get("x")))
-        force_n = point.get("force_n", point.get("n", point.get("y")))
-        if raw is None or force_n is None:
-            raise ValueError(f"invalid calibration point: {point!r}")
-        return float(raw), float(force_n)
-    if isinstance(point, (list, tuple)) and len(point) >= 2:
-        return float(point[0]), float(point[1])
-    raise ValueError(f"invalid calibration point: {point!r}")
+    """Legacy helper; prefer ``orisys.calibration``."""
+    from .calibration import _parse_point
+
+    return _parse_point(point)
 
 
 @dataclass(frozen=True)
 class ForceChannelCalibration:
-    """One force channel: linear coeffs and/or piecewise-linear breakpoints."""
+    """Compatibility wrapper around ``calibration.ChannelCurve`` convert math."""
 
     method: str = "linear"
     slope: float | None = None
@@ -63,75 +64,40 @@ class ForceChannelCalibration:
         unit: str = "N",
         default_method: str = "piecewise_linear",
     ) -> ForceChannelCalibration | None:
-        if not isinstance(block, dict):
-            return None
+        from .calibration import _channel_from_block
 
-        method = str(block.get("method", block.get("model", default_method))).lower()
-        if method in ("linear", "affine"):
-            slope = block.get("slope")
-            offset = block.get("offset")
-            if slope is None or offset is None:
-                return None
-            return cls.linear(float(slope), float(offset), unit=str(block.get("unit", unit)))
-
-        if method != "piecewise_linear":
+        curve = _channel_from_block(
+            "fn", block, unit=unit, default_method=default_method
+        )
+        if curve is None:
             return None
-
-        raw_points = block.get("points", [])
-        if not isinstance(raw_points, (list, tuple)) or len(raw_points) < 2:
-            return None
-        try:
-            points = tuple(sorted(_parse_calibration_point(p) for p in raw_points))
-        except (TypeError, ValueError):
-            return None
-        if len(points) < 2:
-            return None
-
         return cls(
-            method="piecewise_linear",
-            points=points,
-            extrapolate=bool(block.get("extrapolate", True)),
-            clamp_output_min=block.get("clamp_output_min", 0.0),
-            input_mode=str(block.get("input", "magnitude")).lower(),
-            signed=bool(block.get("signed", False)),
-            unit=str(block.get("unit", unit)),
+            method=curve.method,
+            slope=curve.slope,
+            offset=curve.offset,
+            points=curve.points,
+            extrapolate=curve.extrapolate,
+            clamp_output_min=curve.clamp_output_min,
+            input_mode=curve.input_mode,
+            signed=curve.signed,
+            unit=curve.unit,
         )
 
     def convert(self, raw: float) -> float:
-        raw = float(raw)
-        if self.method == "linear":
-            slope = NORMAL_FORCE_CAL_SLOPE if self.slope is None else float(self.slope)
-            offset = NORMAL_FORCE_CAL_OFFSET if self.offset is None else float(self.offset)
-            return slope * raw + offset
+        from .calibration import ChannelCurve
 
-        points = self.points
-        if len(points) < 2:
-            return raw
-
-        if raw <= points[0][0]:
-            segment = (points[0], points[1])
-            if not self.extrapolate:
-                return self._clamp(points[0][1])
-        elif raw >= points[-1][0]:
-            segment = (points[-2], points[-1])
-            if not self.extrapolate:
-                return self._clamp(points[-1][1])
-        else:
-            segment = None
-            for left, right in zip(points, points[1:]):
-                if left[0] <= raw <= right[0]:
-                    segment = (left, right)
-                    break
-            if segment is None:
-                return self._clamp(points[-1][1])
-
-        (raw0, n0), (raw1, n1) = segment
-        if raw1 == raw0:
-            value = n0
-        else:
-            ratio = (raw - raw0) / (raw1 - raw0)
-            value = n0 + ratio * (n1 - n0)
-        return self._clamp(value)
+        return ChannelCurve(
+            id="fn",
+            method=self.method,
+            points=self.points,
+            slope=self.slope if self.slope is not None else NORMAL_FORCE_CAL_SLOPE,
+            offset=self.offset if self.offset is not None else NORMAL_FORCE_CAL_OFFSET,
+            signed=self.signed,
+            extrapolate=self.extrapolate,
+            clamp_output_min=self.clamp_output_min,
+            input_mode=self.input_mode,
+            unit=self.unit,
+        ).convert(raw)
 
     def convert_component(self, raw: float) -> float:
         if not self.signed:
@@ -140,11 +106,6 @@ class ForceChannelCalibration:
         sign = -1.0 if raw < 0.0 else 1.0
         return sign * self.convert(abs(raw))
 
-    def _clamp(self, value: float) -> float:
-        if self.clamp_output_min is not None:
-            return max(float(self.clamp_output_min), float(value))
-        return float(value)
-
 
 _DEFAULT_NORMAL = ForceChannelCalibration.linear(
     NORMAL_FORCE_CAL_SLOPE,
@@ -152,57 +113,41 @@ _DEFAULT_NORMAL = ForceChannelCalibration.linear(
 )
 
 
-def _load_force_calibration_data(sensor_name: str | None) -> dict | None:
+def _load_calibration(sensor_name: str | None):
     if not sensor_name:
         return None
     try:
-        from .configs import load_force_calibration
+        from .calibration import load
 
-        data = load_force_calibration(sensor_name)
+        return load(sensor_type=sensor_name)
     except Exception:
         return None
-    return data if isinstance(data, dict) else None
-
-
-def _channel_from_data(data: dict | None, channel: str) -> ForceChannelCalibration | None:
-    if not isinstance(data, dict):
-        return None
-
-    unit = str(data.get("unit", "N"))
-    channels = data.get("channels")
-    if isinstance(channels, dict):
-        block = channels.get(channel)
-        cal = ForceChannelCalibration.from_channel_dict(block, unit=unit)
-        if cal is not None:
-            return cal
-
-    # Legacy single-channel file: {"normal_force": {"model": "linear", ...}}
-    if channel == "normal":
-        block = data.get("normal_force", data)
-        cal = ForceChannelCalibration.from_channel_dict(
-            block, unit=unit, default_method="linear"
-        )
-        if cal is not None:
-            return cal
-        if isinstance(block, dict):
-            slope = block.get("slope")
-            offset = block.get("offset")
-            if slope is not None and offset is not None:
-                return ForceChannelCalibration.linear(
-                    float(slope),
-                    float(offset),
-                    unit=str(block.get("unit", unit)),
-                )
-    return None
 
 
 def _normal_calibration(sensor_name: str | None = None) -> ForceChannelCalibration:
-    cal = _channel_from_data(_load_force_calibration_data(sensor_name), "normal")
-    return cal if cal is not None else _DEFAULT_NORMAL
+    cal = _load_calibration(sensor_name)
+    if cal is not None:
+        curve = cal.get("fn")
+        if curve is not None:
+            return ForceChannelCalibration(
+                method=curve.method,
+                slope=curve.slope,
+                offset=curve.offset,
+                points=curve.points,
+                extrapolate=curve.extrapolate,
+                clamp_output_min=curve.clamp_output_min,
+                input_mode=curve.input_mode,
+                signed=curve.signed,
+                unit=curve.unit,
+            )
+    return _DEFAULT_NORMAL
 
 
-def _shear_calibration(sensor_name: str | None = None) -> ForceChannelCalibration | None:
-    return _channel_from_data(_load_force_calibration_data(sensor_name), "shear")
+def _shear_curve(sensor_name: str | None, channel: str):
+    cal = _load_calibration(sensor_name)
+    if cal is None:
+        return None
+    return cal.get(channel)
 
 
 def _load_normal_force_coeffs(sensor_name: str | None = None) -> tuple[float, float]:
@@ -225,12 +170,20 @@ def calibrate_normal_force(raw_value: float, *, sensor_name: str | None = None)
 def calibrate_shear_force(raw_value: float, *, sensor_name: str | None = None) -> float:
     """Convert a raw shear magnitude to Newtons using the shear channel curve.
 
-    Returns ``float(raw_value)`` unchanged when no shear calibration is available.
+    Prefers the average of FX/FY magnitude maps when present.
+    Returns ``float(raw_value)`` when unavailable.
     """
-    cal = _shear_calibration(sensor_name)
-    if cal is None:
-        return float(raw_value)
-    return cal.convert(raw_value)
+    cal_x = _shear_curve(sensor_name, "fx")
+    cal_y = _shear_curve(sensor_name, "fy")
+    if cal_x is not None and cal_y is not None:
+        return 0.5 * (
+            cal_x.convert(abs(float(raw_value))) + cal_y.convert(abs(float(raw_value)))
+        )
+    if cal_x is not None:
+        return cal_x.convert(abs(float(raw_value)))
+    if cal_y is not None:
+        return cal_y.convert(abs(float(raw_value)))
+    return float(raw_value)
 
 
 def calibrate_shear_components(
@@ -239,27 +192,11 @@ def calibrate_shear_components(
     *,
     sensor_name: str | None = None,
 ) -> tuple[float, float]:
-    """Convert raw shear components to Newtons.
-
-    When the shear channel uses ``input: components`` and ``signed: true``, each
-    axis is calibrated on absolute magnitude then re-signed. Otherwise the
-    magnitude is calibrated and components are scaled proportionally.
-    """
-    sx = float(shear_x)
-    sy = float(shear_y)
-    cal = _shear_calibration(sensor_name)
+    """Convert raw shear components to Newtons via ``calibration.load`` curves."""
+    cal = _load_calibration(sensor_name)
     if cal is None:
-        return sx, sy
-
-    if cal.input_mode == "components":
-        return cal.convert_component(sx), cal.convert_component(sy)
-
-    magnitude = (sx * sx + sy * sy) ** 0.5
-    if magnitude <= 0.0:
-        return 0.0, 0.0
-    calibrated = cal.convert(magnitude)
-    scale = calibrated / magnitude
-    return sx * scale, sy * scale
+        return float(shear_x), float(shear_y)
+    return cal.convert(0.0, float(shear_x), float(shear_y))[1:]
 
 
 def _nyquist_hz(sample_rate_hz: float) -> float:
@@ -377,3 +314,115 @@ class LowpassFilter:
             self.reset(x)
         y, self._zi = sosfilt(self._sos, x[None, :], zi=self._zi, axis=0)
         return np.asarray(y[0], dtype=np.float64)
+
+
+class CausalMedianFilter:
+    """Causal sliding-median over the last ``window`` samples, one sample at a time.
+
+    The optical-flow force chain produces heavy-tailed jitter (rare multi-sigma
+    spikes). A linear low-pass spreads such a spike over several frames instead
+    of deleting it, whereas a median removes it outright - measured on idle
+    data, a 5-sample median cut the jitter 4x better than a moving average of
+    the same width.
+
+    ``window <= 1`` disables the filter (pass-through). Until ``window`` samples
+    have arrived the median of the available samples is returned, so the output
+    is well defined from the first frame.
+    """
+
+    def __init__(self, window: int = 1, n_channels: int = 3):
+        self.n_channels = int(n_channels)
+        self.window = 1
+        self._buf = None
+        self.configure(window)
+
+    @property
+    def enabled(self) -> bool:
+        return self.window > 1
+
+    def configure(self, window: int | None = None) -> None:
+        if window is not None:
+            try:
+                self.window = max(1, int(window))
+            except (TypeError, ValueError):
+                self.window = 1
+        self._buf = None
+
+    def reset(self, x0=None) -> None:
+        """Drop the window history (e.g. after a tracker reset)."""
+        self._buf = None
+
+    def process(self, values) -> np.ndarray:
+        """Filter one multi-channel sample. Returns float64 array of shape (n_channels,)."""
+        x = np.asarray(values, dtype=np.float64).reshape(-1)
+        if x.size != self.n_channels:
+            raise ValueError(f"expected {self.n_channels} channels, got {x.size}")
+        if not self.enabled:
+            return x.copy()
+        if self._buf is None or self._buf.shape[1] != x.size:
+            self._buf = x[None, :].copy()
+            return x.copy()
+        self._buf = np.vstack((self._buf, x[None, :]))[-self.window:]
+        return np.median(self._buf, axis=0)
+
+
+class SampleRateEstimator:
+    """Robust online estimate of the rate at which :meth:`tick` is called.
+
+    Uses the *median* of the most recent inter-call intervals, so one stall or
+    scheduling hiccup does not poison the estimate. :attr:`rate_hz` returns the
+    seed value until ``min_samples`` intervals have been observed.
+
+    This exists because a fixed floor filter designed for 30 Hz behaves
+    differently at 60 Hz: the cutoff stays put in Hz but the per-frame
+    smoothing halves. Measuring the achieved rate keeps the filter identical in
+    the time domain whatever the deployment runs at.
+    """
+
+    def __init__(
+        self,
+        initial_hz: float = 30.0,
+        window: int = 45,
+        min_samples: int = 8,
+        max_interval_s: float = 1.0,
+    ):
+        self.initial_hz = float(initial_hz) if initial_hz else 30.0
+        self.window = max(3, int(window))
+        self.min_samples = max(2, int(min_samples))
+        self.max_interval_s = float(max_interval_s)
+        self.reset()
+
+    def reset(self, initial_hz: float | None = None) -> None:
+        if initial_hz is not None:
+            self.initial_hz = float(initial_hz) if initial_hz else 30.0
+        self._dts: collections.deque = collections.deque(maxlen=self.window)
+        self._last = None
+        self._rate = self.initial_hz
+        self._measured = False
+
+    @property
+    def rate_hz(self) -> float:
+        return self._rate
+
+    @property
+    def measured(self) -> bool:
+        """True once the estimate comes from real intervals."""
+        return self._measured
+
+    def tick(self, now: float | None = None) -> float:
+        """Register one sample and return the current rate estimate."""
+        now = time.perf_counter() if now is None else float(now)
+        last, self._last = self._last, now
+        if last is None:
+            return self._rate
+        dt = now - last
+        if not (1e-5 < dt <= self.max_interval_s):
+            # Stalls, pauses and the first frame carry no rate information.
+            return self._rate
+        self._dts.append(dt)
+        if len(self._dts) >= self.min_samples:
+            dt_med = float(np.median(self._dts))
+            if dt_med > 0.0:
+                self._rate = 1.0 / dt_med
+                self._measured = True
+        return self._rate

src/orisys/tracker.py

@@ -94,13 +94,30 @@ class Tracker:
         return mask.astype(bool)
 
     def apply_valid_mask(self, flow, valid_mask, erode_iters=1):
-        """Zero flow outside the valid UV domain."""
+        """Zero flow outside the valid UV domain (in place when safe).
+
+        Multiplying by a 0/1 mask is a single streaming pass, whereas
+        ``flow.copy()`` followed by a boolean fancy-index assignment costs a
+        full copy plus a gather/scatter over the masked-out pixels.
+
+        Note: a masked-out *negative* component becomes ``-0.0`` rather than
+        ``+0.0``. The two compare, sum and magnitude identically; only the raw
+        bit pattern of those zeros differs from the previous implementation.
+        """
         if flow is None or valid_mask is None:
             return flow
         mask = self._prepare_valid_mask(valid_mask, flow.shape[:2], erode_iters=erode_iters)
-        flow_out = flow.copy()
-        flow_out[~mask] = 0
-        return flow_out
+        if not getattr(self, "_Tracker__adaptive", False):
+            # The non-adaptive path hands back the DIS state buffer, which feeds
+            # the next frame as its initial guess; never mutate it.
+            flow_out = flow.copy()
+            flow_out[~mask] = 0
+            return flow_out
+        if not flow.flags.writeable:
+            flow = flow.copy()
+        mask_f = mask.astype(np.float32, copy=False)[:, :, None]
+        np.multiply(flow, mask_f, out=flow)
+        return flow
 
     def track(self, frame, valid_mask=None):
         """Main tracking function that dispatches to CUDA or CPU implementation"""

src/orisys/util.py

@@ -75,7 +75,10 @@ def draw_arrows(
     )
     if mask is not None:
         valid &= mask[rr, cc]
-        valid &= mask[end_y, end_x]
+        # Arrow tips may fall outside the frame (the length cap is applied
+        # before the bounds check above), so clamp before indexing: those points
+        # are already False in ``valid``, and in-bounds indices are unchanged.
+        valid &= mask[np.clip(end_y, 0, h - 1), np.clip(end_x, 0, w - 1)]
 
     mag_range = mag.max() - mag.min()
     norm_mag = (

tests/conftest.py

@@ -0,0 +1,163 @@
+"""Shared pytest fixtures for the orisys test suite.
+
+This module was accidentally deleted in commit edc6e42 while four test modules
+(``test_backends.py``, ``test_smoke_api.py``, ``test_errors_and_cleanup.py``,
+``test_longrun_stability.py``) still depend on its fixtures, which made the
+whole suite unrunnable. It is restored here with two fixes:
+
+* the default test video now points at clips that are actually tracked in the
+  repository (``data/sample/``), instead of the never-committed
+  ``tests/idle_1min.mp4``;
+* the stale ``"prototype"`` default config in :func:`make_sensor` is gone, so
+  callers cannot silently bypass the ``stitcher.box_size`` validation.
+
+``tests/test_harness_guards.py`` guards against a repeat deletion.
+"""
+
+import os
+import sys
+from pathlib import Path
+
+import pytest
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+SRC_ROOT = REPO_ROOT / "src"
+BUILD_ROOT = REPO_ROOT / "build"
+EXAMPLES_ROOT = REPO_ROOT / "examples"
+
+# Establish import precedence once, here, before any test module is imported. The
+# test modules insert the same directories, but all of those inserts are guarded
+# by `if path not in sys.path`, so once the paths are present the guards turn
+# them into no-ops and this order sticks.
+#
+# Order matters and is not incidental:
+#   * examples/ must win over build/ because `build/gui` is also a package named
+#     `gui`; with build/ first, `import gui.viewer2d` silently resolves to the
+#     build tooling and fails.
+#   * build/ must precede site-packages so `wheel`, `common` and `release` mean
+#     the repository's build tooling, not the unrelated PyPI `wheel` package.
+#   * src/ provides the checkout's `orisys`.
+# Insert in reverse priority (each insert goes to the front).
+for _path in (SRC_ROOT, BUILD_ROOT, EXAMPLES_ROOT):
+    if str(_path) not in sys.path:
+        sys.path.insert(0, str(_path))
+
+from orisys import Sensor
+from orisys import configs as orisys_configs
+from orisys.backend_availability import check_cupy_available, check_opencl_available
+
+# Video clips that are tracked in git, in preference order. The 720p clip is
+# deliberately not a fallback: tests should run the sanctioned sample or skip,
+# never silently verify against a different resolution.
+DEFAULT_VIDEO_CANDIDATES = (
+    Path("tests") / "idle_1min.mp4",
+    Path("data") / "sample" / "s1.mp4",
+)
+
+
+def _resolve_test_video() -> Path:
+    env_video = os.getenv("ORISYS_TEST_VIDEO")
+    if env_video:
+        raw = Path(env_video)
+        candidates = [
+            raw,                # as provided (absolute or cwd-relative)
+            REPO_ROOT / raw,    # repo-relative
+        ]
+        # Common typo fallback: "test/..." -> "tests/..."
+        if env_video.startswith("test/") or env_video.startswith("test\\"):
+            fixed = Path("tests", *Path(env_video).parts[1:])
+            candidates.append(REPO_ROOT / fixed)
+
+        for candidate in candidates:
+            if candidate.exists():
+                return candidate
+        return raw
+
+    for relative in DEFAULT_VIDEO_CANDIDATES:
+        candidate = REPO_ROOT / relative
+        if candidate.is_file():
+            return candidate
+
+    # Keep the reported path informative when nothing is available; the
+    # ``test_video_path`` fixture turns this into a skip.
+    return REPO_ROOT / DEFAULT_VIDEO_CANDIDATES[-1]
+
+
+@pytest.fixture(scope="session")
+def test_video_path() -> Path:
+    path = _resolve_test_video()
+    if not path.exists():
+        pytest.skip(
+            "Test video not found. Set ORISYS_TEST_VIDEO to a valid video path."
+        )
+    return path
+
+
+@pytest.fixture(scope="session")
+def test_config_name() -> str:
+    requested = os.getenv("ORISYS_TEST_CONFIG")
+
+    def _is_usable_config(name: str) -> bool:
+        cfg = orisys_configs.load_config(name)
+        return "box_size" in cfg.get("stitcher", {})
+
+    if requested:
+        if not _is_usable_config(requested):
+            raise RuntimeError(
+                f"ORISYS_TEST_CONFIG='{requested}' is missing required key "
+                "'stitcher.box_size'. Use a config like 'ddjx01' or provide a full path."
+            )
+        return requested
+
+    # Auto-pick a stable config for tests (avoid prototype variants missing keys).
+    for name in orisys_configs.list_config():
+        try:
+            if _is_usable_config(name):
+                return name
+        except Exception:
+            continue
+
+    raise RuntimeError(
+        "No usable config found for tests (missing 'stitcher.box_size'). "
+        "Set ORISYS_TEST_CONFIG to a valid config JSON/path."
+    )
+
+
+@pytest.fixture(scope="session")
+def available_backends() -> list[str]:
+    backends = ["cpu"]
+    if check_cupy_available():
+        backends.append("cupy")
+    if check_opencl_available():
+        backends.append("opencl")
+    return backends
+
+
+def make_sensor(
+    video_path: Path,
+    config_name: str,
+    backend: str = "cpu",
+    verbose: bool = False,
+) -> Sensor:
+    use_cuda = backend in ("cupy", "opencl")
+    return Sensor(
+        vid_src=str(video_path),
+        cuda=use_cuda,
+        isstitch=True,
+        verbose=verbose,
+        config_name=config_name,
+        backend=backend,
+    )
+
+
+@pytest.fixture
+def sensor_factory(test_video_path, test_config_name):
+    def _factory(backend: str = "cpu", verbose: bool = False):
+        return make_sensor(
+            test_video_path,
+            config_name=test_config_name,
+            backend=backend,
+            verbose=verbose,
+        )
+
+    return _factory

tests/dd06.py

@@ -8,7 +8,6 @@ Flow:
 4. Feed the rectified frame into Sensor.get_img(..., already_processed=True)
 5. Compute deformation/contact and visualize
 
-SDK version: 0.5.0
 """
 from __future__ import annotations
 

tests/test_calibration.py

@@ -0,0 +1,506 @@
+"""Tests for orisys.calibration load/parse/write and Sensor apply."""
+
+from __future__ import annotations
+
+import json
+import shutil
+from pathlib import Path
+
+import pytest
+
+from orisys import Sensor
+from orisys.calibration import (
+    CalSample,
+    CalibrationError,
+    build,
+    check,
+    filter_mismatches,
+    filters_fingerprint,
+    load,
+    parse,
+    pipeline_from_sensor_json,
+    write,
+)
+
+
+def _box_cal_path() -> Path:
+    # Editable checkout: repo_root/sensors/box/force_calibration.json
+    here = Path(__file__).resolve()
+    candidate = here.parents[1] / "sensors" / "box" / "force_calibration.json"
+    assert candidate.is_file(), f"missing shipped cal: {candidate}"
+    return candidate
+
+
+def test_parse_box_v1_piecewise():
+    cal = load(sensor_type="box")
+    assert cal is not None
+    assert cal.get("FN") is not None
+    assert cal.get("FN").convert(10000.0) == pytest.approx(0.377)
+    assert cal.get("FX").convert_component(36000.0) == pytest.approx(1.19)
+    assert cal.get("FX").convert_component(-36000.0) == pytest.approx(-1.19)
+    assert cal.get("FY").convert_component(36000.0) == pytest.approx(1.19)
+
+
+def test_parse_v2_tmp_file(tmp_path: Path):
+    doc = {
+        "schema_version": 2,
+        "unit": "N",
+        "channels": {
+            "normal": {
+                "method": "piecewise_linear",
+                "points": [[0.0, 0.0], [1000.0, 1.0]],
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+            },
+            "shear_x": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "points": [[0.0, 0.0], [500.0, 2.0]],
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+            },
+            "shear_y": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "points": [[0.0, 0.0], [500.0, 3.0]],
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+            },
+        },
+        "meta": {"sensor_type": "box", "sn": "TEST-001"},
+    }
+    path = tmp_path / "force_calibration_v2.json"
+    path.write_text(json.dumps(doc), encoding="utf-8")
+    cal = load(path)
+    assert cal is not None
+    assert check(cal).ok
+    assert cal.convert(1000.0, 500.0, -500.0) == pytest.approx((1.0, 2.0, -3.0))
+
+
+def test_build_write_load_roundtrip(tmp_path: Path):
+    samples = {
+        "fn": [
+            CalSample(weight_n=0.0, raw_mean=0.0, n=10),
+            CalSample(weight_n=1.0, raw_mean=1000.0, n=10),
+        ],
+        "fx": [
+            CalSample(weight_n=0.0, raw_mean=0.0, n=10),
+            CalSample(weight_n=2.0, raw_mean=500.0, n=10),
+        ],
+        "fy": [
+            CalSample(weight_n=0.0, raw_mean=0.0, n=10),
+            CalSample(weight_n=3.0, raw_mean=500.0, n=10),
+        ],
+    }
+    cal = build(
+        samples,
+        identity={"sensor_type": "box", "sn": "RT-1"},
+        pipeline={"dis_mode": 1},
+        origin="user",
+    )
+    path = tmp_path / "out.json"
+    write(cal, path, overwrite=True)
+    loaded = load(path)
+    assert loaded is not None
+    assert loaded.convert(1000.0, 500.0, -500.0) == pytest.approx((1.0, 2.0, -3.0))
+
+
+def test_check_rejects_bad_schema_and_short_points():
+    bad_schema = {"schema_version": 99, "channels": {"normal": {"method": "linear", "slope": 1, "offset": 0}}}
+    result = check(bad_schema)
+    assert not result.ok
+    assert any("schema_version" in e for e in result.errors)
+
+    short = {
+        "schema_version": 2,
+        "channels": {
+            "normal": {
+                "method": "piecewise_linear",
+                "points": [[0.0, 0.0]],
+            }
+        },
+    }
+    result2 = check(short)
+    assert not result2.ok
+
+
+def test_sensor_cal_path_v2_applies_to_read_info(tmp_path: Path):
+    doc = {
+        "schema_version": 2,
+        "unit": "N",
+        "channels": {
+            "normal": {
+                "method": "piecewise_linear",
+                "points": [[0.0, 0.0], [100.0, 5.0]],
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+            },
+            "shear_x": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "points": [[0.0, 0.0], [100.0, 7.0]],
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+            },
+            "shear_y": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "points": [[0.0, 0.0], [100.0, 9.0]],
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+            },
+        },
+    }
+    path = tmp_path / "v2.json"
+    path.write_text(json.dumps(doc), encoding="utf-8")
+    sensor = Sensor(
+        "external",
+        config_name="box",
+        cal_path=str(path),
+        verbose=False,
+        backend="cpu",
+    )
+    try:
+        assert sensor.force_calibrated
+        assert sensor.force_unit == "N"
+        sensor._force_raw = (100.0, 100.0, -100.0)
+        sensor._apply_force_filter()
+        fn, fx, fy = sensor.read_info(
+            sensor.info.FNORMAL,
+            sensor.info.FSHEARX,
+            sensor.info.FSHEARY,
+        )
+        fn_raw, fx_raw, fy_raw = sensor.read_info(
+            sensor.info.FNORMAL_RAW,
+            sensor.info.FSHEARX_RAW,
+            sensor.info.FSHEARY_RAW,
+        )
+        assert (fn_raw, fx_raw, fy_raw) == pytest.approx((100.0, 100.0, -100.0))
+        assert (fn, fx, fy) == pytest.approx((5.0, 7.0, -9.0))
+    finally:
+        sensor.disconnect()
+
+
+def test_set_calibration_swaps_curve(tmp_path: Path):
+    path_a = tmp_path / "a.json"
+    path_b = tmp_path / "b.json"
+    path_a.write_text(
+        json.dumps(
+            {
+                "schema_version": 2,
+                "channels": {
+                    "normal": {
+                        "method": "piecewise_linear",
+                        "points": [[0.0, 0.0], [10.0, 1.0]],
+                    }
+                },
+            }
+        ),
+        encoding="utf-8",
+    )
+    path_b.write_text(
+        json.dumps(
+            {
+                "schema_version": 2,
+                "channels": {
+                    "normal": {
+                        "method": "piecewise_linear",
+                        "points": [[0.0, 0.0], [10.0, 2.0]],
+                    }
+                },
+            }
+        ),
+        encoding="utf-8",
+    )
+    sensor = Sensor(
+        "external",
+        config_name="box",
+        cal_path=str(path_a),
+        verbose=False,
+        backend="cpu",
+    )
+    try:
+        sensor._force_raw = (10.0, 0.0, 0.0)
+        sensor._apply_force_filter()
+        assert sensor.fnormal == pytest.approx(1.0)
+        sensor.set_calibration(path_b)
+        sensor._apply_force_filter()
+        assert sensor.fnormal == pytest.approx(2.0)
+    finally:
+        sensor.disconnect()
+
+
+def test_missing_cal_path_raises():
+    with pytest.raises(CalibrationError):
+        Sensor(
+            "external",
+            config_name="box",
+            cal_path="D:/no/such/force_calibration.json",
+            verbose=False,
+            backend="cpu",
+        )
+
+
+def test_parse_shipped_box_file_directly():
+    cal = parse(json.loads(_box_cal_path().read_text(encoding="utf-8")), source_path=_box_cal_path())
+    assert cal.schema_version == 2
+    assert cal.convert(10000.0, 36000.0, -36000.0) == pytest.approx((0.377, 1.19, -1.19))
+    # The shipped file names both shear axes outright: no shared block, no clone.
+    assert set(cal.channels) == {"fn", "fx", "fy"}
+    fx, fy = cal.get("FX"), cal.get("FY")
+    assert fx is not None and fy is not None and fx is not fy
+    for curve in (fx, fy):
+        assert curve.signed is True
+        assert curve.extrapolate is True
+        assert curve.clamp_output_min == pytest.approx(0.0)
+        assert len(curve.points) == 3
+    assert fx.raw_key == "fshearx"
+    assert fy.raw_key == "fsheary"
+
+
+def test_the_shipped_box_shear_axes_can_drift_apart(tmp_path: Path):
+    """The whole point of the split: FX and FY are independent curves.
+
+    A document with the same shape as the shipped one but different per-axis
+    points must apply each axis's own curve. Re-collapsing the axes into one
+    shared ``shear`` block makes this fail.
+    """
+    doc = {
+        "schema_version": 2,
+        "unit": "N",
+        "channels": {
+            "normal": {
+                "method": "piecewise_linear",
+                "points": [[0.0, 0.0], [1000.0, 1.0]],
+            },
+            "shear_x": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "input": "components",
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+                "points": [[0.0, 0.0], [500.0, 2.0]],
+            },
+            "shear_y": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "input": "components",
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+                "points": [[0.0, 0.0], [500.0, 3.0]],
+            },
+        },
+    }
+    path = tmp_path / "split.json"
+    path.write_text(json.dumps(doc), encoding="utf-8")
+    cal = load(path)
+    assert cal is not None
+    assert cal.convert(0.0, 500.0, 500.0)[1:] == pytest.approx((2.0, 3.0))
+    assert cal.convert(0.0, -500.0, 500.0)[1:] == pytest.approx((-2.0, 3.0))
+
+
+def test_out_of_range_readings_extend_instead_of_being_dropped():
+    """Outside the calibrated range the nearest segment is extended.
+
+    This pins the "extend, never ignore, never reuse a previous coefficient"
+    behaviour of the shipped box file, so flipping ``extrapolate`` has to be a
+    deliberate edit that fails this test first.
+    """
+    cal = load(sensor_type="box")
+    assert cal is not None
+    fx, fy, fn = cal.get("FX"), cal.get("FY"), cal.get("FN")
+    assert fx is not None and fy is not None and fn is not None
+    # 136000 = 2 x the top raw break (68000 -> 2.06): the last segment's slope is
+    # applied again, so the value keeps growing past the calibrated range.
+    (r0, n0), (r1, n1) = fx.points[-2], fx.points[-1]
+    extended = n1 + (n1 - n0) / (r1 - r0) * (136000.0 - r1)
+    assert extended > n1
+    assert fx.convert_component(136000.0) == pytest.approx(extended)
+    assert fy.convert_component(136000.0) == pytest.approx(extended)
+    # A negative beyond the range keeps its sign.
+    assert fx.convert_component(-136000.0) == pytest.approx(-extended)
+    # Below the first point the normal channel floors at clamp_output_min.
+    assert fn.convert(500.0) == pytest.approx(0.0)
+
+
+# ------------------------------------------------------- filter fingerprint
+ALL_OFF_FILTERS = {
+    "flow_ema_alpha": 1.0,
+    "force_median_window": 1,
+    "force_lowpass_cutoff_hz": 0.0,
+    "force_lowpass_order": 2,
+    "force_lowpass_sample_rate_hz": "auto",
+}
+
+
+def _sensor_with_filters(tmp_path: Path, filters: dict) -> Sensor:
+    """An external-frame Sensor whose bundle carries ``filters``."""
+    bundle = _box_cal_path().parent
+    copy = tmp_path / "box"
+    shutil.copytree(bundle, copy)
+    path = copy / "sensor.json"
+    cfg = json.loads(path.read_text(encoding="utf-8"))
+    cfg["filters"] = filters
+    path.write_text(json.dumps(cfg, indent=2), encoding="utf-8")
+    return Sensor(
+        "external",
+        config_name=str(path),
+        cal_path=str(copy / "force_calibration.json"),
+        verbose=False,
+        backend="cpu",
+    )
+
+
+def test_the_fingerprint_keeps_measurement_and_readout_apart():
+    """A change to one group must not be confused with a change to the other."""
+    fp = filters_fingerprint(ALL_OFF_FILTERS)
+    assert fp["measurement"] == {"flow_ema_alpha": 1.0}
+    assert fp["readout"] == {
+        "force_median_window": 1,
+        "force_lowpass_cutoff_hz": 0.0,
+        "force_lowpass_order": 2,
+        "force_lowpass_rate_auto": True,
+    }
+
+
+def test_a_preset_expands_without_inventing_anything():
+    fp = filters_fingerprint({"preset": "low_noise"})
+    assert fp["preset"] == "low_noise"
+    assert fp["measurement"] == {"flow_ema_alpha": 0.3}
+    assert fp["readout"] == {"force_median_window": 3, "force_lowpass_cutoff_hz": 10.0}
+    # An explicit key wins over the preset.
+    explicit = filters_fingerprint({"preset": "low_noise", "force_lowpass_cutoff_hz": 0.0})
+    assert explicit["readout"]["force_lowpass_cutoff_hz"] == 0.0
+    # Keys no source states are absent, never filled in from a default.
+    assert filters_fingerprint({}) == {}
+    assert filters_fingerprint(None) == {}
+    assert filters_fingerprint({"flow_ema_alpha": "not-a-number"}) == {}
+
+
+def test_the_deprecated_master_switch_still_means_all_off():
+    fp = filters_fingerprint(dict(ALL_OFF_FILTERS, enabled=False, flow_ema_alpha=0.3))
+    assert fp["measurement"] == {"flow_ema_alpha": 1.0}
+    assert fp["readout"]["force_median_window"] == 1
+    assert fp["readout"]["force_lowpass_cutoff_hz"] == 0.0
+
+
+def test_a_measurement_change_warns_and_a_readout_change_only_notes():
+    recorded = filters_fingerprint({"preset": "balanced"})
+    expected = filters_fingerprint({"preset": "low_noise"})
+    warns, notes = filter_mismatches(recorded, expected)
+    assert any("not comparable" in w and "flow_ema_alpha" in w for w in warns)
+    assert not any("flow_ema_alpha" in n for n in notes)
+    assert any("force_lowpass_cutoff_hz" in n for n in notes)
+    assert filter_mismatches(recorded, recorded) == ([], [])
+
+
+def test_check_reports_the_two_groups_apart():
+    samples = {
+        key: [
+            CalSample(weight_n=0.0, raw_mean=0.0, n=10),
+            CalSample(weight_n=1.0, raw_mean=1000.0, n=10),
+        ]
+        for key in ("fn", "fx", "fy")
+    }
+    doc = build(
+        samples,
+        identity={"sensor_type": "box", "sn": "FP-1"},
+        pipeline={"filters": filters_fingerprint({"preset": "balanced"})},
+    )
+    result = check(doc, pipeline={"filters": filters_fingerprint({"preset": "low_noise"})})
+    assert result.ok, "a filter difference must not refuse a calibration"
+    assert any("not comparable" in w for w in result.warnings)
+    assert any("readout" in n for n in result.notes)
+    assert not any("readout" in w for w in result.warnings)
+
+
+def test_the_fingerprint_survives_a_write_and_read(tmp_path: Path):
+    samples = {
+        key: [
+            CalSample(weight_n=0.0, raw_mean=0.0, n=10),
+            CalSample(weight_n=1.0, raw_mean=1000.0, n=10),
+        ]
+        for key in ("fn", "fx", "fy")
+    }
+    doc = build(
+        samples,
+        identity={"sensor_type": "box", "sn": "FP-2"},
+        pipeline={"filters": filters_fingerprint({"preset": "balanced"})},
+    )
+    path = tmp_path / "fp.json"
+    write(doc, path, overwrite=True)
+    raw = json.loads(path.read_text(encoding="utf-8"))
+    assert raw["meta"]["filters"]["measurement"] == {"flow_ema_alpha": 0.5}
+    # The flat keys stay for readers that look them up by name.
+    assert raw["meta"]["flow_ema_alpha"] == 0.5
+
+    loaded = load(path)
+    assert loaded.pipeline["filters"]["measurement"] == {"flow_ema_alpha": 0.5}
+    assert loaded.pipeline["filters"]["readout"]["force_median_window"] == 3
+    assert loaded.pipeline["filters"]["preset"] == "balanced"
+    assert loaded.to_dict()["meta"]["filters"] == doc.to_dict()["meta"]["filters"]
+
+
+def test_a_legacy_flat_fingerprint_is_still_read_back(tmp_path: Path):
+    """Documents written before the groups existed keep being comparable."""
+    samples = {
+        key: [
+            CalSample(weight_n=0.0, raw_mean=0.0, n=10),
+            CalSample(weight_n=1.0, raw_mean=1000.0, n=10),
+        ]
+        for key in ("fn", "fx", "fy")
+    }
+    doc = build(samples, identity={"sensor_type": "box", "sn": "FP-3"})
+    legacy = json.loads(json.dumps(doc.to_dict()))
+    legacy["meta"].pop("filters", None)
+    legacy["meta"].update(
+        {"flow_ema_alpha": 0.3, "force_median_window": 3, "force_lowpass_cutoff_hz": 10.0}
+    )
+    path = tmp_path / "legacy.json"
+    path.write_text(json.dumps(legacy), encoding="utf-8")
+    loaded = load(path)
+    assert loaded.pipeline["filters"]["measurement"] == {"flow_ema_alpha": 0.3}
+    assert loaded.pipeline["filters"]["readout"]["force_median_window"] == 3
+    assert loaded.pipeline["filters"]["readout"]["force_lowpass_cutoff_hz"] == 10.0
+
+
+def test_the_effective_state_beats_the_config_file(tmp_path: Path):
+    """A file states an intent; the device states what it is doing."""
+    bundle_json = _box_cal_path().parent / "sensor.json"
+    from_file = pipeline_from_sensor_json(bundle_json)
+    assert from_file["filters"]["measurement"] == {"flow_ema_alpha": 1.0}
+    assert "flow_ema_alpha" not in from_file, "loose top-level filter keys are gone"
+
+    sensor = _sensor_with_filters(tmp_path, {"preset": "balanced"})
+    try:
+        from_state = pipeline_from_sensor_json(
+            bundle_json, filters_state=sensor.filters_state()
+        )
+    finally:
+        sensor.disconnect()
+    assert from_state["filters"]["measurement"] == {"flow_ema_alpha": 0.5}
+    assert from_state["filters"]["readout"]["force_median_window"] == 3
+    assert from_state["filters"]["source"] == "sensor.filters_state"
+    assert from_state["config_ref"] == str(bundle_json)
+
+
+@pytest.mark.parametrize(
+    "preset, alpha, median, cutoff",
+    [
+        ("off", 1.0, 1, 0.0),
+        ("low_latency", 1.0, 3, 0.0),
+        ("balanced", 0.5, 3, 0.0),
+        ("low_noise", 0.3, 3, 10.0),
+    ],
+)
+def test_every_preset_reports_what_it_does(
+    tmp_path: Path, preset: str, alpha: float, median: int, cutoff: float
+):
+    sensor = _sensor_with_filters(tmp_path, {"preset": preset})
+    try:
+        fp = filters_fingerprint(sensor.filters_state())
+    finally:
+        sensor.disconnect()
+    assert fp["measurement"]["flow_ema_alpha"] == pytest.approx(alpha)
+    assert fp["readout"]["force_median_window"] == median
+    assert fp["readout"]["force_lowpass_cutoff_hz"] == pytest.approx(cutoff)

tests/test_draw_arrows.py

@@ -0,0 +1,116 @@
+"""orisys.util.draw_arrows: mask handling and the out-of-frame tip regression."""
+
+from __future__ import annotations
+
+import cv2
+import numpy as np
+import pytest
+
+from orisys.util import _prepare_draw_mask, draw_arrows
+
+
+def flow_of(shape, dx, dy):
+    flow = np.zeros((*shape, 2), dtype=np.float32)
+    flow[..., 0] = dx / 2.0  # draw_arrows doubles the stored value
+    flow[..., 1] = dy / 2.0
+    return flow
+
+
+def background(frame):
+    return cv2.cvtColor(frame, cv2.COLOR_GRAY2BGR)
+
+
+def test_out_of_frame_arrow_tip_is_dropped_not_raised():
+    """Regression: mask[end_y, end_x] was indexed before the bounds check.
+
+    A 40 px grid with the default edge_margin of 15 lets an arrow tip leave the
+    frame, which used to raise IndexError as soon as a valid_mask was supplied.
+    """
+    frame = np.full((48, 48), 100, dtype=np.uint8)
+    flow = flow_of((48, 48), dx=40.0, dy=0.0)
+    mask = np.ones((48, 48), dtype=bool)
+
+    out = draw_arrows(frame, flow, grid_spacing=40, margin=0.8, valid_mask=mask)
+
+    assert out.shape == (48, 48, 3)
+    # The only grid point (20, 20) has a tip at x=58 in a 48 px frame, so the
+    # bounds check must have discarded it: nothing was drawn.
+    assert np.array_equal(out, background(frame))
+
+
+def test_out_of_frame_tip_matches_render_without_mask():
+    """Clamping the mask lookup must not change which points are valid."""
+    frame = np.full((48, 48), 100, dtype=np.uint8)
+    flow = flow_of((48, 48), dx=40.0, dy=0.0)
+    mask = np.ones((48, 48), dtype=bool)
+
+    with_mask = draw_arrows(frame, flow, grid_spacing=40, valid_mask=mask)
+    without = draw_arrows(frame, flow, grid_spacing=40)
+    assert np.array_equal(with_mask, without)
+
+
+def test_in_frame_arrows_are_drawn_through_an_all_true_mask():
+    frame = np.full((96, 96), 90, dtype=np.uint8)
+    flow = flow_of((96, 96), dx=6.0, dy=3.0)
+    mask = np.ones((96, 96), dtype=bool)
+
+    out = draw_arrows(frame, flow, grid_spacing=12, arrow_scale=1.0,
+                      threshold=0.1, valid_mask=mask)
+    assert not np.array_equal(out, background(frame))
+
+
+def test_all_false_mask_draws_nothing():
+    frame = np.full((96, 96), 90, dtype=np.uint8)
+    flow = flow_of((96, 96), dx=6.0, dy=3.0)
+    mask = np.zeros((96, 96), dtype=bool)
+
+    out = draw_arrows(frame, flow, grid_spacing=12, arrow_scale=1.0,
+                      threshold=0.1, valid_mask=mask)
+    assert np.array_equal(out, background(frame))
+
+
+def test_mask_can_exclude_one_side():
+    """Endpoints outside the mask are skipped even when inside the frame."""
+    frame = np.full((96, 96), 90, dtype=np.uint8)
+    flow = flow_of((96, 96), dx=8.0, dy=0.0)
+    mask = np.zeros((96, 96), dtype=bool)
+    mask[24:48, 24:72] = True  # only the upper middle band
+
+    out = draw_arrows(frame, flow, grid_spacing=12, arrow_scale=1.0,
+                      threshold=0.1, valid_mask=mask)
+    assert not np.array_equal(out, background(frame))
+    # Rows below the band stay untouched.
+    assert np.array_equal(out[80:, :, :], background(frame)[80:, :, :])
+
+
+def test_below_threshold_points_get_the_dot_colour():
+    frame = np.full((96, 96), 90, dtype=np.uint8)
+    flow = flow_of((96, 96), dx=0.05, dy=0.05)
+    out = draw_arrows(frame, flow, grid_spacing=12, arrow_scale=1.0,
+                      threshold=1.0, below_threshold_color=(0, 0, 255))
+    # OpenCV colours are BGR, so (0, 0, 255) is red.
+    red = (out[:, :, 2] > 150) & (out[:, :, 0] < 100) & (out[:, :, 1] < 100)
+    assert red.sum() > 0
+
+
+def test_prepare_draw_mask_resizes_to_frame():
+    mask = np.zeros((10, 20), dtype=bool)
+    mask[:, :10] = True
+    out = _prepare_draw_mask(mask, (40, 40))
+    assert out.shape == (40, 40)
+    assert out[:, :20].all()
+    assert not out[:, 20:].any()
+
+
+def test_prepare_draw_mask_passes_none_through():
+    assert _prepare_draw_mask(None, (10, 10)) is None
+
+
+def test_non_square_grid_does_not_raise_with_mask():
+    """Height and width differ, so rr/cc broadcasting must stay (N, N)."""
+    frame = np.full((60, 120), 80, dtype=np.uint8)
+    flow = flow_of((60, 120), dx=5.0, dy=5.0)
+    out = draw_arrows(frame, flow, grid_spacing=10, arrow_scale=1.0,
+                      threshold=0.1, valid_mask=np.ones((60, 120), dtype=bool))
+    assert out.shape == (60, 120, 3)
+    assert not np.array_equal(out, background(frame))

tests/test_export.py

@@ -0,0 +1,281 @@
+"""StreamRecorder / mosaic_videos: off-hot-path arrow overlay export."""
+
+from __future__ import annotations
+
+import os
+import time
+
+import cv2
+import numpy as np
+import pytest
+
+from orisys import FrameSnapshot, StreamRecorder, mosaic_videos
+
+
+_DEFAULT = object()
+
+
+def make_snapshot(seq: int = 0, *, size: int = 64, image=_DEFAULT, flow=_DEFAULT) -> FrameSnapshot:
+    if image is _DEFAULT:
+        image = np.full((size, size), 128, dtype=np.uint8)
+        image[8:-8, 8:-8] = 200
+    if flow is _DEFAULT:
+        flow = np.zeros((size, size, 2), dtype=np.float32)
+        flow[..., 0] = 2.0
+        flow[..., 1] = 1.0
+    return FrameSnapshot(
+        seq=seq,
+        timestamp=time.time(),
+        age_ms=5.0,
+        fps=100.0,
+        unit="raw",
+        normal_force=1.5,
+        shear_x=0.25,
+        shear_y=-0.5,
+        normal_force_raw=1.5,
+        shear_x_raw=0.25,
+        shear_y_raw=-0.5,
+        torque=0.01,
+        image=image,
+        flow=flow,
+    )
+
+
+def read_video(path):
+    cap = cv2.VideoCapture(path)
+    try:
+        assert cap.isOpened(), f"cannot reopen {path}"
+        frames = []
+        while True:
+            ok, frame = cap.read()
+            if not ok:
+                break
+            frames.append(frame)
+        return frames, (int(cap.get(cv2.CAP_PROP_FRAME_WIDTH)),
+                        int(cap.get(cv2.CAP_PROP_FRAME_HEIGHT)))
+    finally:
+        cap.release()
+
+
+def _diff_count(frame, expected, tol=20):
+    """Pixels differing from ``expected`` by more than the codec's noise floor."""
+    d = np.abs(frame.astype(np.int16) - expected.astype(np.int16)).max(axis=2)
+    return int((d > tol).sum())
+
+
+def _near(pixel, value, tol=14):
+    """Codec round-trip shifts solid greys by a few levels (YUV range)."""
+    return all(abs(int(c) - value) <= tol for c in np.ravel(pixel))
+
+
+# --------------------------------------------------------------------- recorder
+def test_recorder_writes_every_frame(tmp_path):
+    path = str(tmp_path / "s0.mp4")
+    # Depth >= frame count so the drop-oldest policy provably does not engage;
+    # exactness of the writer itself is what this test is about.
+    rec = StreamRecorder(path, fps=25.0, grid_spacing=8, overlay_values=False,
+                         queue_depth=64)
+    for i in range(12):
+        rec.on_frame(make_snapshot(i))
+    stats = rec.close()
+
+    assert stats["seen"] == 12
+    assert stats["written"] == 12
+    assert stats["dropped"] == 0
+    assert stats["skipped"] == 0
+    assert "error" not in stats
+    assert stats["thread_alive"] is False
+
+    frames, size = read_video(path)
+    assert len(frames) == 12
+    assert size == (64, 64)
+
+
+def test_recorder_every_skips_frames(tmp_path):
+    path = str(tmp_path / "s0.mp4")
+    rec = StreamRecorder(path, every=3, grid_spacing=8, overlay_values=False,
+                         queue_depth=64)
+    for i in range(12):
+        rec.on_frame(make_snapshot(i))
+    stats = rec.close()
+
+    assert stats["seen"] == 12
+    assert stats["written"] == 4
+    assert stats["skipped"] == 8
+    frames, _ = read_video(path)
+    assert len(frames) == 4
+
+
+def test_on_frame_never_blocks_and_drops_oldest(tmp_path, monkeypatch):
+    """A slow writer must cost frames, never pipeline throughput."""
+    path = str(tmp_path / "s0.mp4")
+    rec = StreamRecorder(path, queue_depth=2, grid_spacing=8, overlay_values=False)
+
+    original = rec._render
+
+    def slow_render(snap):
+        time.sleep(0.05)
+        return original(snap)
+
+    rec._render = slow_render
+
+    t0 = time.perf_counter()
+    for i in range(20):
+        rec.on_frame(make_snapshot(i))
+    ingest = time.perf_counter() - t0
+    stats = rec.close(timeout=30.0)
+
+    # Ingesting 20 frames must not wait on ~1s of encoder work.
+    assert ingest < 0.1, f"on_frame blocked for {ingest * 1000:.1f} ms"
+    assert stats["dropped"] > 0
+    assert stats["written"] + stats["dropped"] + stats["skipped"] == 20
+    assert stats["written"] < 20
+
+
+def test_recorder_reports_missing_arrays(tmp_path):
+    path = str(tmp_path / "s0.mp4")
+    rec = StreamRecorder(path, grid_spacing=8, overlay_values=False)
+    rec.on_frame(make_snapshot(0, image=None))
+    stats = rec.close()
+
+    assert stats["written"] == 0
+    assert "error" in stats
+    assert 'include=("image", "flow")' in stats["error"]
+
+
+def test_recorder_context_manager(tmp_path):
+    path = str(tmp_path / "s0.mp4")
+    with StreamRecorder(path, grid_spacing=8, overlay_values=False) as rec:
+        rec.on_frame(make_snapshot(0))
+    assert os.path.isfile(path)
+    assert rec._writer is None
+
+
+def test_valid_mask_callable_resolved_per_frame(tmp_path):
+    calls = []
+
+    def mask():
+        calls.append(1)
+        return None
+
+    path = str(tmp_path / "s0.mp4")
+    rec = StreamRecorder(path, grid_spacing=8, overlay_values=False, valid_mask=mask)
+    for i in range(5):
+        rec.on_frame(make_snapshot(i))
+    stats = rec.close()
+
+    assert stats["written"] == 5
+    assert len(calls) == 5
+
+
+def test_all_false_mask_suppresses_arrows(tmp_path):
+    """With every grid point masked out the overlay is just the grey frame."""
+    path = str(tmp_path / "s0.mp4")
+    snap = make_snapshot(0)
+    rec = StreamRecorder(path, grid_spacing=8, overlay_values=False,
+                         valid_mask=np.zeros((64, 64), dtype=bool))
+    rec.on_frame(snap)
+    rec.close()
+
+    frames, _ = read_video(path)
+    expected = cv2.cvtColor(snap.image, cv2.COLOR_GRAY2BGR)
+    assert _diff_count(frames[0], expected) == 0
+
+
+def test_arrows_change_pixels_without_mask(tmp_path):
+    path = str(tmp_path / "s0.mp4")
+    snap = make_snapshot(0)
+    rec = StreamRecorder(path, grid_spacing=8, overlay_values=False)
+    rec.on_frame(snap)
+    rec.close()
+
+    frames, _ = read_video(path)
+    expected = cv2.cvtColor(snap.image, cv2.COLOR_GRAY2BGR)
+    assert _diff_count(frames[0], expected) > 100
+
+
+def test_close_without_frames_is_safe(tmp_path):
+    rec = StreamRecorder(str(tmp_path / "empty.mp4"), grid_spacing=8)
+    stats = rec.close()
+    assert stats["written"] == 0
+    assert "error" not in stats
+
+
+def test_stats_report_requested_geometry(tmp_path):
+    rec = StreamRecorder(str(tmp_path / "s0.mp4"), fps=12.0, fourcc="mp4v")
+    assert rec.stats()["fps"] == 12.0
+    assert rec.stats()["fourcc"] == "mp4v"
+    assert rec.stats()["path"].endswith("s0.mp4")
+
+
+# ---------------------------------------------------------------------- mosaic
+def _write_solid(path, value, frames=4, size=(16, 12), fps=10.0):
+    w, h = size
+    writer = cv2.VideoWriter(path, cv2.VideoWriter_fourcc(*"mp4v"), fps, (w, h), True)
+    assert writer.isOpened()
+    try:
+        for _ in range(frames):
+            writer.write(np.full((h, w, 3), value, dtype=np.uint8))
+    finally:
+        writer.release()
+    return path
+
+
+def test_mosaic_grid_geometry(tmp_path):
+    srcs = [_write_solid(str(tmp_path / f"s{i}.mp4"), 40 + 40 * i) for i in range(3)]
+    out = str(tmp_path / "mosaic.mp4")
+    info = mosaic_videos(srcs, out, cols=2, gap=4, fps=10.0)
+
+    assert info["grid"] == (2, 2)
+    # 2 columns x 16 + 1 gap, 2 rows x 12 + 1 gap
+    assert info["size"] == (2 * 16 + 4, 2 * 12 + 4)
+    assert info["frames"] == 4
+    frames, size = read_video(out)
+    assert len(frames) == 4
+    assert size == info["size"]
+    # the empty bottom-right cell stays black
+    assert _near(frames[0][-1, -1], 0, tol=12)
+    # top-left tile carries stream 0's colour
+    assert _near(frames[0][0, 0], 40)
+
+
+def test_mosaic_holds_last_frame_on_short_input(tmp_path):
+    a = _write_solid(str(tmp_path / "a.mp4"), 200, frames=5)
+    b = _write_solid(str(tmp_path / "b.mp4"), 50, frames=3)
+    out = str(tmp_path / "mosaic.mp4")
+    info = mosaic_videos([a, b], out, cols=2, gap=0, fps=10.0)
+
+    assert info["frames"] == 5
+    frames, size = read_video(out)
+    assert len(frames) == 5
+    # b's 4th frame is a repeat of its 3rd, so the right half is still solid 50
+    assert _near(frames[-1][0, size[0] // 2], 50)
+
+
+def test_mosaic_labels_drawn(tmp_path):
+    srcs = [_write_solid(str(tmp_path / f"s{i}.mp4"), 30) for i in range(2)]
+    out = str(tmp_path / "mosaic.mp4")
+    plain = str(tmp_path / "plain.mp4")
+    mosaic_videos(srcs, plain, cols=2, gap=0, fps=10.0)
+    mosaic_videos(srcs, out, cols=2, gap=0, fps=10.0, labels=["#0", "#1"])
+
+    with_label, _ = read_video(out)
+    without, _ = read_video(plain)
+    assert _diff_count(with_label[0], without[0]) > 0
+
+
+def test_mosaic_scale_downscales(tmp_path):
+    srcs = [_write_solid(str(tmp_path / f"s{i}.mp4"), 30, size=(16, 12)) for i in range(4)]
+    out = str(tmp_path / "mosaic.mp4")
+    info = mosaic_videos(srcs, out, cols=2, gap=2, scale=0.5, fps=10.0)
+    assert info["size"] == (8 * 2 + 2, 6 * 2 + 2)
+
+
+def test_mosaic_rejects_missing_input(tmp_path):
+    with pytest.raises(FileNotFoundError):
+        mosaic_videos([str(tmp_path / "nope.mp4")], str(tmp_path / "out.mp4"))
+
+
+def test_mosaic_rejects_empty_input(tmp_path):
+    with pytest.raises(ValueError):
+        mosaic_videos([], str(tmp_path / "out.mp4"))

tests/test_export_sensor_bundle.py

@@ -0,0 +1,48 @@
+"""Tests for sensor-bundle export helpers."""
+
+from __future__ import annotations
+
+from pathlib import Path
+
+import pytest
+
+from orisys.configs import (
+    export_sensor_bundle,
+    export_sensor_bundles,
+    list_sensor_bundles,
+    resolve_sensor_bundle,
+)
+
+
+def test_export_sensor_bundle_json_only(tmp_path: Path) -> None:
+    assert resolve_sensor_bundle("box") is not None
+
+    dest = export_sensor_bundle("box", tmp_path, include_assets=False)
+    assert dest == tmp_path / "box"
+    assert (dest / "sensor.json").is_file()
+    assert (dest / "force_calibration.json").is_file()
+    assert not (dest / "assets").exists()
+
+
+def test_export_sensor_bundles_default_names(tmp_path: Path) -> None:
+    available = list_sensor_bundles()
+    assert "box" in available
+
+    exported = export_sensor_bundles(tmp_path, include_assets=False)
+    names = {path.name for path in exported}
+    assert "box" in names
+    assert "mini" in names
+    for path in exported:
+        assert (path / "sensor.json").is_file()
+        assert not (path / "assets").exists()
+
+
+def test_export_sensor_bundle_no_overwrite(tmp_path: Path) -> None:
+    export_sensor_bundle("box", tmp_path, overwrite=True)
+    with pytest.raises(FileExistsError):
+        export_sensor_bundle("box", tmp_path, overwrite=False)
+
+
+def test_export_sensor_bundle_missing_name(tmp_path: Path) -> None:
+    with pytest.raises(FileNotFoundError):
+        export_sensor_bundle("not-a-real-sensor", tmp_path)

tests/test_filter_presets.py

@@ -0,0 +1,117 @@
+"""The shipped filter presets and the example configs that document them.
+
+``json.load`` cannot carry comments, so the answer to "which filter should I
+use?" lives in three places that must not drift apart: ``FILTER_PRESETS`` in the
+sensor, the table in ``docs/filters.md``, and the copy-paste files in
+``examples/filters/``. The presets are the source of truth; these tests fail
+when a copy stops matching them.
+"""
+
+from __future__ import annotations
+
+import json
+import shutil
+from pathlib import Path
+
+import pytest
+
+from orisys import Sensor
+from orisys.calibration import filters_fingerprint
+from orisys.sensor import FILTER_PRESETS, available_filter_presets
+from orisys import configs as orisys_configs
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+EXAMPLES = REPO_ROOT / "examples" / "filters"
+BUNDLES = ("box", "mini", "finger")
+
+#: What every shipped bundle says: filtering is opt-in, so a fresh install
+#: records the raw reading and the operator turns a stage on deliberately.
+ALL_OFF = {
+    "flow_ema_alpha": 1.0,
+    "force_median_window": 1,
+    "force_lowpass_cutoff_hz": 0.0,
+    "force_lowpass_order": 2,
+    "force_lowpass_sample_rate_hz": "auto",
+}
+
+
+def test_the_preset_names_are_the_documented_ones():
+    assert sorted(available_filter_presets()) == [
+        "balanced",
+        "low_latency",
+        "low_noise",
+        "off",
+    ]
+    # ``available_filter_presets`` hands out copies: a UI cannot edit the truth.
+    snapshot = available_filter_presets()
+    snapshot["off"]["flow_ema_alpha"] = 0.0
+    assert FILTER_PRESETS["off"]["flow_ema_alpha"] == 1.0
+
+
+@pytest.mark.parametrize("preset", sorted(FILTER_PRESETS))
+def test_every_example_file_still_matches_its_preset(preset: str):
+    path = EXAMPLES / f"filters_{preset}.json"
+    assert path.is_file(), f"missing example for preset {preset!r}: {path}"
+    block = json.loads(path.read_text(encoding="utf-8"))
+    # A whole ``filters`` block: the preset's own keys on top of the defaults
+    # every config needs, and nothing else.
+    expected = dict(ALL_OFF)
+    expected.update(FILTER_PRESETS[preset])
+    assert block == expected, f"{path.name} drifted from preset {preset!r}"
+
+
+def test_every_example_file_is_a_real_filters_block():
+    """A file that cannot be dropped into a config is documentation that lies."""
+    for preset in FILTER_PRESETS:
+        block = json.loads((EXAMPLES / f"filters_{preset}.json").read_text(encoding="utf-8"))
+        assert isinstance(block, dict) and block, preset
+        for key in ("flow_ema_alpha", "force_median_window", "force_lowpass_cutoff_hz"):
+            assert key in block, f"{preset}: {key} missing"
+
+
+@pytest.mark.parametrize("bundle", BUNDLES)
+def test_shipped_bundles_ship_with_filtering_off(bundle: str):
+    """Nothing filters unless it was asked for."""
+    path = orisys_configs.resolve_sensor_config_path(bundle)
+    assert path is not None and path.is_file(), f"missing bundle: {bundle}"
+    cfg = json.loads(path.read_text(encoding="utf-8"))
+    assert cfg.get("filters") == ALL_OFF, f"{bundle} no longer ships with filtering off"
+
+
+@pytest.mark.parametrize("bundle", BUNDLES)
+def test_shipped_bundles_report_all_off(bundle: str):
+    """The file and the running device have to agree about the shipped default."""
+    sensor = Sensor("external", config_name=bundle, verbose=False, backend="cpu")
+    try:
+        fp = filters_fingerprint(sensor.filters_state())
+    finally:
+        sensor.disconnect()
+    assert fp["measurement"] == {"flow_ema_alpha": 1.0}
+    assert fp["readout"]["force_median_window"] == 1
+    assert fp["readout"]["force_lowpass_cutoff_hz"] == 0.0
+
+
+def test_a_config_with_no_filters_block_filters_nothing(tmp_path: Path):
+    """Absence is off, not "the values we thought were sensible".
+
+    A key that is missing has to mean the stage is not running: otherwise a
+    device filters a measurement nobody asked for, and nothing in the file says
+    so. Callers with a hand-written config (an old customer file, a bench
+    script) rely on this.
+    """
+    copy = tmp_path / "box"
+    shutil.copytree(REPO_ROOT / "sensors" / "box", copy)
+    path = copy / "sensor.json"
+    cfg = json.loads(path.read_text(encoding="utf-8"))
+    cfg.pop("filters", None)
+    path.write_text(json.dumps(cfg, indent=2), encoding="utf-8")
+
+    sensor = Sensor("external", config_name=str(path), verbose=False, backend="cpu")
+    try:
+        state = sensor.filters_state()
+    finally:
+        sensor.disconnect()
+    assert state["measurement"]["flow_ema_alpha"] == 1.0
+    assert state["readout"]["force_median_window"] == 1
+    assert state["readout"]["force_lowpass_cutoff_hz"] == 0.0
+    assert state["any_stage_applied"] is False

tests/test_harness_guards.py

@@ -0,0 +1,142 @@
+"""Guards for the pytest harness itself.
+
+``tests/conftest.py`` was accidentally deleted in commit edc6e42 while four test
+modules still depended on its fixtures, which made the suite unrunnable without
+anything failing loudly in CI. These tests turn that class of regression into an
+explicit failure, and also catch a stale ``orisys`` install silently shadowing
+``src/orisys`` (a real hazard: base/py312 environments have older orisys copies
+in site-packages).
+"""
+
+from __future__ import annotations
+
+import functools
+import importlib.util
+from pathlib import Path
+
+import pytest
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+CONFTEST_PATH = Path(__file__).resolve().parent / "conftest.py"
+
+# Names that must exist in tests/conftest.py.
+REQUIRED_CONFTEST_NAMES = (
+    "DEFAULT_VIDEO_CANDIDATES",
+    "make_sensor",
+    "test_video_path",
+    "test_config_name",
+    "available_backends",
+    "sensor_factory",
+)
+
+# Fixtures that must be resolvable through pytest.
+REQUIRED_FIXTURES = (
+    "test_video_path",
+    "test_config_name",
+    "available_backends",
+    "sensor_factory",
+)
+
+
+@functools.lru_cache(maxsize=1)
+def _load_conftest_module():
+    """Load tests/conftest.py by path so a deletion is observable here."""
+    spec = importlib.util.spec_from_file_location("_orisys_conftest_probe", CONFTEST_PATH)
+    if spec is None or spec.loader is None:
+        raise AssertionError(f"Cannot load {CONFTEST_PATH}")
+    module = importlib.util.module_from_spec(spec)
+    spec.loader.exec_module(module)
+    return module
+
+
+def test_conftest_defines_shared_fixtures():
+    assert CONFTEST_PATH.is_file(), (
+        f"{CONFTEST_PATH} is missing. test_backends.py, test_smoke_api.py, "
+        "test_errors_and_cleanup.py and test_longrun_stability.py depend on its "
+        "fixtures; it was accidentally deleted in commit edc6e42. Restore it "
+        "instead of deleting it."
+    )
+
+    module = _load_conftest_module()
+    missing = [
+        name for name in REQUIRED_CONFTEST_NAMES if getattr(module, name, None) is None
+    ]
+    assert not missing, (
+        f"tests/conftest.py no longer defines: {', '.join(missing)}. "
+        "The shared sensor-test fixtures are required by the suite."
+    )
+
+
+def test_default_test_video_is_reachable():
+    """At least one default candidate must exist, or every sensor test skips."""
+    module = _load_conftest_module()
+    candidates = [REPO_ROOT / Path(rel) for rel in module.DEFAULT_VIDEO_CANDIDATES]
+    existing = [path for path in candidates if path.is_file()]
+    assert existing, (
+        "None of the default test videos exist:\n  "
+        + "\n  ".join(str(path) for path in candidates)
+        + "\nCommit a sample clip under data/sample/ or set ORISYS_TEST_VIDEO."
+    )
+
+
+def test_fixtures_are_registered_with_pytest(request):
+    missing: list[str] = []
+    for name in REQUIRED_FIXTURES:
+        try:
+            request.getfixturevalue(name)
+        except pytest.FixtureLookupError:
+            missing.append(name)
+    assert not missing, (
+        f"pytest did not register these fixtures: {', '.join(missing)}. "
+        "Check that tests/conftest.py is present and the @pytest.fixture "
+        "decorators are intact."
+    )
+
+
+def test_import_precedence_is_correct():
+    """examples/ must beat build/ for `gui`; build/ must beat site-packages.
+
+    Regression guard: build/gui is a package named `gui`, so if build/ precedes
+    examples/ on sys.path then `import gui.viewer2d` resolves to the build
+    tooling and tests/test_qt_viewer_backend.py fails at collection.
+    """
+    import common
+    import gui
+    import wheel
+
+    examples_gui = (REPO_ROOT / "examples" / "gui").resolve()
+    build_root = (REPO_ROOT / "build").resolve()
+
+    assert Path(gui.__file__).resolve().parent == examples_gui, (
+        f"`gui` resolved to {gui.__file__} instead of {examples_gui}; "
+        "examples/ must precede build/ on sys.path"
+    )
+    for module in (common, wheel):
+        resolved = Path(module.__file__).resolve()
+        assert build_root in resolved.parents, (
+            f"`{module.__name__}` resolved to {resolved}, outside {build_root}; "
+            "build/ must precede site-packages on sys.path"
+        )
+
+
+def test_tests_run_against_checkout_not_stale_install():
+    """Fail loudly when an old orisys in site-packages shadows src/orisys."""
+    src_pkg = (REPO_ROOT / "src" / "orisys").resolve()
+    if not src_pkg.is_dir():
+        pytest.skip("src/orisys is not present in this checkout layout")
+
+    import orisys
+
+    module_file = getattr(orisys, "__file__", None)
+    assert module_file, (
+        "import orisys resolved to a namespace package (__file__ is None) "
+        f"instead of {src_pkg}. A stale orisys in site-packages is shadowing "
+        "the checkout; run `pip uninstall -y orisys` in this environment."
+    )
+
+    resolved_parent = Path(module_file).resolve().parent
+    assert resolved_parent == src_pkg, (
+        f"import orisys resolved to {resolved_parent} instead of {src_pkg}. "
+        "A stale orisys in site-packages is shadowing the checkout; run "
+        "`pip uninstall -y orisys` in this environment."
+    )

tests/test_masked_hhd.py

@@ -70,17 +70,22 @@ def test_sensor_detect_motion_ignores_invalid_region():
         backend="cpu",
     )
     try:
+        # get_img() resizes the frame to the config's camera.resolution_stitch
+        # and stores valid_mask at that same resolution, so the flow buffer must
+        # be sized from sensor.valid_mask rather than from the raw frame.
         frame = np.zeros((728, 672, 3), dtype=np.uint8)
         mask = np.zeros((728, 672), dtype=bool)
         mask[180:540, 160:512] = True
         sensor.get_img(frame=frame, already_processed=True, valid_mask=mask)
 
-        sensor.flow = np.zeros((728, 672, 2), dtype=np.float32)
-        sensor.flow[~mask] = 10.0
+        flow_shape = sensor.valid_mask.shape
+        assert sensor.valid_mask.any() and not sensor.valid_mask.all()
+        sensor.flow = np.zeros((*flow_shape, 2), dtype=np.float32)
+        sensor.flow[~sensor.valid_mask] = 10.0
         assert not sensor.detect_motion(threshold=1.0)
 
         sensor.flow[:] = 0.0
-        sensor.flow[mask] = 10.0
+        sensor.flow[sensor.valid_mask] = 10.0
         assert sensor.detect_motion(threshold=1.0)
     finally:
         sensor.disconnect()

tests/test_nuitka_nofollow.py

@@ -0,0 +1,72 @@
+"""Every third-party import in src/orisys must be excluded from the Nuitka compile.
+
+Omitting one means Nuitka tries to follow it into the compiled extension: compile
+time explodes, and the wheel's contents start depending on whatever happens to be
+installed in the *build* environment rather than on what is declared. ``torch``,
+``torchvision`` and ``pyvkfft`` were imported by the package but missing from the
+exclusion list; this test keeps that list complete.
+"""
+
+from __future__ import annotations
+
+import ast
+import sys
+from pathlib import Path
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+BUILD_ROOT = REPO_ROOT / "build"
+if str(BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(BUILD_ROOT))
+
+from wheel.compile import NUITKA_INCLUDE_PACKAGES, NUITKA_NOFOLLOW_IMPORTS  # noqa: E402
+
+PACKAGE_ROOT = REPO_ROOT / "src" / "orisys"
+FIRST_PARTY = {"orisys", "orisys_blend"}
+
+
+def _third_party_imports() -> dict[str, set[str]]:
+    """Top-level third-party import names -> the files that import them."""
+    stdlib = set(sys.stdlib_module_names)
+    found: dict[str, set[str]] = {}
+
+    for path in sorted(PACKAGE_ROOT.rglob("*.py")):
+        try:
+            tree = ast.parse(path.read_text(encoding="utf-8", errors="ignore"))
+        except SyntaxError:
+            continue
+        for node in ast.walk(tree):
+            names: list[str] = []
+            if isinstance(node, ast.Import):
+                names = [alias.name for alias in node.names]
+            elif isinstance(node, ast.ImportFrom) and node.module and node.level == 0:
+                names = [node.module]
+            for name in names:
+                top = name.split(".")[0]
+                if top in stdlib or top in FIRST_PARTY:
+                    continue
+                found.setdefault(top, set()).add(path.relative_to(REPO_ROOT).as_posix())
+    return found
+
+
+def test_every_third_party_import_is_nofollowed():
+    found = _third_party_imports()
+    assert found, "expected to find third-party imports in src/orisys"
+
+    missing = sorted(set(found) - set(NUITKA_NOFOLLOW_IMPORTS))
+    assert not missing, (
+        "these third-party modules are imported by src/orisys but missing from "
+        "build/wheel/compile.py::NUITKA_NOFOLLOW_IMPORTS:\n  "
+        + "\n  ".join(f"{name} (imported by {sorted(found[name])})" for name in missing)
+        + "\nNuitka will try to follow them into the compiled module; add them to "
+        "the exclusion list so they resolve from the user's environment at runtime."
+    )
+
+
+def test_included_packages_are_first_party_or_subpackages():
+    assert "orisys" in NUITKA_INCLUDE_PACKAGES
+    for name in NUITKA_INCLUDE_PACKAGES:
+        assert name == "orisys" or name.startswith("orisys."), name
+
+
+def test_nofollow_list_has_no_duplicates():
+    assert len(NUITKA_NOFOLLOW_IMPORTS) == len(set(NUITKA_NOFOLLOW_IMPORTS))

tests/test_pipeline.py

@@ -0,0 +1,329 @@
+"""StreamPipeline: staging, snapshot immutability, error propagation, shutdown."""
+
+from __future__ import annotations
+
+import time
+
+import numpy as np
+import pytest
+
+from orisys import FrameSnapshot, StreamPipeline
+
+
+class FakeSensor:
+    """Minimal Sensor stand-in with the same mutable-buffer behaviour.
+
+    It deliberately reuses one image buffer (like ``Sensor._img_gray_buf``) so the
+    pipeline's private-copy contract is actually exercised.
+    """
+
+    class info:
+        VRAW = "vraw"
+        VNORMAL = "vnormal"
+        VSHEAR = "vshear"
+        DEPTH = "depth"
+        CENTROID = "centroid"
+        CONTOUR = "contour"
+
+    def __init__(self, *, fail_at: int | None = None, flow_delay: float = 0.0,
+                 hhd_delay: float = 0.0):
+        self.img = None
+        self.flow = None
+        self.vnormal = None
+        self.vshear = None
+        self.depth_map = None
+        self.centroid = (0, 0)
+        self.contour = np.empty(0)
+        self.ftor = 0.0
+        self._force_raw = (0.0, 0.0, 0.0)
+        self.fnormal = self.fshearx = self.fsheary = 0.0
+        self.force_unit = "raw"
+        self._img_buf = np.zeros((8, 8), dtype=np.uint8)
+        self._flow_buf = np.zeros((8, 8, 2), dtype=np.float32)
+        self._flow_delay = flow_delay
+        self._hhd_delay = hhd_delay
+        self._fail_at = fail_at
+        self._flow_calls = 0
+        self._seen_images: list[np.ndarray] = []
+        self._seen_flow_values: list[float] = []
+        self.contact_calls = 0
+
+    def make_frame(self, seq: int) -> np.ndarray:
+        # writes INTO the shared buffer, exactly like cv2.resize(dst=...)
+        self._img_buf.fill(seq % 251)
+        self.img = self._img_buf
+        return self._img_buf
+
+    def compute_flow(self, img=None, **kwargs) -> None:
+        image = self.img if img is None else img
+        self._flow_calls += 1
+        if self._fail_at is not None and self._flow_calls == self._fail_at:
+            raise RuntimeError("flow exploded")
+        self._seen_images.append(np.array(image, copy=True))
+        time.sleep(self._flow_delay)
+        # rewrite the shared buffer, like the real DIS/EMA path does
+        self._flow_buf.fill(float(self._flow_calls))
+        self.flow = self._flow_buf
+
+    def compute_hhd(self, flow=None, **kwargs) -> None:
+        # Mirrors Sensor.compute_hhd, which derives the forces from the field it
+        # is given - so this only yields frame N's forces if the pipeline passes
+        # frame N's flow explicitly.
+        time.sleep(self._hhd_delay)
+        field = self.flow if flow is None else flow
+        value = (float(field[0, 0, 0])
+                 if isinstance(field, np.ndarray) and field.size else 0.0)
+        self._seen_flow_values.append(value)
+        self.fnormal = value * 10.0
+        self.fshearx = value
+        self.fsheary = -value
+        self._force_raw = (self.fnormal, self.fshearx, self.fsheary)
+        self.ftor = value
+        self.vnormal = self._flow_buf
+        self.vshear = self._flow_buf
+
+    def compute_contact(self) -> None:
+        self.contact_calls += 1
+        self.centroid = (1, 2)
+        self.contour = np.zeros((1, 1, 2), dtype=np.int32)
+        self.depth_map = np.zeros((8, 8), dtype=np.float32)
+
+    def read_info(self, *args):
+        source = {
+            self.info.VRAW: lambda: self.flow.copy(),
+            self.info.VNORMAL: lambda: self.vnormal.copy(),
+            self.info.VSHEAR: lambda: self.vshear.copy(),
+            self.info.DEPTH: lambda: self.depth_map.copy(),
+            self.info.CENTROID: lambda: np.array(self.centroid),
+            self.info.CONTOUR: lambda: self.contour.copy(),
+        }
+        return tuple(source[a]() for a in args)
+
+
+def make_producer(sensor: FakeSensor, count: int):
+    state = {"i": 0}
+
+    def produce():
+        if state["i"] >= count:
+            return None
+        frame = sensor.make_frame(state["i"])
+        state["i"] += 1
+        return frame
+
+    return produce
+
+
+def run_all(sensor: FakeSensor, count: int, **kwargs):
+    """Drive the pipeline with an exhaustive consumer: every frame, in order."""
+    frames: list = []
+    kwargs.setdefault("depth", 2)
+    pipe = StreamPipeline(sensor, make_producer(sensor, count),
+                          on_frame=frames.append, **kwargs)
+    pipe.start()
+    deadline = time.perf_counter() + 10.0
+    while len(frames) < count and time.perf_counter() < deadline:
+        if pipe.error is not None:
+            break
+        time.sleep(0.001)
+    pipe.stop()
+    return pipe, frames
+
+
+def test_on_frame_receives_every_frame_in_order():
+    sensor = FakeSensor()
+    pipe, frames = run_all(sensor, 12)
+    assert len(frames) == 12
+    assert [s.seq for s in frames] == list(range(12))
+    assert pipe.stats.produced == 12
+    assert pipe.stats.published == 12
+
+
+def test_forces_come_from_the_matching_frame():
+    """Each snapshot must carry the forces computed from its own frame's flow."""
+    sensor = FakeSensor()
+    _, frames = run_all(sensor, 10)
+    # frame i's flow value is (i + 1); the fake derives the force from self.flow,
+    # so a mismatched pairing would show up as a repeated or skipped value.
+    assert sensor._seen_flow_values == [float(i + 1) for i in range(10)]
+    assert [s.normal_force for s in frames] == [10.0 * (i + 1) for i in range(10)]
+    assert [s.shear_x for s in frames] == [float(i + 1) for i in range(10)]
+
+
+def test_stages_do_not_read_a_rewritten_image_buffer():
+    """The producer reuses one buffer; no stage may observe a later frame."""
+    sensor = FakeSensor(flow_delay=0.004)
+    run_all(sensor, 8)
+    seen = sensor._seen_images
+    assert len(seen) == 8
+    for i, arr in enumerate(seen):
+        assert np.all(arr == i % 251), f"frame {i} was overwritten before flow ran"
+
+
+def test_snapshot_arrays_are_private_copies():
+    sensor = FakeSensor()
+    _, frames = run_all(sensor, 4, include=("image", "flow", "vnormal"))
+    first = frames[0]
+    assert isinstance(first, FrameSnapshot)
+    assert first.image is not None and first.flow is not None
+    saved = first.flow.copy()
+    # the SDK keeps rewriting its buffers; the snapshot must not change
+    sensor._flow_buf.fill(999.0)
+    sensor._img_buf.fill(7)
+    assert np.array_equal(first.flow, saved)
+    assert not np.any(first.flow == 999.0)
+
+
+def test_include_filters_which_arrays_are_copied():
+    sensor = FakeSensor()
+    _, frames = run_all(sensor, 3, include=("vnormal",))
+    assert frames[0].vnormal is not None
+    assert frames[0].image is None and frames[0].flow is None
+    assert frames[0].depth is None and frames[0].contour is None
+
+
+def test_rejects_unknown_include_field():
+    sensor = FakeSensor()
+    with pytest.raises(ValueError):
+        StreamPipeline(sensor, make_producer(sensor, 1), include=("floww",))
+
+
+def test_contact_stage_runs_when_requested():
+    sensor = FakeSensor()
+    _, frames = run_all(sensor, 5, contact=True,
+                        include=("depth", "centroid", "contour"))
+    assert sensor.contact_calls == 5
+    assert frames[-1].depth is not None
+    assert frames[-1].centroid is not None
+    assert frames[-1].contour is not None
+
+
+def test_stage_exception_surfaces_on_stop():
+    sensor = FakeSensor(fail_at=3)
+    pipe = StreamPipeline(sensor, make_producer(sensor, 20), depth=2)
+    pipe.start()
+    time.sleep(0.4)
+    with pytest.raises(RuntimeError, match="flow exploded"):
+        pipe.stop()
+
+
+def test_stage_exception_surfaces_on_wait():
+    sensor = FakeSensor(fail_at=2)
+    pipe = StreamPipeline(sensor, make_producer(sensor, 20), depth=2)
+    pipe.start()
+    with pytest.raises(RuntimeError):
+        for _ in range(50):
+            pipe.wait(timeout=0.1)
+    pipe.stop()
+
+
+def test_stop_is_idempotent():
+    sensor = FakeSensor()
+    pipe, _ = run_all(sensor, 4)
+    pipe.stop()                     # second stop must not raise
+    assert not pipe.running
+    assert pipe.latest() is not None
+
+
+def test_stop_while_running_does_not_hang():
+    """Stopping mid-stream must unblock the consumer threads.
+
+    The producer stops delivering sentinels once the done flag is set, so a
+    bare blocking Queue.get() in a consumer would wait forever.
+    """
+    sensor = FakeSensor(flow_delay=0.002)
+    pipe = StreamPipeline(sensor, make_producer(sensor, 100000), depth=2)
+    pipe.start()
+    assert pipe.wait(timeout=2.0) is not None
+    t0 = time.perf_counter()
+    pipe.stop(timeout=5.0)
+    elapsed = time.perf_counter() - t0
+    assert elapsed < 2.0, f"stop() took {elapsed:.2f}s; a stage was still blocked"
+    assert not pipe.running
+
+
+def test_context_manager_stops_threads():
+    sensor = FakeSensor()
+    frames: list = []
+    with StreamPipeline(sensor, make_producer(sensor, 6),
+                        on_frame=frames.append) as pipe:
+        deadline = time.perf_counter() + 5.0
+        while len(frames) < 6 and time.perf_counter() < deadline:
+            time.sleep(0.001)
+    assert len(frames) == 6
+    assert not pipe.running
+
+
+def test_wait_exposes_a_latest_wins_view():
+    sensor = FakeSensor()
+    pipe = StreamPipeline(sensor, make_producer(sensor, 5))
+    pipe.start()
+    last = None
+    while True:
+        snap = pipe.wait(timeout=2.0)
+        if snap is None:
+            break
+        if last is not None:
+            assert snap.seq > last.seq
+        last = snap
+    # the pipeline has drained; the final snapshot is the last frame
+    assert last is not None and last.normal_force == 50.0
+    assert pipe.latest() is last
+    # nothing new is coming, so a further poll returns immediately
+    assert pipe.wait(timeout=0.2) is None
+    pipe.stop()
+
+
+def test_wait_timeout_returns_none_without_new_frames():
+    sensor = FakeSensor()
+    pipe = StreamPipeline(sensor, make_producer(sensor, 1))
+    pipe.start()
+    assert pipe.wait(timeout=1.0) is not None
+    t0 = time.perf_counter()
+    assert pipe.wait(timeout=0.1) is None
+    assert time.perf_counter() - t0 < 1.0
+    pipe.stop()
+
+
+def test_stats_track_stage_times_and_age():
+    sensor = FakeSensor(flow_delay=0.002, hhd_delay=0.001)
+    pipe, _ = run_all(sensor, 15)
+    d = pipe.stats.as_dict()
+    assert d["published"] == 15
+    assert d["flow_ms"] >= 1.5           # the injected delay shows up
+    assert d["hhd_ms"] >= 0.8
+    assert d["age_ms"] > 0.0
+    assert d["fps"] > 0.0
+    assert d["produce_ms"] >= 0.0
+
+
+def test_depth_does_not_change_results():
+    for depth in (1, 2, 4):
+        sensor = FakeSensor()
+        _, frames = run_all(sensor, 10, depth=depth)
+        assert [s.normal_force for s in frames] == [10.0 * (i + 1) for i in range(10)]
+
+
+def test_for_finger_runtime_maps_eof_to_none():
+    """``for_finger_runtime`` drives ``grab_and_process`` and maps EOF to None."""
+    sensor = FakeSensor()
+    state = {"i": 0}
+
+    class FakeRuntime:
+        tactile = type("T", (), {"raw_sensor": sensor})()
+
+        def grab_and_process(self, color=False):
+            if state["i"] >= 3:
+                return False, None
+            frame = sensor.make_frame(state["i"])
+            state["i"] += 1
+            return True, frame
+
+    frames: list = []
+    pipe = StreamPipeline.for_finger_runtime(FakeRuntime(), on_frame=frames.append)
+    pipe.start()
+    deadline = time.perf_counter() + 5.0
+    while len(frames) < 3 and time.perf_counter() < deadline:
+        time.sleep(0.001)
+    pipe.stop()
+    assert len(frames) == 3
+    assert pipe.stats.produced == 3

tests/test_pyproject.py

@@ -28,14 +28,25 @@ def test_pyproject_dependencies(packaging_utils):
 
 
 def test_pyproject_dynamic_version(packaging_utils):
+    """The dynamic version must resolve to a valid version from one source.
+
+    Deliberately does NOT assert a literal version: pinning it here means every
+    release has to edit this file too. ``src/orisys/__init__.py::__version__`` is
+    the single source of truth, and build/release/version.py checks that the
+    wheels agree with it.
+    """
+    import re
     import sys
 
     build_dir = REPO_ROOT / "build"
     if str(build_dir) not in sys.path:
         sys.path.insert(0, str(build_dir))
     from common.pyproject_utils import get_version
+    from release.version import dynamic_version_attr
 
-    assert get_version(REPO_ROOT) == "0.5.0"
+    version = get_version(REPO_ROOT)
+    assert re.fullmatch(r"\d+(?:\.\d+)+(?:[-+][0-9A-Za-z.]+)?", version), version
+    assert dynamic_version_attr(REPO_ROOT) == "orisys.__version__"
 
 
 def test_pyproject_bundle_manifest(packaging_utils):
@@ -48,7 +59,9 @@ def test_pyproject_bundle_manifest(packaging_utils):
 
     items = bundle_items(REPO_ROOT)
     names = {item["name"] for item in items}
-    assert names == {"configs", "examples", "docs", "sensors"}
+    # docs/ is intentionally not bundled: it ships with the GitHub repo and the
+    # PyPI project page only, so doc edits do not invalidate built wheels.
+    assert names == {"configs", "examples", "sensors"}
 
     data_files = dict(bundle_data_files(REPO_ROOT))
     assert "orisys/configs" in data_files

tests/test_release_auth.py

@@ -0,0 +1,387 @@
+"""Tests for PyPI credential setup (~/.pypirc handling).
+
+The writer does text surgery to preserve the explanatory comments in the file, so
+these tests check the result of that surgery rather than trusting it. No test
+touches the real ``~/.pypirc``: every path is injected.
+"""
+
+from __future__ import annotations
+
+import sys
+from pathlib import Path
+
+import pytest
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+BUILD_ROOT = REPO_ROOT / "build"
+if str(BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(BUILD_ROOT))
+
+from release import auth  # noqa: E402
+
+TOKEN = "pypi-" + "A" * 30
+
+COMMENTED_TEMPLATE = """\
+# keep me: why this file exists
+# second comment line
+
+[distutils]
+index-servers =
+    pypi
+
+[pypi]
+repository = https://upload.pypi.org/legacy/
+username = __token__
+password = pypi-PASTE-YOUR-PRODUCTION-TOKEN-HERE
+
+# [testpypi] commented out on purpose
+# password = pypi-OLD
+"""
+
+
+def test_parse_pypirc_reads_sections_and_ignores_comments():
+    sections = auth.parse_pypirc(COMMENTED_TEMPLATE)
+    assert sections["pypi"]["username"] == "__token__"
+    assert "testpypi" not in sections, "commented-out sections must stay inactive"
+
+
+def test_placeholder_is_detected_as_not_configured(tmp_path):
+    path = tmp_path / ".pypirc"
+    path.write_text(COMMENTED_TEMPLATE, encoding="utf-8")
+    state = auth.credential_state("pypi", path=path, env={})
+    assert not state.configured
+    assert "placeholder" in state.problem
+
+
+def test_missing_file_is_reported(tmp_path):
+    state = auth.credential_state("pypi", path=tmp_path / "nope", env={})
+    assert not state.configured
+    assert "does not exist" in state.problem
+
+
+def test_env_variables_count_as_configured(tmp_path):
+    state = auth.credential_state(
+        "pypi", path=tmp_path / "nope", env={"TWINE_PASSWORD": "pypi-x"}
+    )
+    assert state.configured
+    assert state.source == "environment variables"
+
+
+def test_wrong_username_is_rejected(tmp_path):
+    path = tmp_path / ".pypirc"
+    path.write_text(
+        "[pypi]\nusername = someone@example.com\npassword = pypi-real-token-value\n",
+        encoding="utf-8",
+    )
+    state = auth.credential_state("pypi", path=path, env={})
+    assert not state.configured
+    assert "__token__" in state.problem
+
+
+def test_write_token_replaces_placeholder_and_keeps_comments(tmp_path):
+    path = tmp_path / ".pypirc"
+    path.write_text(COMMENTED_TEMPLATE, encoding="utf-8")
+
+    auth.write_token("pypi", TOKEN, path=path)
+
+    text = path.read_text(encoding="utf-8")
+    assert "# keep me: why this file exists" in text
+    assert "# [testpypi] commented out on purpose" in text
+    assert f"password = {TOKEN}" in text
+    assert "PASTE-YOUR-PRODUCTION-TOKEN-HERE" not in text
+    assert text.count("[pypi]") == 1
+    assert auth.credential_state("pypi", path=path, env={}).configured
+
+
+def test_write_token_adds_missing_section_and_index_servers(tmp_path):
+    path = tmp_path / ".pypirc"
+    path.write_text(COMMENTED_TEMPLATE, encoding="utf-8")
+
+    auth.write_token("testpypi", TOKEN, path=path)
+
+    text = path.read_text(encoding="utf-8")
+    assert "[testpypi]" in text
+    assert auth.index_servers(text) == {"pypi", "testpypi"}
+    assert auth.credential_state("testpypi", path=path, env={}).configured
+    # The production entry must be untouched.
+    assert "PASTE-YOUR-PRODUCTION-TOKEN-HERE" in text
+
+
+def test_write_token_creates_file_when_absent(tmp_path):
+    path = tmp_path / "nested" / ".pypirc"
+    auth.write_token("pypi", TOKEN, path=path)
+
+    assert path.is_file()
+    text = path.read_text(encoding="utf-8")
+    assert "index-servers" in text
+    assert auth.credential_state("pypi", path=path, env={}).configured
+
+
+def test_write_token_updates_existing_password_in_place(tmp_path):
+    path = tmp_path / ".pypirc"
+    auth.write_token("pypi", TOKEN, path=path)
+    replacement = "pypi-" + "B" * 30
+    auth.write_token("pypi", replacement, path=path)
+
+    text = path.read_text(encoding="utf-8")
+    assert f"password = {replacement}" in text
+    assert TOKEN not in text
+    assert text.count("password") == 1
+
+
+def test_upsert_token_does_not_leak_into_the_next_section():
+    text = "[pypi]\nusername = __token__\n\n[testpypi]\nusername = __token__\n"
+    result = auth.upsert_token(text, "pypi", TOKEN)
+    pypi_block, testpypi_block = result.split("[testpypi]")
+    assert TOKEN in pypi_block
+    assert TOKEN not in testpypi_block
+
+
+def test_validate_token_rejects_empty_and_whitespace():
+    assert auth.validate_token("")
+    assert auth.validate_token("pypi-abc def")
+    assert not auth.validate_token(TOKEN)
+
+
+def test_token_warnings_flag_suspicious_pastes():
+    assert any("pypi-" in warning for warning in auth.token_warnings("not-a-token"))
+    assert any("too short" in warning for warning in auth.token_warnings("pypi-abc"))
+    assert auth.token_warnings(TOKEN) == []
+
+
+def test_prompt_never_echoes_the_token(capsys):
+    token = auth.prompt_for_token("pypi", prompt_fn=lambda label: TOKEN)
+    captured = capsys.readouterr()
+    assert token == TOKEN
+    assert TOKEN not in captured.out
+    assert "hidden" in captured.out
+
+
+def test_prompt_abort_returns_none():
+    def _raise(label):
+        raise EOFError
+
+    assert auth.prompt_for_token("pypi", prompt_fn=_raise) is None
+
+
+def test_ensure_credentials_prompts_when_interactive(tmp_path, monkeypatch, capsys):
+    from release import pypi
+
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    monkeypatch.setattr(auth, "prompt_for_token", lambda index, **k: TOKEN)
+    # _ensure_credentials resolves the path through auth.credential_state, so the
+    # monkeypatched pypirc_path applies there too.
+
+    options = pypi.Options(version="1.2.3", apply=True)
+    assert pypi._ensure_credentials(["pypi"], options, interactive=True) is True
+    assert "[ok  ] wrote [pypi] credentials" in capsys.readouterr().out
+    assert auth.credential_state("pypi", path=tmp_path / ".pypirc", env={}).configured
+
+
+def test_ensure_credentials_fails_without_a_terminal(tmp_path, monkeypatch, capsys):
+    from release import pypi
+
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    options = pypi.Options(version="1.2.3", apply=True)
+
+    assert pypi._ensure_credentials(["pypi"], options, interactive=False) is False
+    output = capsys.readouterr().out
+    assert "--set-token pypi" in output
+    assert "prompted" in output
+    assert not (tmp_path / ".pypirc").exists(), "must not write anything when it cannot prompt"
+
+
+def test_ensure_credentials_dry_run_warns_but_continues(tmp_path, monkeypatch, capsys):
+    from release import pypi
+
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    options = pypi.Options(version="1.2.3", apply=False)
+
+    assert pypi._ensure_credentials(["pypi"], options, interactive=False) is True
+    output = capsys.readouterr().out
+    assert "[warn]" in output
+    assert "dry run continues" in output
+
+
+def test_ensure_credentials_reports_testpypi_alternative(tmp_path, monkeypatch, capsys):
+    from release import pypi
+
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    options = pypi.Options(version="1.2.3", apply=True)
+
+    assert pypi._ensure_credentials(["testpypi"], options, interactive=False) is False
+    output = capsys.readouterr().out
+    assert "--set-token testpypi" in output
+    assert "--pypi-only" in output
+
+
+def test_piped_token_is_used_only_once(tmp_path, monkeypatch, capsys):
+    from release import pypi
+
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    options = pypi.Options(version="1.2.3", apply=True, token=TOKEN)
+
+    assert pypi._ensure_credentials(["pypi", "testpypi"], options, interactive=True) is False
+    # Second index had no token left to consume, so it fell back to the prompt,
+    # which is unavailable in tests; nothing may be written for it.
+    assert options.token is None
+    assert auth.credential_state("pypi", path=tmp_path / ".pypirc", env={}).configured
+    assert not auth.credential_state(
+        "testpypi", path=tmp_path / ".pypirc", env={}
+    ).configured
+
+
+def test_section_not_listed_in_index_servers_is_not_configured(tmp_path):
+    """twine only honours sections named in [distutils] index-servers.
+
+    Regression test for a real failure: a hand-added [testpypi] section looked
+    configured to us while twine answered "Missing 'testpypi' section".
+    """
+    path = tmp_path / ".pypirc"
+    path.write_text(
+        "[distutils]\n"
+        "index-servers =\n"
+        "    pypi\n"
+        "\n"
+        "[pypi]\n"
+        "username = __token__\n"
+        "password = pypi-" + "A" * 30 + "\n"
+        "\n"
+        "[testpypi]\n"
+        "username = __token__\n"
+        "password = pypi-" + "B" * 30 + "\n",
+        encoding="utf-8",
+    )
+    state = auth.credential_state("testpypi", path=path, env={})
+    assert not state.configured
+    assert "index-servers" in state.problem
+    assert "--repair" in state.problem
+    # The production index is unaffected.
+    assert auth.credential_state("pypi", path=path, env={}).configured
+
+
+def test_credential_state_agrees_with_twine(tmp_path):
+    """Our verdict must match twine's own resolver for the same file."""
+    twine_utils = pytest.importorskip("twine.utils")
+
+    path = tmp_path / ".pypirc"
+    path.write_text(
+        "[distutils]\n"
+        "index-servers =\n"
+        "    pypi\n"
+        "\n"
+        "[pypi]\n"
+        "username = __token__\n"
+        "password = pypi-" + "A" * 30 + "\n"
+        "\n"
+        "[testpypi]\n"
+        "username = __token__\n"
+        "password = pypi-" + "B" * 30 + "\n",
+        encoding="utf-8",
+    )
+    twine_sees = set(twine_utils.get_config(str(path)))
+    for index in ("pypi", "testpypi"):
+        ours = auth.credential_state(index, path=path, env={})
+        # twine is the authority: we may only claim configured when twine agrees.
+        if ours.configured:
+            assert index in twine_sees, f"{index} accepted by us but ignored by twine"
+
+
+def test_missing_index_servers_key_falls_back_to_both_indexes(tmp_path):
+    """twine's fallback is 'pypi testpypi' only when the key is absent entirely."""
+    path = tmp_path / ".pypirc"
+    text = "[distutils]\nindex-servers =\n    pypi\n\n[ pypi ]\n".replace("[ pypi ]", "[pypi]")
+    path.write_text(text, encoding="utf-8")
+    assert auth.index_servers(path.read_text(encoding="utf-8")) == {"pypi"}
+
+    without_key = path.read_text(encoding="utf-8").replace("index-servers =\n    pypi\n", "")
+    path.write_text(without_key, encoding="utf-8", newline="")
+    assert auth.index_servers(path.read_text(encoding="utf-8")) == {"pypi", "testpypi"}
+
+
+def test_empty_index_servers_honours_nothing(tmp_path):
+    """A trap: `index-servers =` with no entries means twine honours no sections.
+
+    Unlike a missing key, an empty value does not trigger the pypi+testpypi
+    fallback, so a section that looks configured is ignored.
+    """
+    path = tmp_path / ".pypirc"
+    path.write_text(
+        "[distutils]\nindex-servers =\n\n"
+        "[pypi]\nusername = __token__\npassword = pypi-" + "A" * 30 + "\n",
+        encoding="utf-8",
+    )
+    assert auth.index_servers(path.read_text(encoding="utf-8")) == set()
+    state = auth.credential_state("pypi", path=path, env={})
+    assert not state.configured
+    assert "index-servers" in state.problem
+
+    auth.repair_index_servers(path)
+    assert auth.credential_state("pypi", path=path, env={}).configured
+
+
+def test_index_servers_reads_inline_and_continuation_forms():
+    assert auth.index_servers("[distutils]\nindex-servers = pypi testpypi\n") == {
+        "pypi",
+        "testpypi",
+    }
+    assert auth.index_servers("[distutils]\nindex-servers =\n    pypi\n") == {"pypi"}
+    assert auth.index_servers("") == {"pypi", "testpypi"}
+
+
+def test_unlisted_sections_reports_the_gap(tmp_path):
+    path = tmp_path / ".pypirc"
+    path.write_text(
+        "[distutils]\nindex-servers =\n    pypi\n\n"
+        "[pypi]\npassword = pypi-x\n\n"
+        "[testpypi]\npassword = pypi-y\n",
+        encoding="utf-8",
+    )
+    assert auth.unlisted_sections(path) == ["testpypi"]
+
+
+def test_repair_index_servers_fixes_a_hand_edited_file(tmp_path):
+    path = tmp_path / ".pypirc"
+    path.write_text(
+        "[distutils]\nindex-servers =\n    pypi\n\n"
+        "[pypi]\nusername = __token__\npassword = pypi-" + "A" * 30 + "\n\n"
+        "[testpypi]\nusername = __token__\npassword = pypi-" + "B" * 30 + "\n",
+        encoding="utf-8",
+    )
+    assert not auth.credential_state("testpypi", path=path, env={}).configured
+
+    added = auth.repair_index_servers(path)
+
+    assert added == ["testpypi"]
+    assert auth.index_servers(path.read_text(encoding="utf-8")) == {"pypi", "testpypi"}
+    assert auth.credential_state("testpypi", path=path, env={}).configured
+    # Tokens and comments survive the repair.
+    assert "pypi-" + "B" * 30 in path.read_text(encoding="utf-8")
+
+
+def test_repair_index_servers_is_a_no_op_when_correct(tmp_path):
+    path = tmp_path / ".pypirc"
+    auth.write_token("pypi", "pypi-" + "A" * 30, path=path)
+    before = path.read_text(encoding="utf-8")
+    assert auth.repair_index_servers(path) == []
+    assert path.read_text(encoding="utf-8") == before
+
+
+def test_write_token_makes_the_result_visible_to_twine(tmp_path):
+    """The writer must produce a file twine actually honours, not just one we parse."""
+    path = tmp_path / ".pypirc"
+    path.write_text("[distutils]\nindex-servers =\n    pypi\n", encoding="utf-8")
+
+    auth.write_token("testpypi", "pypi-" + "B" * 30, path=path)
+
+    assert auth.credential_state("testpypi", path=path, env={}).configured
+    twine_utils = pytest.importorskip("twine.utils")
+    assert "testpypi" in set(twine_utils.get_config(str(path)))
+
+
+@pytest.mark.parametrize("index", ["pypi", "testpypi"])
+def test_write_then_state_round_trips(tmp_path, index):
+    path = tmp_path / ".pypirc"
+    auth.write_token(index, TOKEN, path=path)
+    state = auth.credential_state(index, path=path, env={})
+    assert state.configured, state.problem

tests/test_release_publish.py

@@ -0,0 +1,624 @@
+"""Tests for the publish gate, the GitHub plan and the PyPI command shape.
+
+Nothing here touches the network, ``gh`` or an index: the mutating paths are
+verified through their pure planning functions, which is exactly what the CLI
+executes after the gate passes.
+"""
+
+from __future__ import annotations
+
+import json
+import subprocess
+import sys
+import urllib.error
+from pathlib import Path
+
+import pytest
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+BUILD_ROOT = REPO_ROOT / "build"
+if str(BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(BUILD_ROOT))
+
+from release import github, publish, pypi  # noqa: E402
+
+
+def _wheel(tmp_path: Path, name: str, payload: bytes = b"wheel") -> Path:
+    path = tmp_path / name
+    path.write_bytes(payload)
+    return path
+
+
+def _report_payload(version: str, wheels: list[Path], **overrides) -> dict:
+    payload = {
+        "schema": 1,
+        "version": version,
+        "ok": True,
+        "aborted": False,
+        "git": {"commit": "a" * 40},
+        "options": {"skip_tests": False, "allow_dirty": False},
+        "wheels": [
+            {"name": wheel.name, "sha256": publish.sha256_file(wheel), "size": wheel.stat().st_size}
+            for wheel in wheels
+        ],
+    }
+    payload.update(overrides)
+    return payload
+
+
+# --- gate -------------------------------------------------------------------
+
+
+def test_gate_passes_for_matching_wheels(tmp_path):
+    wheels = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    problems, warnings = publish.evaluate_gate(
+        _report_payload("1.2.3", wheels), "1.2.3", {w.name: w for w in wheels}
+    )
+    assert problems == []
+    assert warnings == []
+
+
+def test_gate_rejects_version_mismatch(tmp_path):
+    wheels = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    problems, _ = publish.evaluate_gate(
+        _report_payload("9.9.9", wheels), "1.2.3", {w.name: w for w in wheels}
+    )
+    assert any("report is for version" in problem for problem in problems)
+
+
+def test_gate_rejects_failed_report(tmp_path):
+    wheels = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    problems, _ = publish.evaluate_gate(
+        _report_payload("1.2.3", wheels, ok=False), "1.2.3", {w.name: w for w in wheels}
+    )
+    assert any("result is FAIL" in problem for problem in problems)
+
+
+def test_gate_rejects_waived_guard_options(tmp_path):
+    wheels = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    payload = _report_payload("1.2.3", wheels, options={"skip_tests": True, "no_runtime": True})
+    problems, _ = publish.evaluate_gate(payload, "1.2.3", {w.name: w for w in wheels})
+    assert any("--skip-tests" in problem and "--no-runtime" in problem for problem in problems)
+
+
+def test_gate_rejects_changed_wheel(tmp_path):
+    wheels = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    payload = _report_payload("1.2.3", wheels)
+    wheels[0].write_bytes(b"tampered")
+    problems, _ = publish.evaluate_gate(payload, "1.2.3", {w.name: w for w in wheels})
+    assert any("changed after preflight" in problem for problem in problems)
+
+
+def test_gate_rejects_uncertified_and_missing_wheels(tmp_path):
+    wheels = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    payload = _report_payload("1.2.3", wheels)
+    extra = _wheel(tmp_path, "orisys-1.2.3-cp311-cp311-win_amd64.whl")
+    problems, _ = publish.evaluate_gate(
+        payload, "1.2.3", {w.name: w for w in [*wheels, extra]}
+    )
+    assert any("not covered by the report" in problem for problem in problems)
+
+
+def test_gate_warns_on_commit_drift(tmp_path):
+    wheels = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    payload = _report_payload("1.2.3", wheels)
+    problems, warnings = publish.evaluate_gate(
+        payload, "1.2.3", {w.name: w for w in wheels}, head_commit="b" * 40
+    )
+    assert problems == []
+    assert any("HEAD is" in warning for warning in warnings)
+
+
+def test_load_gate_requires_a_report(tmp_path, monkeypatch):
+    monkeypatch.setattr(publish, "REPO_ROOT", tmp_path, raising=False)
+    with pytest.raises(publish.PublishGateError, match="no preflight report"):
+        publish.load_gate(tmp_path, "1.2.3")
+
+
+def test_load_gate_explains_waived_report(tmp_path):
+    report_dir = tmp_path / "build" / "release" / "reports" / "1.2.3"
+    report_dir.mkdir(parents=True)
+    wheel_dir = tmp_path / "SDK" / "1.2.3"
+    wheel_dir.mkdir(parents=True)
+    wheel = wheel_dir / "orisys-1.2.3-cp310-cp310-win_amd64.whl"
+    wheel.write_bytes(b"wheel")
+    (report_dir / "preflight.json").write_text(
+        json.dumps(_report_payload("1.2.3", [wheel], options={"skip_tests": True})),
+        encoding="utf-8",
+    )
+    with pytest.raises(publish.PublishGateError, match="--skip-tests"):
+        publish.load_gate(tmp_path, "1.2.3")
+
+
+def test_load_gate_returns_certified_wheels(tmp_path):
+    report_dir = tmp_path / "build" / "release" / "reports" / "1.2.3"
+    report_dir.mkdir(parents=True)
+    wheel_dir = tmp_path / "SDK" / "1.2.3"
+    wheel_dir.mkdir(parents=True)
+    wheel = wheel_dir / "orisys-1.2.3-cp310-cp310-win_amd64.whl"
+    wheel.write_bytes(b"wheel")
+    (report_dir / "preflight.json").write_text(
+        json.dumps(_report_payload("1.2.3", [wheel])), encoding="utf-8"
+    )
+    gate = publish.load_gate(tmp_path, "1.2.3")
+    assert [record.name for record in gate.wheels] == [wheel.name]
+    assert gate.wheels[0].sha256 == publish.sha256_file(wheel)
+    assert gate.git_commit == "a" * 40
+
+
+# --- github -----------------------------------------------------------------
+
+
+def test_github_steps_shape(tmp_path):
+    assets = [_wheel(tmp_path, f"orisys-1.2.3-cp3n{n}-cp3n{n}-win_amd64.whl") for n in (0, 1)]
+    steps = github.build_github_steps(
+        version="1.2.3",
+        branch="main",
+        tag="v1.2.3",
+        assets=assets,
+        notes_file=None,
+    )
+    by_description = {step.description: step.argv for step in steps}
+    assert by_description["create tag"] == ["git", "tag", "v1.2.3"]
+    assert by_description["push branch"] == ["git", "push", "origin", "main"]
+    assert by_description["push tag"] == ["git", "push", "origin", "v1.2.3"]
+
+    release_argv = by_description["create GitHub Release with assets"]
+    assert release_argv[:2] == ["gh", "release"]
+    assert "v1.2.3" in release_argv
+    assert "--verify-tag" in release_argv
+    assert "--latest" in release_argv
+    assert release_argv[-2:] == [str(asset) for asset in assets]
+
+
+def test_github_steps_include_notes_file(tmp_path):
+    notes = tmp_path / "notes.md"
+    notes.write_text("hello", encoding="utf-8")
+    steps = github.build_github_steps(
+        version="1.2.3", branch="main", tag="v1.2.3", assets=[], notes_file=notes
+    )
+    release_argv = next(
+        step.argv for step in steps if step.description.startswith("create GitHub Release")
+    )
+    assert "--notes-file" in release_argv
+    assert str(notes) in release_argv
+
+
+def test_release_notes_list_every_wheel():
+    notes = github.build_release_notes(
+        "1.2.3", [Path("a.whl"), Path("b.whl")], "c" * 40
+    )
+    assert "a.whl" in notes and "b.whl" in notes
+    assert "cccccccccccc" in notes
+
+
+def test_manifest_scope_excludes_internal_docs():
+    """The public repo must not receive our internal process documents."""
+    entry = github.manifest_entry()
+    docs_entry = next(item for item in entry["sync"] if item["from"] == "docs")
+    assert set(docs_entry["include"]) == {"get_started.md", "api.md"}
+    assert "publishing.md" not in docs_entry["include"]
+    assert "pypi_readme.md" not in docs_entry["include"]
+
+
+def test_manifest_scope_covers_examples_and_sensor_json_only():
+    entry = github.manifest_entry()
+    examples_entry = next(item for item in entry["sync"] if item["from"] == "examples")
+    # Whole tree (no include list), with caches excluded.
+    assert "include" not in examples_entry
+    assert set(examples_entry["exclude"]) >= {"__pycache__", "*.pyc"}
+
+    sensors_entry = next(item for item in entry["sync"] if item["from"] == "sensors")
+    assert sensors_entry["include"]
+    assert all(
+        name.endswith(".json") for name in sensors_entry["include"]
+    ), "binary sensor assets belong in the wheel, not the public repo"
+
+
+def test_github_steps_resume_skips_tag_creation(tmp_path):
+    """A tag pushed by an earlier failed run must not block the release upload."""
+    assets = [_wheel(tmp_path, "orisys-1.2.3-cp310-cp310-win_amd64.whl")]
+    steps = github.build_github_steps(
+        version="1.2.3",
+        branch="main",
+        tag="v1.2.3",
+        assets=assets,
+        notes_file=None,
+        create_tag=False,
+    )
+    descriptions = [step.description for step in steps]
+    assert "create tag" not in descriptions
+    assert descriptions[-1] == "create GitHub Release with assets"
+    # The pushes stay: pushing an up-to-date ref is a safe no-op.
+    assert "push branch" in descriptions and "push tag" in descriptions
+
+
+def test_non_github_remote_is_reported(tmp_path):
+    repo = tmp_path / "release"
+    repo.mkdir()
+    subprocess.run(["git", "init", "-q"], cwd=repo, check=True, capture_output=True)
+    subprocess.run(
+        ["git", "remote", "add", "origin", "ssh://git@internal.example:24928/orisys-tech/orisys-sdk.git"],
+        cwd=repo,
+        check=True,
+        capture_output=True,
+    )
+    problem = github.non_github_remote_problem(repo)
+    assert problem is not None and "not a GitHub host" in problem
+
+    subprocess.run(
+        ["git", "remote", "set-url", "origin", "git@github.com:orisys-tech/orisys-sdk.git"],
+        cwd=repo,
+        check=True,
+        capture_output=True,
+    )
+    assert github.non_github_remote_problem(repo) is None
+
+
+def _synthetic_publish_layout(tmp_path: Path, version: str, *, tag_exists: bool):
+    """Build a fake SDK checkout + release repo and point the module at them."""
+    sdk = tmp_path / "sdk"
+    wheel_dir = sdk / "SDK" / version
+    wheel_dir.mkdir(parents=True)
+    wheels = [wheel_dir / f"orisys-{version}-cp310-cp310-win_amd64.whl"]
+    wheels[0].write_bytes(b"wheel")
+
+    report_dir = sdk / "build" / "release" / "reports" / version
+    report_dir.mkdir(parents=True)
+    (report_dir / "preflight.json").write_text(
+        json.dumps(_report_payload(version, wheels)), encoding="utf-8"
+    )
+
+    release = tmp_path / "orisys-sdk-release"
+    release.mkdir()
+    for command in (
+        ["git", "init", "-q"],
+        ["git", "config", "user.email", "test@example.invalid"],
+        ["git", "config", "user.name", "test"],
+        ["git", "remote", "add", "origin", "git@github.com:orisys-tech/orisys-sdk.git"],
+    ):
+        subprocess.run(command, cwd=release, check=True, capture_output=True)
+    (release / "README.md").write_text("x", encoding="utf-8")
+    subprocess.run(["git", "add", "-A"], cwd=release, check=True, capture_output=True)
+    subprocess.run(["git", "commit", "-qm", "init"], cwd=release, check=True, capture_output=True)
+    if tag_exists:
+        subprocess.run(["git", "tag", f"v{version}"], cwd=release, check=True, capture_output=True)
+
+    manifest = sdk / "tools" / "downstream_sync_manifest.json"
+    manifest.parent.mkdir(parents=True)
+    manifest.write_text(
+        json.dumps(
+            {
+                "version": 1,
+                "downstreams": [
+                    {"name": "orisys-sdk-release", "path": "../orisys-sdk-release", "sync": []}
+                ],
+            }
+        ),
+        encoding="utf-8",
+    )
+    return sdk, release, wheels[0]
+
+
+def test_publish_dry_run_resumes_when_tag_already_exists(tmp_path, monkeypatch, capsys):
+    sdk, release, wheel = _synthetic_publish_layout(tmp_path, "1.2.3", tag_exists=True)
+    monkeypatch.setattr(github, "REPO_ROOT", sdk)
+    monkeypatch.setattr(github, "MANIFEST_PATH", sdk / "tools" / "downstream_sync_manifest.json")
+    monkeypatch.setattr(github, "_check_gh", lambda repo: [])
+    monkeypatch.setattr(github, "_release_exists", lambda repo, tag: False)
+
+    exit_code = github.publish(
+        github.Options(version="1.2.3", apply=False, skip_fetch=True)
+    )
+    output = capsys.readouterr().out
+    assert exit_code == 0
+    assert "already exist" in output and "skipping tag creation" in output
+    assert "git tag v1.2.3" not in output
+    assert "gh release create v1.2.3" in output
+
+
+def test_publish_dry_run_creates_tag_when_absent(tmp_path, monkeypatch, capsys):
+    sdk, release, wheel = _synthetic_publish_layout(tmp_path, "1.2.4", tag_exists=False)
+    monkeypatch.setattr(github, "REPO_ROOT", sdk)
+    monkeypatch.setattr(github, "MANIFEST_PATH", sdk / "tools" / "downstream_sync_manifest.json")
+    monkeypatch.setattr(github, "_check_gh", lambda repo: [])
+    monkeypatch.setattr(github, "_release_exists", lambda repo, tag: False)
+
+    exit_code = github.publish(
+        github.Options(version="1.2.4", apply=False, skip_fetch=True)
+    )
+    output = capsys.readouterr().out
+    assert exit_code == 0
+    assert "git tag v1.2.4" in output
+
+
+def test_publish_refuses_when_release_already_exists(tmp_path, monkeypatch, capsys):
+    sdk, release, wheel = _synthetic_publish_layout(tmp_path, "1.2.5", tag_exists=True)
+    monkeypatch.setattr(github, "REPO_ROOT", sdk)
+    monkeypatch.setattr(github, "MANIFEST_PATH", sdk / "tools" / "downstream_sync_manifest.json")
+    monkeypatch.setattr(github, "_check_gh", lambda repo: [])
+    monkeypatch.setattr(github, "_release_exists", lambda repo, tag: True)
+
+    exit_code = github.publish(
+        github.Options(version="1.2.5", apply=False, skip_fetch=True)
+    )
+    assert exit_code == 1
+    assert "already exists; nothing to publish" in capsys.readouterr().out
+
+
+def _synthetic_report_layout(tmp_path: Path, version: str) -> tuple[Path, Path]:
+    """A fake SDK checkout with wheels and a passing preflight report."""
+    sdk = tmp_path / "sdk"
+    wheel_dir = sdk / "SDK" / version
+    wheel_dir.mkdir(parents=True)
+    wheel = wheel_dir / f"orisys-{version}-cp310-cp310-win_amd64.whl"
+    wheel.write_bytes(b"wheel")
+
+    report_dir = sdk / "build" / "release" / "reports" / version
+    report_dir.mkdir(parents=True)
+    (report_dir / "preflight.json").write_text(
+        json.dumps(_report_payload(version, [wheel])), encoding="utf-8"
+    )
+    return sdk, wheel
+
+
+def test_upload_phases_default_is_testpypi_only():
+    assert pypi.upload_phases(pypi.Options(version="1.2.3")) == ["testpypi"]
+
+
+def test_upload_phases_confirm_pypi_adds_the_real_index():
+    options = pypi.Options(version="1.2.3", confirm_pypi=True)
+    assert pypi.upload_phases(options) == ["testpypi", "pypi"]
+
+
+def test_upload_phases_pypi_only_skips_the_rehearsal():
+    # The relevant case: a production token cannot be used against TestPyPI.
+    assert pypi.upload_phases(pypi.Options(version="1.2.3", pypi_only=True)) == ["pypi"]
+
+
+def test_pypi_only_dry_run_targets_pypi_only(tmp_path, monkeypatch, capsys):
+    sdk, wheel = _synthetic_report_layout(tmp_path, "1.2.3")
+    monkeypatch.setattr(pypi, "REPO_ROOT", sdk)
+    monkeypatch.setattr(pypi, "index_state", lambda index, **k: pypi.IndexState(versions=[]))
+    from release import auth
+
+    auth.write_token("pypi", "pypi-" + "A" * 30, path=tmp_path / ".pypirc")
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+
+    exit_code = pypi.publish(
+        pypi.Options(version="1.2.3", apply=False, pypi_only=True, skip_check=True)
+    )
+    output = capsys.readouterr().out
+    assert exit_code == 0
+    assert "--pypi-only" in output
+    assert "upload 1 wheel(s) to pypi" in output
+    assert "testpypi" not in output
+
+
+def test_pypi_only_and_confirm_pypi_are_mutually_exclusive():
+    from release.cli import _cmd_pypi
+
+    with pytest.raises(SystemExit) as excinfo:
+        _cmd_pypi(["--version", "1.2.3", "--pypi-only", "--confirm-pypi"])
+    assert excinfo.value.code == 2
+
+
+def test_manifest_checks_use_the_python_placeholder():
+    entry = github.manifest_entry()
+    for command in entry["checks"]:
+        assert command.startswith("{python} "), command
+
+
+# --- pypi -------------------------------------------------------------------
+
+
+def test_twine_upload_argv_targets_the_repository():
+    argv = pypi.twine_upload_argv([Path("a.whl")], "testpypi")
+    assert argv[:3] == [sys.executable, "-m", "twine"]
+    assert "--repository" in argv and "testpypi" in argv
+    assert argv[-1] == "a.whl"
+
+
+def test_twine_upload_argv_defaults_to_pypi():
+    argv = pypi.twine_upload_argv([Path("a.whl")], None)
+    assert "--repository" not in argv
+
+
+def test_credentials_hint_points_at_the_setup_command(tmp_path, monkeypatch):
+    from release import auth
+
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    monkeypatch.delenv("TWINE_PASSWORD", raising=False)
+    hint = pypi.credentials_hint("pypi")
+    assert hint is not None
+    assert "release auth --set-token pypi" in hint
+
+
+def test_credentials_hint_for_testpypi_mentions_pypi_only(tmp_path, monkeypatch):
+    from release import auth
+
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    monkeypatch.delenv("TWINE_PASSWORD", raising=False)
+    hint = pypi.credentials_hint("testpypi")
+    assert hint is not None
+    assert "--set-token testpypi" in hint
+    assert "--pypi-only" in hint
+
+
+def test_credentials_hint_silent_when_configured(tmp_path, monkeypatch):
+    from release import auth
+
+    path = tmp_path / ".pypirc"
+    auth.write_token("pypi", "pypi-" + "A" * 30, path=path)
+    monkeypatch.setattr(auth, "pypirc_path", lambda: path)
+    monkeypatch.delenv("TWINE_PASSWORD", raising=False)
+    assert pypi.credentials_hint("pypi") is None
+
+
+def test_index_state_parses_versions(monkeypatch):
+    class Response:
+        def __init__(self, payload):
+            self._payload = json.dumps(payload).encode()
+
+        def read(self, *args):
+            return self._payload
+
+        def __enter__(self):
+            return self
+
+        def __exit__(self, *exc):
+            return False
+
+    monkeypatch.setattr(
+        pypi.urllib.request,
+        "urlopen",
+        lambda *a, **k: Response({"releases": {"1.2.3": [{"filename": "a"}], "0.0.0": []}}),
+    )
+    state = pypi.index_state("pypi")
+    assert state.known
+    assert state.versions == ["1.2.3"]
+
+
+def test_index_state_reports_lookup_failure(monkeypatch):
+    def _raise(*args, **kwargs):
+        raise urllib.error.URLError("offline")
+
+    monkeypatch.setattr(pypi.urllib.request, "urlopen", _raise)
+    state = pypi.index_state("pypi")
+    assert not state.known
+    assert "offline" in state.error
+
+
+def test_index_files_returns_none_when_version_absent(monkeypatch):
+    class Response:
+        def read(self, *args):
+            return json.dumps({"releases": {}}).encode()
+
+        def __enter__(self):
+            return self
+
+        def __exit__(self, *exc):
+            return False
+
+    monkeypatch.setattr(pypi.urllib.request, "urlopen", lambda *a, **k: Response())
+    assert pypi.index_files("pypi", "1.2.3") == (None, None)
+
+
+def test_index_files_distinguishes_lookup_failure_from_absence(monkeypatch):
+    """A network hiccup must not be reported as "not published yet"."""
+
+    def _raise(*args, **kwargs):
+        raise urllib.error.URLError("connection reset")
+
+    monkeypatch.setattr(pypi.urllib.request, "urlopen", _raise)
+    filenames, error = pypi.index_files("testpypi", "1.2.3")
+    assert filenames is None
+    assert error is not None and "connection reset" in error
+
+
+def test_index_files_returns_filenames(monkeypatch):
+    class Response:
+        def read(self, *args):
+            return json.dumps(
+                {"releases": {"1.2.3": [{"filename": "b.whl"}, {"filename": "a.whl"}]}}
+            ).encode()
+
+        def __enter__(self):
+            return self
+
+        def __exit__(self, *exc):
+            return False
+
+    monkeypatch.setattr(pypi.urllib.request, "urlopen", lambda *a, **k: Response())
+    assert pypi.index_files("pypi", "1.2.3") == (["a.whl", "b.whl"], None)
+
+
+def test_wait_for_release_retries_until_indexing_finishes(monkeypatch):
+    """TestPyPI lags the upload response; the check must poll, not give up."""
+    calls = {"n": 0}
+    slept: list[float] = []
+
+    def _fake(index, version, *, timeout=20.0):
+        calls["n"] += 1
+        if calls["n"] < 3:
+            return None, None
+        return ["a.whl"], None
+
+    monkeypatch.setattr(pypi, "index_files", _fake)
+    filenames, error = pypi.wait_for_release(
+        "testpypi", "1.2.3", attempts=5, delay=1.0, sleep=slept.append
+    )
+    assert filenames == ["a.whl"]
+    assert error is None
+    assert calls["n"] == 3
+    assert slept == [1.0, 1.0]
+
+
+def test_wait_for_release_reports_the_last_error(monkeypatch):
+    def _fake(index, version, *, timeout=20.0):
+        return None, "HTTP 503"
+
+    monkeypatch.setattr(pypi, "index_files", _fake)
+    filenames, error = pypi.wait_for_release(
+        "pypi", "1.2.3", attempts=2, delay=0.0, sleep=lambda _: None
+    )
+    assert filenames is None
+    assert error == "HTTP 503"
+
+
+def test_existing_release_state_satisfied_conflict_absent(monkeypatch, capsys):
+    expected = {"orisys-1.2.3-cp310-cp310-win_amd64.whl"}
+    monkeypatch.setattr(pypi, "index_files", lambda i, v, **k: (None, None))
+    assert pypi.existing_release_state("pypi", "1.2.3", expected) == "absent"
+
+    monkeypatch.setattr(pypi, "index_files", lambda i, v, **k: (sorted(expected), None))
+    assert pypi.existing_release_state("pypi", "1.2.3", expected) == "satisfied"
+
+    monkeypatch.setattr(
+        pypi, "index_files", lambda i, v, **k: (["orisys-1.2.3-cp311-cp311-win_amd64.whl"], None)
+    )
+    assert pypi.existing_release_state("pypi", "1.2.3", expected) == "conflict"
+    output = capsys.readouterr().out
+    assert "different file set" in output and "missing" in output
+
+
+def test_publish_rerun_after_success_is_not_a_failure(tmp_path, monkeypatch, capsys):
+    """Re-running a finished phase must succeed, not look like a new error."""
+    sdk, wheel = _synthetic_report_layout(tmp_path, "1.2.3")
+    monkeypatch.setattr(pypi, "REPO_ROOT", sdk)
+    from release import auth
+
+    auth.write_token("pypi", "pypi-" + "A" * 30, path=tmp_path / ".pypirc")
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    monkeypatch.setattr(
+        pypi, "index_files", lambda i, v, **k: ([wheel.name], None)
+    )
+
+    exit_code = pypi.publish(
+        pypi.Options(version="1.2.3", apply=True, pypi_only=True, skip_check=True)
+    )
+    output = capsys.readouterr().out
+    assert exit_code == 0
+    assert "already serves orisys 1.2.3" in output
+    assert "every requested index already has this release" in output
+
+
+def test_publish_aborts_on_a_conflicting_existing_release(tmp_path, monkeypatch, capsys):
+    sdk, wheel = _synthetic_report_layout(tmp_path, "1.2.3")
+    monkeypatch.setattr(pypi, "REPO_ROOT", sdk)
+    from release import auth
+
+    auth.write_token("pypi", "pypi-" + "A" * 30, path=tmp_path / ".pypirc")
+    monkeypatch.setattr(auth, "pypirc_path", lambda: tmp_path / ".pypirc")
+    monkeypatch.setattr(pypi, "index_files", lambda i, v, **k: (["other.whl"], None))
+
+    exit_code = pypi.publish(
+        pypi.Options(version="1.2.3", apply=True, pypi_only=True, skip_check=True)
+    )
+    assert exit_code == 1
+    assert "different file set" in capsys.readouterr().out
+
+
+def test_index_json_urls_cover_both_indexes():
+    assert pypi.INDEX_JSON["testpypi"].startswith("https://test.pypi.org/")
+    assert pypi.INDEX_JSON["pypi"].startswith("https://pypi.org/")

tests/test_release_version.py

@@ -0,0 +1,405 @@
+"""Tests for build/release version guards, report writing and preflight steps."""
+
+from __future__ import annotations
+
+import io
+import json
+import subprocess
+import sys
+import urllib.error
+from pathlib import Path
+
+import pytest
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+BUILD_ROOT = REPO_ROOT / "build"
+if str(BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(BUILD_ROOT))
+
+from release import report as report_mod  # noqa: E402
+from release import version as version_mod  # noqa: E402
+from release.preflight import Preflight, PreflightOptions  # noqa: E402
+
+PYPROJECT = """
+[project]
+name = "orisys"
+description = "synthetic"
+
+[tool.setuptools.dynamic]
+version = {attr = "orisys.__version__"}
+""".lstrip()
+
+
+def _make_repo(tmp_path: Path, *, version: str = "1.2.3", with_git: bool = False) -> Path:
+    (tmp_path / "pyproject.toml").write_text(PYPROJECT, encoding="utf-8")
+    package = tmp_path / "src" / "orisys"
+    package.mkdir(parents=True)
+    (package / "__init__.py").write_text(f'__version__ = "{version}"\n', encoding="utf-8")
+    if with_git:
+        (tmp_path / ".git").mkdir()
+    return tmp_path
+
+
+def _stage_wheel(repo: Path, version: str, name: str | None = None) -> Path:
+    directory = repo / "SDK" / version
+    directory.mkdir(parents=True, exist_ok=True)
+    wheel = directory / (name or f"orisys-{version}-cp310-cp310-win_amd64.whl")
+    wheel.write_bytes(b"not really a wheel")
+    return wheel
+
+
+class _FakeResponse:
+    def __init__(self, payload: dict) -> None:
+        self._buffer = io.BytesIO(json.dumps(payload).encode("utf-8"))
+
+    def read(self, *args):
+        return self._buffer.read(*args)
+
+    def __enter__(self):
+        return self
+
+    def __exit__(self, *exc) -> bool:
+        return False
+
+
+def test_wheel_version_parsing():
+    assert version_mod.wheel_version(Path("orisys-1.2.3-cp310-cp310-win_amd64.whl")) == "1.2.3"
+    assert version_mod.wheel_version(Path("orisys-1.0.0-1-cp312-abi3-manylinux_2_28_x86_64.whl")) == "1.0.0"
+    assert version_mod.wheel_version(Path("something-else.whl")) is None
+
+
+def test_sdk_versions_are_numerically_sorted(tmp_path):
+    for name in ("0.9.0", "0.4.10", "1.2.3"):
+        (tmp_path / "SDK" / name).mkdir(parents=True)
+    (tmp_path / "SDK" / "not-a-version").mkdir()
+    assert version_mod.sdk_versions(tmp_path)[:3] == ["0.4.10", "0.9.0", "1.2.3"]
+
+
+def test_sdk_versions_empty_without_sdk_dir(tmp_path):
+    assert version_mod.sdk_versions(tmp_path) == []
+
+
+def test_sdk_wheels_lists_only_that_version(tmp_path):
+    repo = _make_repo(tmp_path)
+    _stage_wheel(repo, "1.2.3")
+    _stage_wheel(repo, "0.4.3")
+    wheels = version_mod.sdk_wheels(repo, "1.2.3")
+    assert [w.name for w in wheels] == ["orisys-1.2.3-cp310-cp310-win_amd64.whl"]
+
+
+def test_dynamic_version_attr_read_from_pyproject(tmp_path):
+    repo = _make_repo(tmp_path)
+    assert version_mod.dynamic_version_attr(repo) == "orisys.__version__"
+
+
+def test_dynamic_version_attr_none_when_absent(tmp_path):
+    (tmp_path / "pyproject.toml").write_text("[project]\nname = 'x'\n", encoding="utf-8")
+    assert version_mod.dynamic_version_attr(tmp_path) is None
+
+
+def test_pypi_released_versions_parses_response(tmp_path, monkeypatch):
+    fake = _FakeResponse({"releases": {"0.4.2": [{"filename": "a"}], "1.2.3": [{"filename": "b"}], "0.0.0": []}})
+    monkeypatch.setattr(version_mod.urllib.request, "urlopen", lambda *a, **k: fake)
+    versions, error = version_mod.pypi_released_versions()
+    assert error is None
+    # An empty file list means nothing was ever uploaded for that version.
+    assert versions == ["0.4.2", "1.2.3"]
+
+
+def test_pypi_released_versions_reports_http_404_as_empty(monkeypatch):
+    def _raise(*args, **kwargs):
+        raise urllib.error.HTTPError(version_mod.PYPI_JSON_URL, 404, "not found", {}, None)
+
+    monkeypatch.setattr(version_mod.urllib.request, "urlopen", _raise)
+    assert version_mod.pypi_released_versions() == ([], None)
+
+
+def test_pypi_released_versions_returns_error_on_failure(monkeypatch):
+    def _raise(*args, **kwargs):
+        raise urllib.error.URLError("no network")
+
+    monkeypatch.setattr(version_mod.urllib.request, "urlopen", _raise)
+    versions, error = version_mod.pypi_released_versions()
+    assert versions is None
+    assert error and "URLError" in error
+
+
+def test_python_for_tag_uses_envs_root(tmp_path):
+    executable = tmp_path / "py310" / "python.exe"
+    executable.parent.mkdir(parents=True)
+    executable.write_bytes(b"")
+    assert version_mod.python_for_tag("cp310", envs_root=tmp_path) == executable
+    assert version_mod.python_for_tag("cp311", envs_root=tmp_path) is None
+
+
+# --- report -----------------------------------------------------------------
+
+
+def test_write_report_round_trips(tmp_path):
+    payload = {
+        "version": "1.2.3",
+        "ok": False,
+        "git": {"commit": "abc", "branch": "dev", "dirty": True},
+        "interpreter": {"version": "3.10.19", "executable": "python"},
+        "duration_s": 1.5,
+        "options": {"skip_tests": True},
+        "steps": [{"name": "tests", "ok": True, "detail": "skipped", "duration_s": 0.0, "data": {}}],
+        "wheels": [{"name": "w.whl", "size": 12, "sha256": "deadbeef"}],
+    }
+    json_path, text_path = report_mod.write_report(payload, tmp_path / "reports")
+    loaded = json.loads(json_path.read_text(encoding="utf-8"))
+    assert loaded["schema"] == report_mod.SCHEMA_VERSION
+    assert loaded["wheels"][0]["sha256"] == "deadbeef"
+
+    text = text_path.read_text(encoding="utf-8")
+    assert "FAIL" in text
+    assert "deadbeef" in text
+    assert "waived guards: skip_tests" in text
+
+
+# --- preflight steps --------------------------------------------------------
+
+
+def test_preflight_resolves_version_from_pyproject(tmp_path):
+    repo = _make_repo(tmp_path, version="0.6.0")
+    preflight = Preflight(PreflightOptions(), repo_root=repo)
+    assert preflight.version == "0.6.0"
+    assert preflight.version_source == "pyproject.toml dynamic attr"
+
+
+def test_preflight_explicit_version_wins(tmp_path):
+    repo = _make_repo(tmp_path, version="0.6.0")
+    preflight = Preflight(PreflightOptions(version="0.7.0"), repo_root=repo)
+    assert preflight.version == "0.7.0"
+    assert preflight.version_source == "explicit --version"
+
+
+def test_repo_state_fails_outside_git(tmp_path, capsys):
+    repo = _make_repo(tmp_path)
+    step = Preflight(PreflightOptions(), repo_root=repo)._repo_state()
+    assert not step.ok
+    assert "not a git repository" in step.detail
+
+
+def test_version_consistency_detects_mismatch(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    step = Preflight(PreflightOptions(version="9.9.9"), repo_root=repo)._version_consistency()
+    assert not step.ok
+    assert "1.2.3" in step.detail and "9.9.9" in step.detail
+
+
+def test_version_consistency_passes_on_match(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    step = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)._version_consistency()
+    assert step.ok, step.detail
+
+
+def test_duplicate_guard_allows_staged_sdk_dir(tmp_path, monkeypatch):
+    """A populated SDK/<version>/ is the normal preflight input, not a hazard."""
+    repo = _make_repo(tmp_path, version="1.2.3")
+    _stage_wheel(repo, "1.2.3")
+    monkeypatch.setattr(version_mod, "git_tags", lambda root: [])
+    step = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)._duplicate_guard()
+    assert step.ok, step.detail
+    assert "staged wheel(s) to verify" in step.detail
+
+
+def test_duplicate_guard_blocks_released_tag(tmp_path, monkeypatch):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    _stage_wheel(repo, "1.2.3")
+    monkeypatch.setattr(version_mod, "git_tags", lambda root: ["v1.2.3", "v0.5.1"])
+    step = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)._duplicate_guard()
+    assert not step.ok
+    assert "already mark 1.2.3 as released" in step.detail
+    assert "--force" in step.detail
+
+
+def test_duplicate_guard_force_accepts_released_tag(tmp_path, monkeypatch):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    monkeypatch.setattr(version_mod, "git_tags", lambda root: ["1.2.3"])
+    step = Preflight(
+        PreflightOptions(version="1.2.3", force=True), repo_root=repo
+    )._duplicate_guard()
+    assert step.ok, step.detail
+    assert "accepted via --force" in step.detail
+
+
+def test_duplicate_guard_reports_unreleased_version(tmp_path, monkeypatch):
+    repo = _make_repo(tmp_path, version="0.5.3")
+    monkeypatch.setattr(version_mod, "git_tags", lambda root: ["v1.2.3"])
+    step = Preflight(PreflightOptions(version="0.5.3"), repo_root=repo)._duplicate_guard()
+    assert step.ok, step.detail
+    assert "no local git tag marks 0.5.3" in step.detail
+
+
+def test_duplicate_guard_flags_published_version(tmp_path, monkeypatch):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    monkeypatch.setattr(version_mod, "git_tags", lambda root: [])
+    monkeypatch.setattr(version_mod, "pypi_released_versions", lambda *a, **k: (["1.2.3"], None))
+    step = Preflight(
+        PreflightOptions(version="1.2.3", check_pypi=True), repo_root=repo
+    )._duplicate_guard()
+    assert not step.ok
+    assert "already published on PyPI" in step.detail
+
+
+def test_released_tags_for_matches_version_spellings():
+    tags = ["v0.5.1", "0.5.1", "v0.4.3", "0.50"]
+    assert version_mod.released_tags_for("0.5.1", tags) == ["0.5.1", "v0.5.1"]
+    assert version_mod.released_tags_for("1.2.3", tags) == []
+
+
+def test_git_tags_reads_repo_tags(tmp_path):
+    repo = tmp_path / "repo"
+    repo.mkdir()
+    for command in (
+        ["git", "init", "-q"],
+        ["git", "config", "user.email", "test@example.invalid"],
+        ["git", "config", "user.name", "test"],
+    ):
+        subprocess.run(command, cwd=repo, check=True, capture_output=True)
+    (repo / "f.txt").write_text("x", encoding="utf-8")
+    subprocess.run(["git", "add", "f.txt"], cwd=repo, check=True, capture_output=True)
+    subprocess.run(["git", "commit", "-qm", "init"], cwd=repo, check=True, capture_output=True)
+    subprocess.run(["git", "tag", "v1.2.3"], cwd=repo, check=True, capture_output=True)
+
+    assert "v1.2.3" in version_mod.git_tags(repo)
+
+
+def test_version_string_scan_flags_stale_literal(tmp_path):
+    repo = tmp_path / "repo"
+    (repo / "docs").mkdir(parents=True)
+    (repo / "docs" / "a.md").write_text("版本：0.4.0\n", encoding="utf-8")
+    (repo / "README.md").write_text("release 1.2.3\n", encoding="utf-8")
+    hits = version_mod.find_version_literals(repo, "1.2.3")
+    assert [(path, line) for path, line, _ in hits] == [("docs/a.md", 1)]
+
+
+def test_version_string_scan_ignores_dependency_constraints(tmp_path):
+    repo = tmp_path / "repo"
+    repo.mkdir()
+    (repo / "docs.md").write_text(
+        "pip install numpy>=1.24.4 scipy==1.13 opencv-python>=4.10.0.84\n",
+        encoding="utf-8",
+    )
+    assert version_mod.find_version_literals(repo, "1.2.3") == []
+
+
+def test_version_string_scan_honours_allowlist(tmp_path, monkeypatch):
+    monkeypatch.setitem(
+        version_mod.VERSION_STRING_ALLOWLIST, "docs.md", frozenset({"0.4.0"})
+    )
+    repo = tmp_path / "repo"
+    repo.mkdir()
+    (repo / "docs.md").write_text("历史版本：0.4.0\n", encoding="utf-8")
+    assert version_mod.find_version_literals(repo, "1.2.3") == []
+
+
+def test_version_string_scan_skips_tests_directory(tmp_path):
+    repo = tmp_path / "repo"
+    (repo / "tests").mkdir(parents=True)
+    (repo / "tests" / "test_x.py").write_text('v = "0.1.2"\n', encoding="utf-8")
+    assert version_mod.find_version_literals(repo, "1.2.3") == []
+
+
+def test_version_string_scan_accepts_current_version_and_v_prefix(tmp_path):
+    repo = tmp_path / "repo"
+    repo.mkdir()
+    (repo / "README.md").write_text("current 1.2.3 and tag v1.2.3\n", encoding="utf-8")
+    assert version_mod.find_version_literals(repo, "1.2.3") == []
+
+
+def test_preflight_version_strings_step_fails_on_leftover(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    (repo / "docs").mkdir()
+    (repo / "docs" / "guide.md").write_text("版本：0.4.0\n", encoding="utf-8")
+    step = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)._version_strings()
+    assert not step.ok
+    assert "0.4.0" in step.detail
+    assert "VERSION_STRING_ALLOWLIST" in step.detail
+
+
+def test_preflight_version_strings_step_passes_on_clean_tree(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    (repo / "README.md").write_text("no version literal here\n", encoding="utf-8")
+    step = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)._version_strings()
+    assert step.ok, step.detail
+
+
+def test_repo_has_no_stale_version_literals():
+    """The real repository must satisfy its own version-string gate."""
+    from common.pyproject_utils import get_version
+
+    version = get_version(REPO_ROOT)
+    assert version_mod.find_version_literals(REPO_ROOT, version) == []
+
+
+def test_bundle_precheck_fails_when_pattern_resolves_nothing(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    (repo / "pyproject.toml").write_text(
+        PYPROJECT
+        + """
+[[tool.orisys.bundle.items]]
+name = "configs"
+source = "config"
+target = "configs"
+patterns = ["*.json"]
+""",
+        encoding="utf-8",
+    )
+    step = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)._bundle_precheck()
+    assert not step.ok
+    assert "resolved 0 files" in step.detail
+
+
+def test_wheel_inspection_fails_without_wheels(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    step = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)._wheel_inspection()
+    assert not step.ok
+    assert "does not exist" in step.detail
+
+
+def test_wheel_runtime_fails_without_video(tmp_path, monkeypatch):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    _stage_wheel(repo, "1.2.3")
+    monkeypatch.setattr("release.preflight.default_verification_video", lambda root: None)
+    preflight = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)
+    preflight._discover_wheels()
+    step = preflight._wheel_runtime()
+    assert not step.ok
+    assert "never silently skipped" in step.detail
+
+
+def test_wheel_runtime_skip_is_recorded(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    step = Preflight(
+        PreflightOptions(version="1.2.3", no_runtime=True), repo_root=repo
+    )._wheel_runtime()
+    assert step.ok
+    assert "SKIPPED" in step.detail
+
+
+def test_tests_skip_is_loud_and_recorded(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    step = Preflight(
+        PreflightOptions(version="1.2.3", skip_tests=True), repo_root=repo
+    )._tests()
+    assert step.ok
+    assert "SKIPPED" in step.detail
+    assert step.data["status"] == "skipped"
+
+
+def test_execute_marks_failure_and_aborts(tmp_path, capsys):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    preflight = Preflight(PreflightOptions(version="1.2.3"), repo_root=repo)
+    preflight._execute(preflight._repo_state)
+    assert preflight.aborted
+    assert preflight.steps[-1].name == "repo-state"
+    assert not preflight.steps[-1].ok
+
+
+def test_execute_keep_going_does_not_abort(tmp_path):
+    repo = _make_repo(tmp_path, version="1.2.3")
+    preflight = Preflight(PreflightOptions(version="1.2.3", keep_going=True), repo_root=repo)
+    preflight._execute(preflight._repo_state)
+    assert not preflight.aborted

tests/test_signal_processing.py

@@ -2,11 +2,14 @@
 
 from __future__ import annotations
 
+import json
+from pathlib import Path
+
 import numpy as np
 import pytest
 from scipy.signal import butter, filtfilt
 
-from orisys import Sensor
+from orisys import Sensor, configs
 from orisys.signal_processing import (
     NORMAL_FORCE_CAL_OFFSET,
     NORMAL_FORCE_CAL_SLOPE,
@@ -224,12 +227,13 @@ def test_box_read_info_applies_force_calibration_json():
 
 def test_read_info_force_stays_raw_without_calibration_json(monkeypatch):
     monkeypatch.setattr(
-        "orisys.sensor.configs.load_force_calibration",
-        lambda _name: None,
+        "orisys.calibration.load",
+        lambda *args, **kwargs: None,
     )
     sensor = Sensor("external", config_name="box", verbose=False, backend="cpu")
     try:
         assert sensor._force_cal_sensor_name is None
+        assert sensor.calibration is None
         sensor._force_raw = (111.0, -22.0, 33.0)
         sensor._apply_force_filter()
         fn, fx, fy = sensor.read_info(
@@ -262,3 +266,239 @@ def test_configure_hhd_downsample_invalidates_solver_cache():
             sensor.configure(hhd_downsample="nope")
     finally:
         sensor.disconnect()
+
+
+# ------------------------------------------------- bundle resolution anchors
+#
+# The bundle is chosen by the *running* root's folder layout, not by the root's
+# name and not by whichever checkout happens to be importable. These build small
+# real trees, because ``_runtime_roots`` asks the filesystem whether a directory
+# carries ``examples/`` beside ``sensors/``.
+_CAL_DOC = {
+    "schema_version": 2,
+    "unit": "N",
+    "channels": {
+        "normal": {"method": "piecewise_linear", "points": [[0.0, 0.0], [1000.0, 1.0]]},
+        "shear_x": {
+            "method": "piecewise_linear",
+            "signed": True,
+            "points": [[0.0, 0.0], [500.0, 2.0]],
+        },
+        "shear_y": {
+            "method": "piecewise_linear",
+            "signed": True,
+            "points": [[0.0, 0.0], [500.0, 3.0]],
+        },
+    },
+}
+
+
+def _make_root(base, *, name="anything", sensor_json=True, calibration=True):
+    """A runnable SDK root: ``examples/`` beside ``sensors/<name>/``.
+
+    ``sensor.json`` is copied from the shipped bundle because it is a *sensor
+    config*: a stub document would make ``_load_config`` depend on whichever
+    config the machine happens to resolve, which is not what these tests are
+    about.
+    """
+    root = base / name
+    (root / "examples").mkdir(parents=True, exist_ok=True)
+    (root / "examples" / "basic_pipeline.py").write_text("# demo\n", encoding="utf-8")
+    bundle = root / "sensors" / "mini"
+    bundle.mkdir(parents=True, exist_ok=True)
+    if sensor_json:
+        shipped = Path(__file__).resolve().parents[1] / "sensors" / "mini" / "sensor.json"
+        (bundle / "sensor.json").write_text(
+            shipped.read_text(encoding="utf-8"), encoding="utf-8"
+        )
+    if calibration:
+        (bundle / "force_calibration.json").write_text(
+            json.dumps(_CAL_DOC), encoding="utf-8"
+        )
+    return root
+
+
+def _bare_sensor(**attrs):
+    """A Sensor instance without running ``__init__``/``_load_config``.
+
+    The note-formatting helpers touch no sensor state, so a whole sensor (and
+    therefore a whole machine config) is not needed to test them.
+    """
+    sensor = object.__new__(Sensor)
+    for key, value in attrs.items():
+        setattr(sensor, key, value)
+    return sensor
+
+
+def test_runtime_root_anchor_keys_on_layout_not_on_the_folder_name(tmp_path):
+    named = _make_root(tmp_path, name="some-random-name")
+    assert configs._is_sdk_runtime_root(named) is True
+
+    no_examples = tmp_path / "dist-like"
+    (no_examples / "sensors" / "mini").mkdir(parents=True)
+    assert configs._is_sdk_runtime_root(no_examples) is False
+
+    neither = tmp_path / "plain"
+    neither.mkdir()
+    assert configs._is_sdk_runtime_root(neither) is False
+
+
+def test_runtime_roots_walk_up_from_a_subdirectory(tmp_path, monkeypatch):
+    """Launching from ``<root>/examples`` still finds ``<root>``.
+
+    Regression: the ancestor filter used to compare against *every* anchor, so a
+    platform ancestor such as ``D:\\`` disqualified every root and this list came
+    back empty.
+    """
+    root = _make_root(tmp_path, name="renamed-release")
+    subdir = root / "examples"
+    monkeypatch.setattr(configs.Path, "cwd", classmethod(lambda cls: subdir))
+    roots = [str(path) for path in configs._runtime_roots()]
+    assert str(root) in roots, roots
+    # The point of the regression: every returned entry is a genuine runnable
+    # root, never a bare platform ancestor that merely sat above the launcher.
+    for entry in roots:
+        assert configs._is_sdk_runtime_root(Path(entry)), entry
+    assert str(root.parent) not in roots
+    assert str(root.drive + "\\") not in roots
+
+
+def test_a_parent_root_never_outranks_the_root_below_it(tmp_path, monkeypatch):
+    """Walking up must not let a parent's bundle shadow the real run root.
+
+    A parent that itself looks runnable (``examples/`` *and* ``sensors/``) must
+    not outrank the root below it, or its bundle would shadow the one the
+    operator is actually running from.
+    """
+    parent = tmp_path / "workspace"
+    inner = _make_root(parent, name="inner-release")
+    # Give the PARENT its own bundle. ``_make_root(parent, name=…)`` would put
+    # examples/ and sensors/ inside that named child, leaving the parent itself
+    # not runnable -- which is what made this assertion fail twice.
+    (parent / "examples").mkdir(parents=True, exist_ok=True)
+    (parent / "sensors" / "mini").mkdir(parents=True, exist_ok=True)
+    (parent / "sensors" / "mini" / "sensor.json").write_text(
+        "{}", encoding="utf-8"
+    )
+    assert configs._is_sdk_runtime_root(parent) is True
+    assert configs._is_sdk_runtime_root(inner) is True
+
+    monkeypatch.setattr(configs.Path, "cwd", classmethod(lambda cls: inner))
+    roots = [str(path) for path in configs._runtime_roots()]
+    assert str(inner) in roots, roots
+    assert str(parent) not in roots, roots
+    # Nothing nested below the launcher's root may appear either.
+    assert not any(
+        Path(entry).is_relative_to(inner) and entry != str(inner) for entry in roots
+    )
+
+
+def test_the_running_root_bundle_beats_a_calibration_less_checkout(
+    tmp_path, monkeypatch
+):
+    """The reported bug: a nearer bundle without coefficients must not win."""
+    running = _make_root(tmp_path, name="running-root")
+    checkout = _make_root(tmp_path, name="importable-checkout", calibration=False)
+    monkeypatch.setattr(configs, "_runtime_roots", lambda: [running, checkout])
+    # Pinned to real directories, so a leftover or unrelated bundle elsewhere on
+    # the machine cannot decide the outcome.
+    monkeypatch.setattr(
+        configs,
+        "_candidate_sensor_roots",
+        lambda: [running / "sensors", checkout / "sensors"],
+    )
+
+    bundle = configs.resolve_sensor_bundle("mini")
+    assert bundle is not None
+    assert bundle.root == (running / "sensors" / "mini").resolve()
+    assert bundle.force_calibration_json == (
+        running / "sensors" / "mini" / "force_calibration.json"
+    ).resolve()
+
+    # The whole point: the running root's document is the one the SDK loads.
+    from orisys.calibration import load as load_calibration
+
+    cal = load_calibration(sensor_type="mini")
+    assert cal is not None
+    assert cal.schema_version == 2
+    assert sorted(cal.channels) == ["fn", "fx", "fy"]
+    assert cal.source_path == (
+        running / "sensors" / "mini" / "force_calibration.json"
+    ).resolve()
+
+
+def test_a_nearer_bundle_wins_even_without_coefficients(tmp_path, monkeypatch):
+    """Nearest bundle wins, so a calibration-less nearer one hides a farther one.
+
+    That is the chosen precedence (the running root is authoritative), and the
+    diagnostic exists precisely so this stops being silent: this is the shape of
+    the original report, where a checkout's ``mini`` has only ``sensor.json``.
+    """
+    checkout = _make_root(tmp_path, name="checkout", calibration=False)
+    running = _make_root(tmp_path, name="run-root")
+    monkeypatch.setattr(configs, "_runtime_roots", lambda: [checkout, running])
+    monkeypatch.setattr(
+        configs,
+        "_candidate_sensor_roots",
+        lambda: [checkout / "sensors", running / "sensors"],
+    )
+    bundle = configs.resolve_sensor_bundle("mini")
+    assert bundle is not None
+    assert bundle.root == (checkout / "sensors" / "mini").resolve()
+    assert bundle.force_calibration_json is None
+    info = configs.describe_bundle_resolution("mini")
+    assert info["found_root"] == (checkout / "sensors" / "mini").resolve()
+    assert info["force_calibration_json"] is False
+
+
+def test_describe_bundle_resolution_names_the_bundle_and_the_searched_roots(
+    tmp_path, monkeypatch
+):
+    checkout = _make_root(tmp_path, name="checkout", calibration=False)
+    running = _make_root(tmp_path, name="run-root")
+    roots = [checkout / "sensors", running / "sensors"]
+    # Patched at the root list, so no real bundle on this machine can satisfy
+    # the lookup while the "nothing found" case is being asserted.
+    monkeypatch.setattr(configs, "_candidate_sensor_roots", lambda: list(roots))
+
+    info = configs.describe_bundle_resolution("mini")
+    assert info["found_root"] == (checkout / "sensors" / "mini").resolve()
+    assert info["force_calibration_json"] is False
+    assert [str(path) for path in info["searched"]] == [str(p) for p in roots]
+
+    (checkout / "sensors" / "mini" / "sensor.json").unlink()
+    (running / "sensors" / "mini" / "sensor.json").unlink()
+    missing = configs.describe_bundle_resolution("mini")
+    assert missing["found_root"] is None
+    assert missing["sensor_json"] is None
+    assert missing["force_calibration_json"] is False
+
+
+def test_the_calibration_note_names_the_bundle_that_was_found(tmp_path, monkeypatch):
+    """The note explains a bundle with no coefficients, not a "missing file"."""
+    checkout = _make_root(tmp_path, name="checkout", calibration=False)
+    roots = [checkout / "sensors"]
+    monkeypatch.setattr(configs, "_candidate_sensor_roots", lambda: list(roots))
+
+    # Composed via _bare_sensor: the note reads only _force_cal_attempts, so this
+    # needs no machine config and cannot fail on config resolution.
+    sensor = _bare_sensor(
+        _force_cal_attempts=[configs.describe_bundle_resolution("mini")],
+        _force_cal_sensor_name=None,
+    )
+    note = sensor._force_calibration_note()
+    assert "has no force_calibration.json" in note
+    assert str((checkout / "sensors" / "mini").resolve()) in note
+    assert "roots searched" in note
+
+    # No bundle anywhere: say that instead of naming a root.
+    (checkout / "sensors" / "mini" / "sensor.json").unlink()
+    sensor = _bare_sensor(
+        _force_cal_attempts=[configs.describe_bundle_resolution("mini")],
+        _force_cal_sensor_name=None,
+    )
+    note = sensor._force_calibration_note()
+    assert "no sensor bundle resolved" in note
+    # A dict always keys ``found_root``, so guard its value: an unguarded copy of
+    # this branch prints "bundle found at None".
+    assert "None" not in note

tests/test_wheel_build.py

@@ -19,25 +19,25 @@ def wheel_package():
 
 def test_compliant_manylinux_tags(wheel_package):
     assert wheel_package.is_compliant_manylinux_wheel(
-        Path("orisys-0.5.0-cp310-cp310-manylinux_2_17_x86_64.whl")
+        Path("orisys-1.2.3-cp310-cp310-manylinux_2_17_x86_64.whl")
     )
     assert wheel_package.is_compliant_manylinux_wheel(
-        Path("orisys-0.5.0-cp310-cp310-manylinux2014_x86_64.whl")
+        Path("orisys-1.2.3-cp310-cp310-manylinux2014_x86_64.whl")
     )
     assert wheel_package.is_compliant_manylinux_wheel(
-        Path("orisys-0.5.0-cp310-cp310-manylinux_2_28_x86_64.whl")
+        Path("orisys-1.2.3-cp310-cp310-manylinux_2_28_x86_64.whl")
     )
 
 
 def test_rejects_illegal_manylinux_tags(wheel_package):
     assert not wheel_package.is_compliant_manylinux_wheel(
-        Path("orisys-0.5.0-cp310-cp310-manylinux_x86_64.whl")
+        Path("orisys-1.2.3-cp310-cp310-manylinux_x86_64.whl")
     )
     assert not wheel_package.is_compliant_manylinux_wheel(
-        Path("orisys-0.5.0-cp310-cp310-linux_x86_64.whl")
+        Path("orisys-1.2.3-cp310-cp310-linux_x86_64.whl")
     )
     assert not wheel_package.is_compliant_manylinux_wheel(
-        Path("orisys-0.5.0-cp310-cp310-win_amd64.whl")
+        Path("orisys-1.2.3-cp310-cp310-win_amd64.whl")
     )
 
 

tests/test_wheel_contents.py

@@ -0,0 +1,378 @@
+"""Tests for :mod:`common.verify.wheel_contents`.
+
+Every check is exercised in both directions: a well-formed synthetic wheel must
+pass, and each specific defect must fail with the check named in the report.
+Synthetic wheels keep the tests fast and keep them independent of whatever
+happens to sit in ``SDK/``.
+"""
+
+from __future__ import annotations
+
+import base64
+import hashlib
+import sys
+import zipfile
+from pathlib import Path
+
+import pytest
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+BUILD_ROOT = REPO_ROOT / "build"
+if str(BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(BUILD_ROOT))
+
+from common.verify import wheel_contents  # noqa: E402
+from common.verify.wheel_contents import inspect_wheel  # noqa: E402
+
+VERSION = "1.2.3"
+DIST_INFO = f"orisys-{VERSION}.dist-info"
+
+CORE_DEPS = ("numpy>=1.24.4", "opencv-python>=4.10.0.84")
+EXTRAS = {"cuda12": ("cupy-cuda12x>=12.3.0",), "gui": ("open3d>=0.17.0",)}
+
+PYPROJECT = f"""
+[project]
+name = "orisys"
+version = "{VERSION}"
+requires-python = ">=3.10"
+dependencies = [{", ".join(repr(dep) for dep in CORE_DEPS)}]
+
+[project.optional-dependencies]
+cuda12 = ["cupy-cuda12x>=12.3.0"]
+gui = ["open3d>=0.17.0"]
+
+[[tool.orisys.bundle.items]]
+name = "configs"
+source = "config"
+target = "configs"
+patterns = ["*.json"]
+
+[[tool.orisys.bundle.items]]
+name = "sensors"
+source = "sensors"
+target = "sensors"
+patterns = ["**/*.json"]
+preserve_tree = true
+
+[[tool.orisys.bundle.items]]
+name = "docs"
+source = "docs"
+target = "docs"
+patterns = ["*.md"]
+
+[[tool.orisys.bundle.items]]
+name = "examples"
+source = "examples"
+target = "examples"
+patterns = ["*.py", "README.md"]
+preserve_tree = true
+"""
+
+# Source tree files, keyed by path relative to the synthetic repo root.
+SOURCE_FILES = {
+    "config/box.json": '{"name": "box"}',
+    "sensors/box/sensor.json": '{"name": "box"}',
+    "sensors/finger/manifest.json": '{"name": "finger"}',
+    "docs/api.md": "# api\n",
+    "examples/basic_pipeline.py": "print('hi')\n",
+    "examples/README.md": "# examples\n",
+}
+
+# Where each source file must land inside the wheel.
+BUNDLED_ENTRIES = {
+    "orisys/configs/box.json": SOURCE_FILES["config/box.json"],
+    "orisys/sensors/box/sensor.json": SOURCE_FILES["sensors/box/sensor.json"],
+    "orisys/sensors/finger/manifest.json": SOURCE_FILES["sensors/finger/manifest.json"],
+    "orisys/docs/api.md": SOURCE_FILES["docs/api.md"],
+    "orisys/examples/basic_pipeline.py": SOURCE_FILES["examples/basic_pipeline.py"],
+    "orisys/examples/README.md": SOURCE_FILES["examples/README.md"],
+}
+
+
+def _metadata_text(
+    *,
+    version: str = VERSION,
+    requires_python: str | None = ">=3.10",
+    classifiers: tuple[str, ...] = ("Programming Language :: Python :: 3.10",),
+    project_urls: tuple[str, ...] = ("Homepage, https://example.invalid",),
+    license_line: str | None = "License: Proprietary",
+    core_deps: tuple[str, ...] = CORE_DEPS,
+    extras: dict[str, tuple[str, ...]] | None = None,
+    dynamic: tuple[str, ...] = (),
+    name: str = "orisys",
+) -> str:
+    if extras is None:
+        extras = EXTRAS
+    lines = ["Metadata-Version: 2.4", f"Name: {name}", f"Version: {version}", "Summary: synthetic"]
+    if requires_python:
+        lines.append(f"Requires-Python: {requires_python}")
+    if license_line:
+        lines.append(license_line)
+    lines.extend(f"Classifier: {value}" for value in classifiers)
+    lines.extend(f"Project-URL: {value}" for value in project_urls)
+    lines.extend(f"Dynamic: {value}" for value in dynamic)
+    lines.extend(f"Requires-Dist: {dep}" for dep in core_deps)
+    for extra, requirements in extras.items():
+        lines.append(f"Provides-Extra: {extra}")
+        lines.extend(f'Requires-Dist: {req}; extra == "{extra}"' for req in requirements)
+    return "\n".join(lines) + "\n"
+
+
+def _write_source_tree(root: Path) -> None:
+    root.mkdir(parents=True, exist_ok=True)
+    (root / "pyproject.toml").write_text(PYPROJECT, encoding="utf-8")
+    for relative, text in SOURCE_FILES.items():
+        path = root / relative
+        path.parent.mkdir(parents=True, exist_ok=True)
+        # write_bytes, not write_text: text mode would translate "\n" to "\r\n"
+        # on Windows and the byte-for-byte bundle comparison would fail.
+        path.write_bytes(text.encode("utf-8"))
+
+
+def _record(entries: dict[str, bytes]) -> str:
+    lines = []
+    for name, data in sorted(entries.items()):
+        digest = base64.urlsafe_b64encode(hashlib.sha256(data).digest()).rstrip(b"=").decode()
+        lines.append(f"{name},sha256={digest},{len(data)}")
+    lines.append(f"{DIST_INFO}/RECORD,,")
+    return "\n".join(lines) + "\n"
+
+
+def _make_wheel(
+    tmp_path: Path,
+    *,
+    filename: str | None = None,
+    metadata: str | None = None,
+    drop: tuple[str, ...] = (),
+    extra_entries: dict[str, bytes] | None = None,
+    override_bytes: dict[str, bytes] | None = None,
+    drop_record: bool = False,
+    corrupt_record_hash: bool = False,
+) -> tuple[Path, Path]:
+    """Build a synthetic wheel plus its matching source tree."""
+    repo = tmp_path / "repo"
+    _write_source_tree(repo)
+
+    if metadata is None:
+        metadata = _metadata_text()
+
+    entries: dict[str, bytes] = {name: data.encode("utf-8") for name, data in BUNDLED_ENTRIES.items()}
+    entries["orisys/__init__.cp312-win_amd64.pyd"] = b"compiled"
+    entries["orisys_blend/__init__.py"] = b"# blend\n"
+    entries["orisys_blend/kernel.py"] = b"# kernel\n"
+    entries[f"{DIST_INFO}/METADATA"] = metadata.encode("utf-8")
+    entries[f"{DIST_INFO}/WHEEL"] = b"Wheel-Version: 1.0\n"
+
+    entries.update(extra_entries or {})
+    entries.update(override_bytes or {})
+    for name in drop:
+        entries.pop(name, None)
+
+    if not drop_record:
+        record = _record(entries)
+        if corrupt_record_hash:
+            record = record.replace("sha256=", "sha256=AAAA", 1)
+        entries[f"{DIST_INFO}/RECORD"] = record.encode("utf-8")
+
+    wheel = tmp_path / (filename or f"orisys-{VERSION}-cp312-cp312-win_amd64.whl")
+    with zipfile.ZipFile(wheel, "w", zipfile.ZIP_DEFLATED) as zf:
+        for name, data in entries.items():
+            zf.writestr(name, data)
+    return wheel, repo
+
+
+def _failed_names(result) -> set[str]:
+    return {check.name for check in result.failures}
+
+
+@pytest.fixture(autouse=True)
+def _isolated_repo_root(monkeypatch, tmp_path):
+    """Keep inspect_wheel's default repo root from leaking the real repo in."""
+    monkeypatch.setattr(wheel_contents, "REPO_ROOT", tmp_path / "unused")
+
+
+def test_good_wheel_passes(tmp_path):
+    wheel, repo = _make_wheel(tmp_path)
+    result = inspect_wheel(wheel, expected_version=VERSION, repo_root=repo)
+    assert result.ok, result.render()
+    assert result.version == VERSION
+    assert result.platform_tag == "win_amd64"
+    assert not result.warnings, result.warnings
+
+
+def test_missing_wheel_file_fails(tmp_path):
+    result = inspect_wheel(tmp_path / "nope-1.2.3-cp312-cp312-win_amd64.whl")
+    assert not result.ok
+    assert "wheel-exists" in _failed_names(result)
+
+
+def test_unparsable_filename_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, filename="orisys-1.2.3-cp312-cp312.whl")
+    result = inspect_wheel(wheel, repo_root=repo)
+    assert "filename" in _failed_names(result)
+
+
+def test_version_mismatch_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path)
+    result = inspect_wheel(wheel, expected_version="9.9.9", repo_root=repo)
+    failed = _failed_names(result)
+    assert {"filename", "metadata-version"} <= failed
+
+
+def test_missing_requires_python_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, metadata=_metadata_text(requires_python=None))
+    assert "metadata-requires-python" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_missing_classifier_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, metadata=_metadata_text(classifiers=()))
+    assert "metadata-classifiers" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_missing_project_url_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, metadata=_metadata_text(project_urls=()))
+    assert "metadata-project-urls" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_missing_license_fails(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path,
+        metadata=_metadata_text(license_line=None, classifiers=("Intended Audience :: Developers",)),
+    )
+    assert "metadata-license" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_dynamic_version_is_rejected(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, metadata=_metadata_text(dynamic=("version", "summary")))
+    result = inspect_wheel(wheel, repo_root=repo)
+    assert "metadata-no-dynamic-version" in _failed_names(result)
+    assert any("Dynamic" in warning for warning in result.warnings)
+
+
+def test_missing_core_requirement_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, metadata=_metadata_text(core_deps=("numpy>=1.24.4",)))
+    assert "metadata-requires-dist" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_missing_extra_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, metadata=_metadata_text(extras={"cuda12": EXTRAS["cuda12"]}))
+    assert "metadata-extras" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_missing_compiled_extension_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, drop=("orisys/__init__.cp312-win_amd64.pyd",))
+    assert "compiled-extension" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_python_source_leak_fails(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path, extra_entries={"orisys/sensor.py": b"# leaked\n"}
+    )
+    result = inspect_wheel(wheel, repo_root=repo)
+    assert "no-python-sources" in _failed_names(result)
+    assert "orisys/sensor.py" in result.render()
+
+
+def test_example_python_files_are_allowed(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path, extra_entries={"orisys/examples/plot_data.py": b"# shipped on purpose\n"}
+    )
+    assert inspect_wheel(wheel, repo_root=repo).ok
+
+
+def test_missing_bundled_file_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, drop=("orisys/sensors/box/sensor.json",))
+    result = inspect_wheel(wheel, repo_root=repo)
+    assert "bundle-completeness" in _failed_names(result)
+    assert "orisys/sensors/box/sensor.json" in result.render()
+
+
+def test_missing_bundled_file_warns_when_not_strict(tmp_path):
+    """A file added to the tree after an old wheel was built is not a defect."""
+    wheel, repo = _make_wheel(tmp_path, drop=("orisys/sensors/box/sensor.json",))
+    result = inspect_wheel(wheel, repo_root=repo, strict_bundle=False)
+    assert result.ok, result.render()
+    assert any("absent from the wheel" in warning for warning in result.warnings)
+
+
+def test_bundle_drift_is_fatal_when_strict(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path, override_bytes={"orisys/docs/api.md": b"# stale\n"}
+    )
+    assert "bundle-fidelity" in _failed_names(inspect_wheel(wheel, repo_root=repo, strict_bundle=True))
+
+
+def test_bundle_drift_warns_when_not_strict(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path, override_bytes={"orisys/docs/api.md": b"# stale\n"}
+    )
+    result = inspect_wheel(wheel, repo_root=repo, strict_bundle=False)
+    assert result.ok, result.render()
+    assert any("differ from the source tree" in warning for warning in result.warnings)
+
+
+def test_pycache_entry_fails(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path, extra_entries={"orisys/examples/__pycache__/x.pyc": b"junk"}
+    )
+    assert "no-forbidden-entries" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_scratch_directory_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, extra_entries={"tests/test_smoke.py": b"x"})
+    assert "no-forbidden-entries" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_traversing_entry_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, extra_entries={"../escape.txt": b"x"})
+    assert "archive-paths" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_record_hash_mismatch_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, corrupt_record_hash=True)
+    assert "record" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_missing_record_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path, drop_record=True)
+    assert "record" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_size_limit_fails(tmp_path):
+    wheel, repo = _make_wheel(tmp_path)
+    assert "size-limit" in _failed_names(inspect_wheel(wheel, repo_root=repo, max_bytes=1))
+
+
+def test_bad_manylinux_tag_fails(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path, filename=f"orisys-{VERSION}-cp312-cp312-linux_x86_64.whl"
+    )
+    assert "platform-tag" in _failed_names(inspect_wheel(wheel, repo_root=repo))
+
+
+def test_good_manylinux_tag_passes(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path,
+        filename=f"orisys-{VERSION}-cp312-cp312-manylinux_2_28_x86_64.whl",
+    )
+    assert inspect_wheel(wheel, repo_root=repo).ok
+
+
+def test_wrong_distribution_name_fails(tmp_path):
+    wheel, repo = _make_wheel(
+        tmp_path,
+        filename=f"notorisys-{VERSION}-cp312-cp312-win_amd64.whl",
+        metadata=_metadata_text(name="notorisys"),
+    )
+    failed = _failed_names(inspect_wheel(wheel, repo_root=repo))
+    assert {"filename", "metadata-name"} <= failed
+
+
+def test_wheel_layout_module_resolves_to_build_tree():
+    import wheel
+
+    resolved = Path(wheel.__file__).resolve()
+    assert BUILD_ROOT.resolve() in resolved.parents, (
+        f"`wheel` resolved to {resolved}; build/ must precede site-packages so the "
+        "build tooling imports the repository's wheel package."
+    )

tests/test_wheel_setup_metadata.py

@@ -0,0 +1,172 @@
+"""Tests for build/wheel/package.py metadata plumbing.
+
+The Nuitka wheel is built from a generated ``setup.py``, which is exactly where
+the early 0.5.x releases silently lost ``Requires-Python``, classifiers, project URLs
+and the license. These tests run setuptools for real (in a temp dir, on a stub
+package tree) and assert on the METADATA it produces.
+"""
+
+from __future__ import annotations
+
+import subprocess
+import sys
+from pathlib import Path
+
+import pytest
+
+REPO_ROOT = Path(__file__).resolve().parents[1]
+BUILD_ROOT = REPO_ROOT / "build"
+if str(BUILD_ROOT) not in sys.path:
+    sys.path.insert(0, str(BUILD_ROOT))
+
+from wheel.package import metadata_kwargs, read_long_description, write_wheel_setup  # noqa: E402
+
+PROJECT = {
+    "name": "orisys",
+    "description": "SDK for Orisys Technology Visuotactile Sensors",
+    "requires-python": ">=3.10",
+    "license": {"text": "Proprietary"},
+    "authors": [{"name": "Orisys-Tech"}],
+    "maintainers": [{"name": "Yijian Zhang", "email": "zhangyijian@orisys-tech.cn"}],
+    "dependencies": ["numpy>=1.24.4"],
+    "optional-dependencies": {"gui": ["open3d>=0.17.0"]},
+    "classifiers": [
+        "Development Status :: 4 - Beta",
+        "License :: Other/Proprietary License",
+    ],
+    "urls": {
+        "Homepage": "https://www.orisys-tech.cn",
+        "Documentation": "https://github.com/Orisys-Tech/orisys-sdk",
+    },
+}
+
+LONG_DESCRIPTION = "# Orisys SDK\n\nlong description body.\n"
+
+
+def _stub_wheel_root(wheel_dir: Path) -> None:
+    """Minimal package tree so the generated setup.py can build metadata."""
+    (wheel_dir / "wheel_root" / "orisys").mkdir(parents=True)
+    (wheel_dir / "wheel_root" / "orisys" / "__init__.cp312-win_amd64.pyd").write_bytes(b"x")
+    (wheel_dir / "wheel_root" / "orisys" / "examples").mkdir()
+    (wheel_dir / "wheel_root" / "orisys" / "examples" / "__init__.py").write_text("", encoding="utf-8")
+    (wheel_dir / "wheel_root" / "orisys_blend").mkdir()
+    (wheel_dir / "wheel_root" / "orisys_blend" / "__init__.py").write_text("", encoding="utf-8")
+
+
+def _generate(wheel_dir: Path, tmp_path: Path) -> Path:
+    _stub_wheel_root(wheel_dir)
+    write_wheel_setup(
+        wheel_dir,
+        version="1.2.3",
+        package_data={"orisys": ["*.pyd"]},
+        install_requires=["numpy>=1.24.4"],
+        extras_require={"gui": ["open3d>=0.17.0"]},
+        project=PROJECT,
+        long_description=LONG_DESCRIPTION,
+    )
+
+    completed = subprocess.run(
+        [sys.executable, "setup.py", "-q", "dist_info"],
+        cwd=wheel_dir,
+        capture_output=True,
+        text=True,
+        check=False,
+    )
+    assert completed.returncode == 0, (
+        f"generated setup.py failed:\nstdout:\n{completed.stdout}\nstderr:\n{completed.stderr}"
+    )
+
+    candidates = sorted(wheel_dir.glob("**/*.dist-info/METADATA"))
+    assert candidates, f"no METADATA produced under {wheel_dir}"
+    return candidates[0]
+
+
+def test_metadata_kwargs_translates_pyproject():
+    kwargs = metadata_kwargs(PROJECT)
+    assert kwargs["description"] == PROJECT["description"]
+    assert kwargs["python_requires"] == ">=3.10"
+    assert kwargs["license"] == "Proprietary"
+    assert kwargs["classifiers"] == PROJECT["classifiers"]
+    assert kwargs["project_urls"] == PROJECT["urls"]
+    assert kwargs["author"] == "Orisys-Tech"
+    assert kwargs["maintainer"] == "Yijian Zhang <zhangyijian@orisys-tech.cn>"
+
+
+def test_metadata_kwargs_accepts_string_license_and_drops_empties():
+    kwargs = metadata_kwargs({"name": "orisys", "license": "Proprietary"})
+    assert kwargs["license"] == "Proprietary"
+    assert "python_requires" not in kwargs
+    assert "classifiers" not in kwargs
+
+
+def test_read_long_description_uses_pypi_readme(tmp_path):
+    (tmp_path / "docs").mkdir()
+    (tmp_path / "docs" / "pypi_readme.md").write_text(LONG_DESCRIPTION, encoding="utf-8")
+    assert read_long_description(tmp_path) == LONG_DESCRIPTION
+
+
+def test_read_long_description_missing_returns_none(tmp_path, capsys):
+    assert read_long_description(tmp_path) is None
+    assert "not found" in capsys.readouterr().out
+
+
+def test_generated_wheel_metadata_is_complete(tmp_path):
+    wheel_dir = tmp_path / "wheel"
+    wheel_dir.mkdir()
+    metadata_path = _generate(wheel_dir, tmp_path)
+    text = metadata_path.read_text(encoding="utf-8")
+
+    assert "Name: orisys" in text
+    assert "Version: 1.2.3" in text
+    assert f"Summary: {PROJECT['description']}" in text
+    assert "Requires-Python: >=3.10" in text
+    assert "License: Proprietary" in text
+    assert "Classifier: Development Status :: 4 - Beta" in text
+    assert "Classifier: License :: Other/Proprietary License" in text
+    assert "Project-URL: Homepage, https://www.orisys-tech.cn" in text
+    assert "Project-URL: Documentation, https://github.com/Orisys-Tech/orisys-sdk" in text
+    assert "Requires-Dist: numpy>=1.24.4" in text
+    assert 'Provides-Extra: gui' in text
+    assert "Description-Content-Type: text/markdown" in text
+    assert "long description body." in text
+
+
+def test_generated_wheel_metadata_keeps_version_static(tmp_path):
+    """``Version`` (and ``Name``) must never be annotated as dynamic.
+
+    setuptools marks every field supplied through the legacy ``setup()`` path as
+    ``Dynamic:`` even when the value is present and correct (verified by
+    ``test_generated_wheel_metadata_is_complete``). PEP 643 ``Dynamic`` is
+    sdist-only and pip/PyPI ignore it in wheels, so only the identity fields are
+    asserted here.
+    """
+    wheel_dir = tmp_path / "wheel"
+    wheel_dir.mkdir()
+    text = _generate(wheel_dir, tmp_path).read_text(encoding="utf-8")
+    dynamic = {line[len("Dynamic: ") :].strip() for line in text.splitlines() if line.startswith("Dynamic:")}
+    assert "version" not in dynamic, f"wheel METADATA marks Version as dynamic: {sorted(dynamic)}"
+    assert "name" not in dynamic, f"wheel METADATA marks Name as dynamic: {sorted(dynamic)}"
+
+
+def test_write_wheel_setup_without_project_keeps_legacy_shape(tmp_path):
+    """Calling without metadata must not crash (backwards compatible)."""
+    wheel_dir = tmp_path / "wheel"
+    wheel_dir.mkdir()
+    setup_py = write_wheel_setup(
+        wheel_dir,
+        version="0.0.1",
+        package_data={"orisys": ["*.pyd"]},
+        install_requires=["numpy"],
+        extras_require={},
+    )
+    text = setup_py.read_text(encoding="utf-8")
+    assert 'name="orisys"' in text
+    assert 'version="0.0.1"' in text
+    assert "long_description" not in text
+
+
+def test_pypi_readme_exists_in_repo():
+    assert (REPO_ROOT / "docs" / "pypi_readme.md").is_file(), (
+        "docs/pypi_readme.md is the PyPI long description source; without it "
+        "wheels are published with no project description."
+    )

tools/downstream_sync_manifest.json

@@ -5,21 +5,21 @@
       "name": "orisys-sdk-release",
       "path": "../orisys-sdk-release",
       "sync": [
-        {"from": "docs", "to": "docs"},
-        {"from": "examples", "to": "examples", "include": [
-          "README.md",
-          "basic_pipeline.py",
-          "mini_pipeline.py",
-          "finger_pipeline.py",
-          "finger_pipeline_3dview.py",
-          "plot_data.py",
-          "two_sensor_pipeline.py"
-        ]},
-        {"from": "config", "to": "config", "include": ["box.json", "finger.json", "mini.json"]}
+        {"from": "docs", "to": "docs", "include": ["get_started.md", "api.md"]},
+        {"from": "examples", "to": "examples", "exclude": ["__pycache__", "*.pyc", "*.pyo"]},
+        {"from": "config", "to": "config", "include": ["box.json", "finger.json", "mini.json"]},
+        {"from": "sensors", "to": "sensors", "include": [
+          "box/sensor.json",
+          "box/force_calibration.json",
+          "finger/sensor.json",
+          "finger/manifest.json",
+          "mini/sensor.json"
+        ]}
       ],
       "checks": [
-        "python -m py_compile examples/basic_pipeline.py examples/finger_pipeline.py examples/finger_pipeline_3dview.py examples/plot_data.py",
-        "python -c \"import pathlib; p=pathlib.Path('.'); hits=[f for f in p.rglob('*') if f.is_file() and 'examples/products' in f.read_text(encoding='utf-8', errors='ignore').replace('\\\\','/')]; print('stale products paths:' if hits else 'no stale products paths'); [print(x) for x in hits]\""
+        "{python} -c \"import pathlib, py_compile; files=sorted(pathlib.Path('examples').rglob('*.py')); [py_compile.compile(str(f), doraise=True) for f in files]; print('compiled %d example module(s)' % len(files))\"",
+        "{python} -c \"import pathlib, sys; bad=[str(p) for p in pathlib.Path('.').rglob('*') if p.is_file() and p.suffix in ('.md','.py') and 'examples/products' in p.read_text(encoding='utf-8', errors='ignore').replace(chr(92),'/')]; print('stale products paths:' if bad else 'no stale products paths'); [print(' ', x) for x in bad]; sys.exit(1 if bad else 0)\"",
+        "{python} -c \"import pathlib, sys; leaked=[str(p) for p in pathlib.Path('.').rglob('*') if p.name in ('publishing.md','pypi_readme.md')]; print('internal docs leaked into the public repo:', leaked); sys.exit(1 if leaked else 0)\""
       ]
     },
     {
@@ -29,7 +29,7 @@
         {"from": "config", "to": "config", "include": ["box.json", "mini.json", "dd06-ov-0810.json"]}
       ],
       "checks": [
-        "python tests/test_smoke.py"
+        "{python} tests/test_smoke.py"
       ]
     },
     {
@@ -40,8 +40,8 @@
         {"from": "assets/finger", "to": "assets/finger"}
       ],
       "checks": [
-        "python tests/test_smoke.py",
-        "python -c \"import pathlib; t=pathlib.Path('README.md').read_text(encoding='utf-8'); print('README still mentions examples/products' if 'examples/products' in t else 'README products path ok')\""
+        "{python} tests/test_smoke.py",
+        "{python} -c \"import pathlib; t=pathlib.Path('README.md').read_text(encoding='utf-8'); print('README still mentions examples/products' if 'examples/products' in t else 'README products path ok')\""
       ]
     }
   ]

tools/sync_downstreams.py

@@ -2,7 +2,9 @@
 """Plan and apply downstream file syncs from tools/downstream_sync_manifest.json.
 
 The ``apply`` command copies files/directories listed in the manifest. It does
-not delete extra downstream files and does not run downstream tests.
+not delete extra downstream files and does not run downstream tests by default;
+``run-checks`` (or ``release github``) runs the manifest's ``checks`` commands
+with ``{python}`` replaced by the running interpreter.
 """
 
 from __future__ import annotations
@@ -10,13 +12,24 @@ from __future__ import annotations
 import argparse
 import json
 import shutil
+import subprocess
 import sys
+from dataclasses import dataclass
 from pathlib import Path
 
 
 MANIFEST_NAME = "downstream_sync_manifest.json"
 
 
+@dataclass(frozen=True)
+class SyncJob:
+    """One source -> destination copy, with optional name patterns to skip."""
+
+    source: Path
+    dest: Path
+    exclude: tuple[str, ...] = ()
+
+
 def sdk_root() -> Path:
     return Path(__file__).resolve().parent.parent
 
@@ -43,18 +56,19 @@ def selected_downstreams(manifest: dict, target: str | None) -> list[dict]:
     return matches
 
 
-def expand_jobs(root: Path, item: dict) -> list[tuple[Path, Path]]:
+def expand_jobs(root: Path, item: dict) -> list[SyncJob]:
     dest_root = (root / item["path"]).resolve()
-    jobs: list[tuple[Path, Path]] = []
+    jobs: list[SyncJob] = []
     for entry in item.get("sync", []):
         src_base = root / entry["from"]
         dest_base = dest_root / entry["to"]
+        exclude = tuple(entry.get("exclude") or ())
         includes = entry.get("include")
         if includes:
             for name in includes:
-                jobs.append((src_base / name, dest_base / name))
+                jobs.append(SyncJob(src_base / name, dest_base / name, exclude))
         else:
-            jobs.append((src_base, dest_base))
+            jobs.append(SyncJob(src_base, dest_base, exclude))
     return jobs
 
 
@@ -68,8 +82,9 @@ def print_plan(root: Path, items: list[dict]) -> None:
         jobs = expand_jobs(root, item)
         if jobs:
             print("sync:")
-            for src, dest in jobs:
-                print(f"  {src} -> {dest}")
+            for job in jobs:
+                note = f"  (excluding {', '.join(job.exclude)})" if job.exclude else ""
+                print(f"  {job.source} -> {job.dest}{note}")
         else:
             print("sync: (none)")
         checks = item.get("checks") or []
@@ -94,14 +109,14 @@ def check_paths(root: Path, items: list[dict]) -> int:
         else:
             print(f"MISS downstream root: {dest_root}")
             missing.append(str(dest_root))
-        for src, dest in expand_jobs(root, item):
-            src_ok = src.exists()
-            dest_note = "exists" if dest.exists() else "missing (ok until apply)"
+        for job in expand_jobs(root, item):
+            src_ok = job.source.exists()
+            dest_note = "exists" if job.dest.exists() else "missing (ok until apply)"
             status = "ok  " if src_ok else "MISS"
-            print(f"{status} source: {src}")
-            print(f"     dest:   {dest} [{dest_note}]")
+            print(f"{status} source: {job.source}")
+            print(f"     dest:   {job.dest} [{dest_note}]")
             if not src_ok:
-                missing.append(str(src))
+                missing.append(str(job.source))
         print()
     if missing:
         print(f"{len(missing)} missing path(s).")
@@ -110,14 +125,16 @@ def check_paths(root: Path, items: list[dict]) -> int:
     return 0
 
 
-def copy_job(src: Path, dest: Path) -> None:
-    if not src.exists():
-        raise FileNotFoundError(src)
-    if src.is_dir():
-        shutil.copytree(src, dest, dirs_exist_ok=True)
+def copy_job(job: SyncJob) -> None:
+    if not job.source.exists():
+        raise FileNotFoundError(job.source)
+    if job.source.is_dir():
+        # exclude keeps caches out of the public repo (e.g. __pycache__, *.pyc)
+        ignore = shutil.ignore_patterns(*job.exclude) if job.exclude else None
+        shutil.copytree(job.source, job.dest, dirs_exist_ok=True, ignore=ignore)
         return
-    dest.parent.mkdir(parents=True, exist_ok=True)
-    shutil.copy2(src, dest)
+    job.dest.parent.mkdir(parents=True, exist_ok=True)
+    shutil.copy2(job.source, job.dest)
 
 
 def apply_sync(root: Path, items: list[dict]) -> int:
@@ -128,16 +145,45 @@ def apply_sync(root: Path, items: list[dict]) -> int:
     copied = 0
     for item in items:
         print(f"== {item['name']} ==")
-        for src, dest in expand_jobs(root, item):
-            copy_job(src, dest)
+        for job in expand_jobs(root, item):
+            copy_job(job)
             copied += 1
-            print(f"copied {src} -> {dest}")
+            print(f"copied {job.source} -> {job.dest}")
         print()
     print(f"copied {copied} sync job(s).")
     print("checks were not run; execute the listed check commands manually.")
     return 0
 
 
+def run_checks(root: Path, items: list[dict], *, python: str | None = None) -> int:
+    """Run each manifest ``checks`` command inside the downstream repo.
+
+    ``{python}`` in a command is replaced with ``python`` (or the interpreter
+    given). Returns the number of failed checks.
+    """
+    interpreter = python or sys.executable
+    failures = 0
+    for item in items:
+        dest_root = (root / item["path"]).resolve()
+        checks = item.get("checks") or []
+        if not checks:
+            continue
+        print(f"== {item['name']} ==")
+        for command in checks:
+            resolved = command.replace("{python}", interpreter)
+            print(f"running: {resolved}")
+            completed = subprocess.run(
+                resolved, shell=True, cwd=dest_root, check=False
+            )
+            if completed.returncode != 0:
+                print(f"[FAIL] exit {completed.returncode}: {resolved}")
+                failures += 1
+            else:
+                print("[ok  ] check passed")
+        print()
+    return failures
+
+
 def parse_args(argv: list[str]) -> argparse.Namespace:
     parser = argparse.ArgumentParser(description=__doc__)
     sub = parser.add_subparsers(dest="command", required=True)
@@ -151,6 +197,9 @@ def parse_args(argv: list[str]) -> argparse.Namespace:
     apply_cmd = sub.add_parser("apply", help="copy manifest sources to downstreams")
     apply_cmd.add_argument("--target", help="limit to one downstream name")
 
+    run = sub.add_parser("run-checks", help="run the manifest checks in each downstream")
+    run.add_argument("--target", help="limit to one downstream name")
+
     return parser.parse_args(argv)
 
 
@@ -165,6 +214,8 @@ def main(argv: list[str] | None = None) -> int:
         return check_paths(root, items)
     if args.command == "apply":
         return apply_sync(root, items)
+    if args.command == "run-checks":
+        return 1 if run_checks(root, items) else 0
     raise SystemExit(f"unknown command: {args.command}")