Merge e98f078c1d into 2c136aca74

* fix(ci): SAST actually scans the code + drop deprecated flaky semgrep action

Two real problems in the Static Application Security Testing job:

1. **It scanned a path that no longer exists.** `bandit -r src/` and
   `semgrep … src/` pointed at the repo-root `src/`, but the Python code
   moved to `archive/v1/src/` (64 .py files) when the runtime was rewritten
   in Rust. So the SAST scan matched nothing — a silent no-op (this is also
   why `bandit-results.sarif` was "Path does not exist" on recent runs).
   Fixed both to `archive/v1/src/`.

2. **Deprecated + redundant + flaky semgrep step.** The
   `returntocorp/semgrep-action@v1` step pulled `returntocorp/semgrep-agent:v1`
   from Docker Hub every run (intermittently timing out → red check, e.g. on
   #929) and is EOL. It was redundant: the pip `semgrep --sarif` step is what
   feeds GitHub Security; the action only pushed to the Semgrep cloud app via
   SEMGREP_APP_TOKEN. Removed it and folded its `p/docker` + `p/kubernetes`
   rulesets into the pip semgrep command, so coverage is preserved with no
   Docker pull.

The job stays `continue-on-error: true` (non-gating). YAML validated.

Co-Authored-By: claude-flow <ruv@ruv.net>

* fix(protocol): resolve 0xC511_0004 magic collision (closes #928)

Background

`0xC511_0004` was assigned to two different packet formats in firmware
— `EDGE_FUSED_MAGIC` (ADR-063, 48-byte `edge_fused_vitals_pkt_t`) and
`WASM_OUTPUT_MAGIC` (ADR-040, variable-length `wasm_output_pkt_t`).
Both were transmitted. The sensing-server only had a WASM parser for
that magic and no fused-vitals parser, so on the ESP32-C6 + MR60BHA2
mmWave configuration the fused-vitals packet was silently misparsed
as a malformed WASM output — `breathing_rate` was read as
`event_count`, mmWave-fused vitals were lost, and spurious WASM events
were emitted to subscribers.

Fix

1. Reassign `WASM_OUTPUT_MAGIC` to `0xC511_0007` (next free slot per
   the registry in `rv_feature_state.h`). Smaller blast radius than
   moving fused-vitals — the registry already treats `0xC511_0004` as
   fused-vitals canonical and several years of deployed feature
   tracking depends on that assignment.

2. Add `parse_edge_fused_vitals` + `EdgeFusedVitalsPacket` in
   `wifi-densepose-sensing-server::main`. Byte layout taken directly
   from `edge_processing.h:129`, mirroring the firmware's
   `_Static_assert(sizeof(edge_fused_vitals_pkt_t) == 48)` so future
   firmware changes that grow the packet will break this parser
   loudly instead of silently.

3. Add a dispatch arm in the UDP receive loop. Fused-vitals is tried
   BEFORE WASM so a stale firmware (still emitting 0xC511_0004 with
   the WASM payload) fails to parse as fused-vitals (size mismatch),
   then fails to parse as WASM (magic mismatch on the new 0x...0007),
   and gets dropped — a deliberate "fail loud" outcome rather than the
   pre-fix silent garbage.

4. Update the registry comment in `rv_feature_state.h` to add the new
   0x...0007 row.

5. Add five tests in a new `issue_928_magic_collision_tests` mod:
   - `parse_edge_fused_vitals_extracts_fields_correctly`
   - `parse_edge_fused_vitals_rejects_short_buffer`
   - `parse_edge_fused_vitals_rejects_wrong_magic`
   - `parse_wasm_output_rejects_legacy_0004_magic`
   - `parse_wasm_output_accepts_new_0007_magic`

WebSocket payload

Fused-vitals now broadcasts as `{"type": "edge_fused_vitals", ...}`
with the mmWave-specific block nested under `mmwave`. Schema is
additive — existing subscribers that only inspect `type` are
unaffected; subscribers that switch on `type` gain a new branch.

Deployment note

This is a wire-protocol change. Firmware older than this commit that
emits WASM output on 0xC511_0004 will lose its WASM event stream
against an updated host (host expects 0xC511_0007). Per the issue
discussion, "fail loud" is preferred to silent misparsing. Operators
running C6+mmWave should reflash firmware concurrent with the host
upgrade.

Test results
  cargo test -p wifi-densepose-sensing-server --no-default-features
  --bin sensing-server
  → 122 passed / 0 failed (5 new + 117 existing, unchanged)

Co-Authored-By: claude-flow <ruv@ruv.net>

.github/workflows/ci.yml

@@ -108,16 +108,18 @@ jobs:
     - name: Install Rust toolchain
       uses: dtolnay/rust-toolchain@stable
 
-    - name: Cache cargo
-      uses: actions/cache@v4
+    # Swatinem/rust-cache replaces a naive `actions/cache` of the whole
+    # `v2/target`. That manual cache of a 38-crate target dir (multi-GB) was an
+    # intermittent failure source — several CI runs this cycle died at the
+    # cache/setup step (after toolchain install, before "Run Rust tests"),
+    # needing a rerun. rust-cache is purpose-built for Rust: it caches the
+    # registry + git + a pruned target, evicts stale deps, and restores far more
+    # reliably (and faster) on large workspaces. `workspaces: v2` points it at
+    # the v2/ cargo workspace (keys on v2/Cargo.lock, caches v2/target).
+    - name: Cache cargo (Swatinem/rust-cache)
+      uses: Swatinem/rust-cache@v2
       with:
-        path: |
-          ~/.cargo/registry
-          ~/.cargo/git
-          v2/target
-        key: ${{ runner.os }}-cargo-${{ hashFiles('v2/Cargo.lock') }}
-        restore-keys: |
-          ${{ runner.os }}-cargo-
+        workspaces: v2
 
     - name: Run Rust tests
       working-directory: v2

.github/workflows/security-scan.yml

@@ -46,7 +46,10 @@ jobs:
 
     - name: Run Bandit security scan
       run: |
-        bandit -r src/ -f sarif -o bandit-results.sarif
+        # The Python codebase lives under archive/v1/src (it moved there when
+        # the runtime was rewritten in Rust). Scanning `src/` matched nothing,
+        # so this SAST step was a silent no-op.
+        bandit -r archive/v1/src/ -f sarif -o bandit-results.sarif
       continue-on-error: true
 
     - name: Upload Bandit results to GitHub Security
@@ -57,22 +60,20 @@ jobs:
         sarif_file: bandit-results.sarif
         category: bandit
 
-    - name: Run Semgrep security scan
-      continue-on-error: true
-      uses: returntocorp/semgrep-action@v1
-      with:
-        config: >-
-          p/security-audit
-          p/secrets
-          p/python
-          p/docker
-          p/kubernetes
-      env:
-        SEMGREP_APP_TOKEN: ${{ secrets.SEMGREP_APP_TOKEN }}
-        
-    - name: Generate Semgrep SARIF
+    # Removed the deprecated `returntocorp/semgrep-action@v1` step: it was
+    # redundant (the pip `semgrep --sarif` below is what feeds GitHub Security;
+    # the action only pushed to the Semgrep cloud app via SEMGREP_APP_TOKEN) and
+    # it pulled `returntocorp/semgrep-agent:v1` from Docker Hub on every run,
+    # which intermittently timed out and turned this check red. The pip semgrep
+    # (installed above) needs no Docker pull. The action's `p/docker` +
+    # `p/kubernetes` rulesets are folded into the command below so coverage is
+    # preserved.
+    - name: Run Semgrep + generate SARIF
       run: |
-        semgrep --config=p/security-audit --config=p/secrets --config=p/python --sarif --output=semgrep.sarif src/
+        semgrep \
+          --config=p/security-audit --config=p/secrets --config=p/python \
+          --config=p/docker --config=p/kubernetes \
+          --sarif --output=semgrep.sarif archive/v1/src/
       continue-on-error: true
 
     - name: Upload Semgrep results to GitHub Security

CHANGELOG.md

@@ -12,6 +12,10 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 - **MQTT multi-node deployments now create one Home-Assistant device per node — closes #898.** After the #872 MQTT wiring landed, the JSON→`VitalsSnapshot` bridge hard-coded a single `node_id` (the MQTT client id) and the publisher used a single `OwnedDiscoveryBuilder`, so every physical node collapsed into one device (`identifiers:["wifi_densepose_wifi-densepose-1"]`), contradicting the "one device per node" docs. The bridge now emits one snapshot per node in the sensing update's `nodes[]` (each with its own `node_id` + RSSI, falling back to a single aggregate snapshot for wifi/simulate sources), and the publisher derives a per-node builder (`OwnedDiscoveryBuilder::for_node`) that publishes discovery + availability lazily on first sight of each `node_id` and routes state to per-node topics — yielding N distinct HA devices with per-node availability/LWT. Unit-tested (distinct nodes → distinct `wifi_densepose_<node>` identifiers); 71 MQTT tests pass.
 - **Person count no longer pinned to 1 — addresses #803.** The aggregate occupancy reported by the sensing server was derived from `smoothed_person_score`, an EMA-smoothed *activity* score (amplitude variance / motion / spectral energy). That score saturates near a single occupant — one moving person maxes it out — so it cannot discriminate occupancy *count* and stayed clamped at 1 across S3/C6 and the Python/Docker/Rust servers. Meanwhile the count-aware per-node estimates the ESP32 paths already compute (firmware `n_persons`, and the DynamicMinCut `corr_persons`) were stashed in `NodeState::prev_person_count` and then **discarded** by the aggregator (same dead-wiring class as #872). The aggregator now takes `max(activity_count, node_max)` via a unit-tested `aggregate_person_count` helper, so a node positively estimating 2–3 occupants is surfaced instead of overwritten. The fix can only ever *raise* the count when a node reports more people, so the single-occupant case is provably never inflated (regression-guarded by test). **Second half:** the pure-CSI per-node path itself clamped its own estimate — the DynamicMinCut occupancy (`estimate_persons_from_correlation`, 0–3) was mapped to a score via `corr_persons / 3.0`, putting 2 people at 0.667, *just under* the 0.70 up-threshold of `score_to_person_count`, so the per-node count never climbed past 1 (so `node_max` was also stuck at 1 for CSI-only nodes). Replaced it with a threshold-aligned `corr_persons_to_score` mapping (1→0.40, 2→0.74, 3→0.96) whose steady state round-trips back to the same count through the EMA + hysteresis, while still gating transient noise. A convergence test replays the exact EMA loop to prove min-cut=2 now reports 2 (and documents that the old `/3.0` mapping reported 1). Full multi-person accuracy still depends on the underlying estimator quality; this removes the two server-side clamps that masked it. 586 sensing-server tests pass.
 - **MQTT publisher now actually runs (`--mqtt`) — closes #872.** The `--mqtt*` flags were defined only in `cli::Args` (dead code, referenced nowhere) while the binary parses a *separate* `main::Args` with no mqtt fields, and `main.rs` never started the `mqtt::` publisher — so MQTT/Home-Assistant integration was completely unwired (`--mqtt` errored as an unexpected argument, and even with the Docker image's `--features mqtt` build the publisher never ran). Earlier attempts chased a Docker *rebuild*; the real cause was disconnected *code*. Extracted the flags into a shared `cli::MqttArgs` (`#[command(flatten)]` into both structs), spawn the publisher on `--mqtt`, and bridge the JSON sensing broadcast into the typed `VitalsSnapshot` stream with a defensive `serde_json::Value` mapping. Verified end-to-end against `mosquitto`: 20 HA auto-discovery entities + live state (presence/person-count/…). 577 (default) / 580 (`--features mqtt`) tests pass.
+- **Mass Casualty triage never reports a survivor with a heartbeat as Deceased (safety) — PR #926.** Both triage paths in `wifi-densepose-mat` — `TriageCalculator::calculate` (`combine_assessments(Absent, None) ⇒ Deceased`) and the detection path `EnsembleClassifier::determine_triage` (`!has_breathing && !has_movement ⇒ Deceased`) — ignored the `heartbeat` field. A survivor with a detectable **pulse** but no sensed breathing/movement (respiratory arrest — the most time-critical *savable* state, Immediate/Red) was therefore reported **Deceased (Black)** and deprioritized for rescue. The domain path was in fact only reachable *because* a heartbeat made `has_vitals()` true, so every "Deceased" was a live person. Both paths now escalate to **Immediate** when a heartbeat is present; total absence of breathing, movement *and* heartbeat is unchanged (domain → `Unknown`, ensemble → `Deceased`). 2 safety regression tests; full MAT suite (177) green.
+- **Per-node Home-Assistant devices now report each node's *own* presence/motion — PR #918.** After the one-device-per-node fan-out landed, the MQTT bridge still applied the *room-level aggregate* `classification` to every node, so in a multi-node deployment a node watching an empty corner inherited another node's "present" (and `motion_level: "absent"` was mis-mapped to full motion). Each node in the broadcast `nodes[]` already carries its own `classification`; the bridge now reads it per node (extracted into a testable `vitals_snapshots_from_sensing_json`), keeping vitals + person count room-level. 4 unit tests.
+- **`--model` gives an actionable diagnostic instead of a cryptic magic error — PR #919 (refs #894).** Passing a HuggingFace `ruvnet/wifi-densepose-pretrained` file (`model.safetensors` / `model-q4.bin` / `model.rvf.jsonl`) to `--model` produced `invalid magic at offset 0: … got 0x77455735`, then a silent fall back to heuristics. The load-failure path now detects the format (safetensors / quantized blob / JSONL manifest) and explains that those files are a different format **and** encoder architecture than the RVF binary container the progressive loader expects, pointing to #894. Pure `diagnose_model_load_error` + 4 tests.
+- **`--export-rvf` no longer silently produces a placeholder model — PR #920.** The `--export-rvf` handler ran *before* `--train`/`--pretrain` and unconditionally wrote placeholder sine-wave weights, so the documented `--train … --export-rvf <path>` workflow short-circuited to a fake model and never trained (while printing "exported successfully"). It now emits the placeholder **container-format demo** only standalone (with a clear warning), and falls through to real training when `--train`/`--pretrain` is set; docs point to `--save-rvf` for the real model. 3 guard tests.
 
 ### Added
 - **WiFi-CSI pose: efficiency frontier + per-room calibration service** (ADR-150 §3.2–3.6). Two beyond-SOTA results on the MM-Fi benchmark, plus the deployment mechanism that resolves real-world generalization:
@@ -33,6 +37,7 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 
 ### Security
 - **ESP32 OTA upload now fails closed when no PSK is provisioned** (#596 audit finding — critical, **breaking change for unprovisioned nodes**). `ota_check_auth()` previously returned `true` when `s_ota_psk[0] == '\0'`, so a freshly-flashed node would accept attacker-controlled firmware over plain HTTP on port 8032 from any host on the WiFi. No Secure Boot V2, no signed-image verification — a single LAN call could brick or backdoor a node. The fix rejects every OTA upload until a PSK is written to NVS (the OTA HTTP server still starts so operators can run `provision.py --ota-psk <hex>` over USB-CDC without reflashing). **Operators affected**: any deployment that relied on the unauthenticated OTA endpoint working out of the box now needs to provision a PSK before subsequent OTA pushes will succeed. Boot-time `ESP_LOGW` makes the new posture visible.
+- **Bearer-token auth accepts the scheme case-insensitively (RFC 6750) — PR #929.** `require_bearer` parsed the `Authorization` header with a case-sensitive `strip_prefix("Bearer ")`, so a *correct* `RUVIEW_API_TOKEN` sent as `Authorization: bearer <token>` (or `BEARER`, or with extra whitespace) was rejected with a confusing 401 — needless friction when enabling auth. The scheme is now matched with `eq_ignore_ascii_case` (per RFC 6750 §2.1 / RFC 7235 §2.1); the token compare is unchanged — still exact and constant-time (`ct_eq`) — so a wrong token or a non-Bearer scheme (`Basic …`) still returns 401. Audited the surrounding code while here: `ct_eq` correctly rejects length mismatch (no prefix-auth bypass) and the middleware fails closed. New `accepts_case_insensitive_bearer_scheme` test.
 - **Path-traversal vulnerabilities patched in five sensing-server endpoints** (closes #615 — critical). New `wifi_densepose_sensing_server::path_safety::safe_id()` enforces `[A-Za-z0-9._-]` only (no leading `.`, max 64 chars) before any user-controlled identifier reaches a `format!()` building a filesystem path. Applied at:
   - `POST /api/v1/recording/start` (`recording.rs` — `session_name`)
   - `GET /api/v1/recording/download/:id` (`recording.rs` — `id`)

docs/user-guide.md

@@ -1048,7 +1048,7 @@ The Rust sensing server binary accepts the following flags:
 | `--dataset` | (none) | Path to dataset directory (MM-Fi or Wi-Pose) |
 | `--dataset-type` | `mmfi` | Dataset format: `mmfi` or `wipose` |
 | `--epochs` | `100` | Training epochs |
-| `--export-rvf` | (none) | Export RVF model container and exit |
+| `--export-rvf` | (none) | Export a **placeholder** RVF container-format demo and exit — **not a trained model**. For a real model use `--train` (+ `--save-rvf`) or download a pretrained encoder. |
 | `--save-rvf` | (none) | Save model state to RVF on shutdown |
 | `--model` | (none) | Load a trained `.rvf` model for inference |
 | `--load-rvf` | (none) | Load model config from RVF container |
@@ -1359,7 +1359,7 @@ docker run --rm \
   -v $(pwd)/output:/output \
   --entrypoint /app/sensing-server \
   ruvnet/wifi-densepose:latest \
-  --train --dataset /data --epochs 100 --export-rvf /output/model.rvf
+  --train --dataset /data --epochs 100 --save-rvf /output/model.rvf
 ```
 
 The pipeline runs 10 phases:

firmware/esp32-csi-node/main/rv_feature_state.h

@@ -12,7 +12,8 @@
  *   0xC5110003 — ADR-069 feature vector (edge_processing.h)
  *   0xC5110004 — ADR-063 fused vitals   (edge_processing.h)
  *   0xC5110005 — ADR-039 compressed CSI (edge_processing.h)
- *   0xC5110006 — ADR-081 feature state  (this file) ← new
+ *   0xC5110006 — ADR-081 feature state  (this file)
+ *   0xC5110007 — ADR-040 WASM output    (wasm_runtime.h, reassigned per issue #928)
  */
 
 #ifndef RV_FEATURE_STATE_H

firmware/esp32-csi-node/main/wasm_runtime.h

@@ -43,7 +43,16 @@
 
 #define WASM_MAX_MODULE_SIZE (128 * 1024)  /**< Max .wasm binary size (128 KB). */
 #define WASM_STACK_SIZE      (8 * 1024)    /**< WASM execution stack (8 KB). */
-#define WASM_OUTPUT_MAGIC    0xC5110004    /**< WASM output packet magic. */
+/* Issue #928: WASM output was originally 0xC5110004, but that magic is
+ * canonically owned by ADR-063 fused vitals (edge_processing.h). Both packets
+ * were transmitted on the same magic, and the host parser only knew the WASM
+ * shape, so on the ESP32-C6 + MR60BHA2 mmWave config the 48-byte fused-vitals
+ * packet was being read as garbage WASM events. Reassigned to 0xC5110007 (next
+ * free slot in the registry — see rv_feature_state.h). Firmware older than
+ * this commit will silently lose its WASM event stream against an updated host
+ * — that's the deliberate "fail loud" choice over silent misparsing.
+ */
+#define WASM_OUTPUT_MAGIC    0xC5110007    /**< WASM output packet magic (post-#928). */
 #define WASM_MAX_EVENTS      16            /**< Max events per output packet. */
 
 /* ---- WASM Event (5 bytes: u8 type + f32 value) ---- */
@@ -54,7 +63,7 @@ typedef struct __attribute__((packed)) {
 
 /* ---- WASM Output Packet ---- */
 typedef struct __attribute__((packed)) {
-    uint32_t magic;         /**< WASM_OUTPUT_MAGIC = 0xC5110004. */
+    uint32_t magic;         /**< WASM_OUTPUT_MAGIC = 0xC5110007 (issue #928). */
     uint8_t  node_id;       /**< ESP32 node identifier. */
     uint8_t  module_id;     /**< Module slot index. */
     uint16_t event_count;   /**< Number of events in this packet. */

pyproject.toml

@@ -135,7 +135,7 @@ dev = [
     "mypy>=1.6.0",
     "pre-commit>=3.5.0",
     "bandit>=1.7.0",
-    "safety>=2.3.0",
+    "safety>=3.8.0",
     "factory-boy>=3.3.0",
     "freezegun>=1.2.0",
     "responses>=0.23.0",

v2/crates/wifi-densepose-mat/src/detection/ensemble.rs

@@ -172,6 +172,14 @@ impl EnsembleClassifier {
         let has_movement = reading.movement.movement_type != MovementType::None;
 
         if !has_breathing && !has_movement {
+            // SAFETY: a detectable heartbeat means the survivor is ALIVE. No
+            // sensed breathing/movement *with* a pulse is respiratory arrest —
+            // the most time-critical savable state (Immediate), never Deceased.
+            // Only the total absence of breathing, movement AND heartbeat is
+            // reported Deceased.
+            if reading.heartbeat.is_some() {
+                return TriageStatus::Immediate;
+            }
             return TriageStatus::Deceased;
         }
 
@@ -295,6 +303,27 @@ mod tests {
         assert_eq!(result.recommended_triage, TriageStatus::Deceased);
     }
 
+    /// SAFETY regression: heartbeat present but no sensed breathing/movement is
+    /// respiratory arrest — Immediate, never Deceased. Only the *total* absence
+    /// of breathing, movement AND heartbeat (the test above) is Deceased.
+    #[test]
+    fn test_heartbeat_with_no_breathing_or_movement_is_immediate() {
+        // breathing: None, heartbeat: Some(72 bpm), movement: None
+        let reading = make_reading(None, Some(72.0), MovementType::None);
+
+        let classifier = EnsembleClassifier::new(EnsembleConfig {
+            min_ensemble_confidence: 0.0,
+            ..EnsembleConfig::default()
+        });
+
+        let result = classifier.classify(&reading);
+        assert_eq!(
+            result.recommended_triage,
+            TriageStatus::Immediate,
+            "a survivor with a pulse must never be triaged Deceased"
+        );
+    }
+
     #[test]
     fn test_ensemble_confidence_weighting() {
         let classifier = EnsembleClassifier::new(EnsembleConfig {

v2/crates/wifi-densepose-mat/src/domain/triage.rs

@@ -104,7 +104,20 @@ impl TriageCalculator {
         let movement_status = Self::assess_movement(vitals);
 
         // Step 4: Combine assessments
-        Self::combine_assessments(breathing_status, movement_status)
+        let status = Self::combine_assessments(breathing_status, movement_status);
+
+        // Step 5: SAFETY OVERRIDE — a detectable heartbeat means the survivor is
+        // ALIVE. `combine_assessments` only sees breathing + movement, so a
+        // person with a pulse but no *sensed* breathing/movement (respiratory
+        // arrest, or breathing too shallow for CSI to pick up) would otherwise
+        // be reported Deceased and deprioritized for rescue. No breathing + a
+        // pulse is the most time-critical *savable* state, so escalate to
+        // Immediate rather than ever calling a survivor with a heartbeat dead.
+        if status == TriageStatus::Deceased && vitals.heartbeat.is_some() {
+            return TriageStatus::Immediate;
+        }
+
+        status
     }
 
     /// Assess breathing status
@@ -217,7 +230,9 @@ enum MovementAssessment {
 #[cfg(test)]
 mod tests {
     use super::*;
-    use crate::domain::{BreathingPattern, ConfidenceScore, MovementProfile};
+    use crate::domain::{
+        BreathingPattern, ConfidenceScore, HeartbeatSignature, MovementProfile, SignalStrength,
+    };
     use chrono::Utc;
 
     fn create_vitals(
@@ -233,6 +248,29 @@ mod tests {
         }
     }
 
+    /// SAFETY regression: a survivor with a detectable heartbeat but no sensed
+    /// breathing or movement is in respiratory arrest — Immediate (Red), and
+    /// must NEVER be reported Deceased. (Before the fix, `combine_assessments`
+    /// ignored heartbeat and returned Deceased; that path was in fact only
+    /// reachable *because* a heartbeat made `has_vitals()` true.)
+    #[test]
+    fn heartbeat_with_no_breathing_or_movement_is_immediate_not_deceased() {
+        let vitals = VitalSignsReading {
+            breathing: None,
+            heartbeat: Some(HeartbeatSignature {
+                rate_bpm: 72.0,
+                variability: 0.1,
+                strength: SignalStrength::Moderate,
+            }),
+            movement: MovementProfile::default(),
+            timestamp: Utc::now(),
+            confidence: ConfidenceScore::new(0.8),
+        };
+        let status = TriageCalculator::calculate(&vitals);
+        assert_eq!(status, TriageStatus::Immediate, "pulse present ⇒ alive");
+        assert_ne!(status, TriageStatus::Deceased);
+    }
+
     #[test]
     fn test_no_vitals_is_unknown() {
         let vitals = create_vitals(None, MovementProfile::default());

v2/crates/wifi-densepose-sensing-server/src/bearer_auth.rs

@@ -100,7 +100,17 @@ pub async fn require_bearer(
         .headers()
         .get(AUTHORIZATION)
         .and_then(|v| v.to_str().ok())
-        .and_then(|s| s.strip_prefix("Bearer "));
+        // RFC 6750 §2.1 / RFC 7235 §2.1: the auth-scheme ("Bearer") is
+        // case-insensitive. Match it as such (and tolerate extra leading
+        // whitespace before the token) so a correct token isn't rejected
+        // just because a client sent `bearer`/`BEARER`. The token compare
+        // below stays exact + constant-time.
+        .and_then(|s| {
+            let (scheme, token) = s.split_once(' ')?;
+            scheme
+                .eq_ignore_ascii_case("Bearer")
+                .then(|| token.trim_start())
+        });
     let ok = supplied
         .map(|s| ct_eq(s.as_bytes(), expected.as_bytes()))
         .unwrap_or(false);
@@ -185,6 +195,31 @@ mod tests {
         );
     }
 
+    #[tokio::test]
+    async fn accepts_case_insensitive_bearer_scheme() {
+        // RFC 6750 §2.1 / RFC 7235 §2.1: the auth-scheme is case-insensitive.
+        // A correct token must authenticate regardless of scheme casing or
+        // extra whitespace; a wrong token must still be rejected.
+        async fn req_status(auth_value: &str) -> StatusCode {
+            let r = wrap(AuthState::from_token("s3cr3t"));
+            let mut req = Request::builder()
+                .method("GET")
+                .uri("/api/v1/info")
+                .body(Body::empty())
+                .unwrap();
+            req.headers_mut()
+                .insert(AUTHORIZATION, auth_value.parse().unwrap());
+            r.oneshot(req).await.unwrap().status()
+        }
+        assert_eq!(req_status("Bearer s3cr3t").await, StatusCode::OK);
+        assert_eq!(req_status("bearer s3cr3t").await, StatusCode::OK);
+        assert_eq!(req_status("BEARER s3cr3t").await, StatusCode::OK);
+        assert_eq!(req_status("Bearer  s3cr3t").await, StatusCode::OK); // extra space
+        // Scheme leniency must NOT weaken the token check.
+        assert_eq!(req_status("bearer nope").await, StatusCode::UNAUTHORIZED);
+        assert_eq!(req_status("Basic s3cr3t").await, StatusCode::UNAUTHORIZED);
+    }
+
     #[tokio::test]
     async fn enabled_blocks_api_with_wrong_bearer() {
         let r = wrap(AuthState::from_token("s3cr3t"));

v2/crates/wifi-densepose-sensing-server/src/csi.rs

@@ -45,13 +45,14 @@ pub fn parse_esp32_vitals(buf: &[u8]) -> Option<Esp32VitalsPacket> {
     })
 }
 
-/// Parse a WASM output packet (magic 0xC511_0004).
+/// Parse a WASM output packet (magic 0xC511_0007 — reassigned per issue #928;
+/// the original 0xC511_0004 collided with ADR-063 fused vitals).
 pub fn parse_wasm_output(buf: &[u8]) -> Option<WasmOutputPacket> {
     if buf.len() < 8 {
         return None;
     }
     let magic = u32::from_le_bytes([buf[0], buf[1], buf[2], buf[3]]);
-    if magic != 0xC511_0004 {
+    if magic != 0xC511_0007 {
         return None;
     }
 

v2/crates/wifi-densepose-sensing-server/src/main.rs

@@ -1114,7 +1114,7 @@ fn parse_esp32_vitals(buf: &[u8]) -> Option<Esp32VitalsPacket> {
     })
 }
 
-// ── ADR-040: WASM Output Packet (magic 0xC511_0004) ───────────────────────────
+// ── ADR-040: WASM Output Packet (magic 0xC511_0007 — reassigned per #928) ─────
 
 /// Single WASM event (type + value).
 #[derive(Debug, Clone, Serialize)]
@@ -1131,13 +1131,14 @@ struct WasmOutputPacket {
     events: Vec<WasmEvent>,
 }
 
-/// Parse a WASM output packet (magic 0xC511_0004).
+/// Parse a WASM output packet (magic 0xC511_0007 — reassigned per issue #928;
+/// the original 0xC511_0004 was a collision with ADR-063 fused vitals).
 fn parse_wasm_output(buf: &[u8]) -> Option<WasmOutputPacket> {
     if buf.len() < 8 {
         return None;
     }
     let magic = u32::from_le_bytes([buf[0], buf[1], buf[2], buf[3]]);
-    if magic != 0xC511_0004 {
+    if magic != 0xC511_0007 {
         return None;
     }
 
@@ -1169,6 +1170,187 @@ fn parse_wasm_output(buf: &[u8]) -> Option<WasmOutputPacket> {
     })
 }
 
+// ── ADR-063: Edge Fused Vitals Packet (magic 0xC511_0004) ─────────────────────
+//
+// 48-byte packed struct emitted by the ESP32-C6 + MR60BHA2 mmWave config when
+// `mmwave_sensor_get_state().detected` is true. Byte layout from
+// `firmware/esp32-csi-node/main/edge_processing.h` line 129 — kept in lockstep
+// with the firmware's `_Static_assert(sizeof(edge_fused_vitals_pkt_t) == 48)`.
+// Issue #928 surfaced that this magic was being parsed as WASM output and the
+// fused vitals were silently lost. Adding the proper parser here.
+
+#[derive(Debug, Clone, Serialize)]
+struct EdgeFusedVitalsPacket {
+    node_id: u8,
+    /// Bit0=presence, Bit1=fall, Bit2=motion, Bit3=mmwave_present.
+    flags: u8,
+    /// Fused breathing rate in BPM (firmware sends BPM*100; we scale here).
+    breathing_rate_bpm: f32,
+    /// Fused heartrate in BPM (firmware sends BPM*10000; we scale here).
+    heartrate_bpm: f32,
+    rssi: i8,
+    n_persons: u8,
+    /// `mmwave_type_t` enum value from firmware.
+    mmwave_type: u8,
+    /// 0-100 fusion quality score.
+    fusion_confidence: u8,
+    motion_energy: f32,
+    presence_score: f32,
+    timestamp_ms: u32,
+    /// Raw mmWave heart rate (BPM).
+    mmwave_hr_bpm: f32,
+    /// Raw mmWave breathing rate (BPM).
+    mmwave_br_bpm: f32,
+    /// Distance to nearest target (cm).
+    mmwave_distance_cm: f32,
+    /// Target count from mmWave.
+    mmwave_targets: u8,
+    /// mmWave signal quality 0-100.
+    mmwave_confidence: u8,
+}
+
+/// Parse an ADR-063 edge fused vitals packet (magic 0xC511_0004, 48 bytes).
+fn parse_edge_fused_vitals(buf: &[u8]) -> Option<EdgeFusedVitalsPacket> {
+    if buf.len() < 48 {
+        return None;
+    }
+    let magic = u32::from_le_bytes([buf[0], buf[1], buf[2], buf[3]]);
+    if magic != 0xC511_0004 {
+        return None;
+    }
+
+    let node_id = buf[4];
+    let flags = buf[5];
+    let breathing_raw = u16::from_le_bytes([buf[6], buf[7]]);
+    let heartrate_raw = u32::from_le_bytes([buf[8], buf[9], buf[10], buf[11]]);
+    let rssi = buf[12] as i8;
+    let n_persons = buf[13];
+    let mmwave_type = buf[14];
+    let fusion_confidence = buf[15];
+    let motion_energy = f32::from_le_bytes([buf[16], buf[17], buf[18], buf[19]]);
+    let presence_score = f32::from_le_bytes([buf[20], buf[21], buf[22], buf[23]]);
+    let timestamp_ms = u32::from_le_bytes([buf[24], buf[25], buf[26], buf[27]]);
+    let mmwave_hr_bpm = f32::from_le_bytes([buf[28], buf[29], buf[30], buf[31]]);
+    let mmwave_br_bpm = f32::from_le_bytes([buf[32], buf[33], buf[34], buf[35]]);
+    let mmwave_distance_cm = f32::from_le_bytes([buf[36], buf[37], buf[38], buf[39]]);
+    let mmwave_targets = buf[40];
+    let mmwave_confidence = buf[41];
+    // buf[42..48] are firmware reserved fields (reserved3 u16 + reserved4 u32).
+
+    Some(EdgeFusedVitalsPacket {
+        node_id,
+        flags,
+        breathing_rate_bpm: breathing_raw as f32 / 100.0,
+        heartrate_bpm: heartrate_raw as f32 / 10000.0,
+        rssi,
+        n_persons,
+        mmwave_type,
+        fusion_confidence,
+        motion_energy,
+        presence_score,
+        timestamp_ms,
+        mmwave_hr_bpm,
+        mmwave_br_bpm,
+        mmwave_distance_cm,
+        mmwave_targets,
+        mmwave_confidence,
+    })
+}
+
+#[cfg(test)]
+mod issue_928_magic_collision_tests {
+    //! Issue #928 — `0xC511_0004` was being parsed as WASM output, eating the
+    //! C6+mmWave fused-vitals packets. After this fix, `0xC511_0004` routes to
+    //! `parse_edge_fused_vitals` and WASM output owns the freshly-allocated
+    //! `0xC511_0007` slot. Tests guard both halves of the swap.
+    use super::*;
+
+    /// Build a 48-byte synthetic fused-vitals packet matching the firmware's
+    /// `edge_fused_vitals_pkt_t` layout from `edge_processing.h:129`.
+    fn build_fused_vitals_packet() -> Vec<u8> {
+        let mut buf = vec![0u8; 48];
+        buf[0..4].copy_from_slice(&0xC511_0004u32.to_le_bytes());
+        buf[4] = 9;                                            // node_id
+        buf[5] = 0b0000_1001;                                   // flags: presence | mmwave_present
+        buf[6..8].copy_from_slice(&1600u16.to_le_bytes());      // breathing 16.00 BPM
+        buf[8..12].copy_from_slice(&720_000u32.to_le_bytes());  // heartrate 72.0 BPM
+        buf[12] = (-55i8) as u8;                                // rssi
+        buf[13] = 1;                                            // n_persons
+        buf[14] = 2;                                            // mmwave_type
+        buf[15] = 85;                                           // fusion_confidence
+        buf[16..20].copy_from_slice(&0.42f32.to_le_bytes());    // motion_energy
+        buf[20..24].copy_from_slice(&0.95f32.to_le_bytes());    // presence_score
+        buf[24..28].copy_from_slice(&1_234_567u32.to_le_bytes()); // timestamp_ms
+        buf[28..32].copy_from_slice(&71.5f32.to_le_bytes());    // mmwave_hr_bpm
+        buf[32..36].copy_from_slice(&15.8f32.to_le_bytes());    // mmwave_br_bpm
+        buf[36..40].copy_from_slice(&182.0f32.to_le_bytes());   // mmwave_distance_cm
+        buf[40] = 1;                                            // mmwave_targets
+        buf[41] = 90;                                           // mmwave_confidence
+        // bytes 42..48 — firmware reserved fields, left as zero
+        buf
+    }
+
+    #[test]
+    fn parse_edge_fused_vitals_extracts_fields_correctly() {
+        let buf = build_fused_vitals_packet();
+        let pkt = parse_edge_fused_vitals(&buf).expect("must parse a well-formed packet");
+        assert_eq!(pkt.node_id, 9);
+        assert_eq!(pkt.flags, 0b0000_1001);
+        assert!((pkt.breathing_rate_bpm - 16.0).abs() < 1e-3, "breathing scale 100");
+        assert!((pkt.heartrate_bpm - 72.0).abs() < 1e-3, "heartrate scale 10000");
+        assert_eq!(pkt.rssi, -55);
+        assert_eq!(pkt.n_persons, 1);
+        assert_eq!(pkt.mmwave_type, 2);
+        assert_eq!(pkt.fusion_confidence, 85);
+        assert!((pkt.motion_energy - 0.42).abs() < 1e-6);
+        assert!((pkt.presence_score - 0.95).abs() < 1e-6);
+        assert_eq!(pkt.timestamp_ms, 1_234_567);
+        assert!((pkt.mmwave_hr_bpm - 71.5).abs() < 1e-6);
+        assert!((pkt.mmwave_br_bpm - 15.8).abs() < 1e-3);
+        assert!((pkt.mmwave_distance_cm - 182.0).abs() < 1e-6);
+        assert_eq!(pkt.mmwave_targets, 1);
+        assert_eq!(pkt.mmwave_confidence, 90);
+    }
+
+    #[test]
+    fn parse_edge_fused_vitals_rejects_short_buffer() {
+        let buf = build_fused_vitals_packet();
+        // Truncate to 47 bytes — one short of the 48-byte minimum.
+        assert!(parse_edge_fused_vitals(&buf[..47]).is_none());
+    }
+
+    #[test]
+    fn parse_edge_fused_vitals_rejects_wrong_magic() {
+        let mut buf = build_fused_vitals_packet();
+        buf[0..4].copy_from_slice(&0xC511_0007u32.to_le_bytes()); // WASM magic, not fused
+        assert!(parse_edge_fused_vitals(&buf).is_none());
+    }
+
+    #[test]
+    fn parse_wasm_output_rejects_legacy_0004_magic() {
+        // The old WASM magic collided with fused vitals — must no longer be
+        // accepted. A real fused-vitals packet starts with 0xC511_0004 and
+        // would have been misparsed before this fix.
+        let buf = build_fused_vitals_packet();
+        assert!(parse_wasm_output(&buf).is_none(),
+                "issue #928: WASM parser must NOT accept 0xC511_0004");
+    }
+
+    #[test]
+    fn parse_wasm_output_accepts_new_0007_magic() {
+        // Build a tiny well-formed WASM output packet on the new magic.
+        let mut buf = vec![0u8; 8];
+        buf[0..4].copy_from_slice(&0xC511_0007u32.to_le_bytes());
+        buf[4] = 5;                                          // node_id
+        buf[5] = 1;                                          // module_id
+        buf[6..8].copy_from_slice(&0u16.to_le_bytes());      // event_count = 0
+        let pkt = parse_wasm_output(&buf).expect("0xC511_0007 must parse");
+        assert_eq!(pkt.node_id, 5);
+        assert_eq!(pkt.module_id, 1);
+        assert!(pkt.events.is_empty());
+    }
+}
+
 // ── ESP32 UDP frame parser ───────────────────────────────────────────────────
 
 fn parse_esp32_frame(buf: &[u8]) -> Option<Esp32Frame> {
@@ -4979,7 +5161,45 @@ async fn udp_receiver_task(state: SharedState, udp_port: u16) {
                     }
                 }
 
-                // ADR-040: Try WASM output packet (magic 0xC511_0004).
+                // ADR-063: Try edge fused vitals packet (magic 0xC511_0004).
+                // Must come BEFORE the WASM parser — issue #928: these two
+                // packet types shared a magic and the WASM parser was eating
+                // fused-vitals frames on the C6+mmWave config. The reassign of
+                // WASM_OUTPUT_MAGIC → 0xC511_0007 (firmware side) plus this
+                // dedicated parser resolve the collision.
+                if let Some(fused) = parse_edge_fused_vitals(&buf[..len]) {
+                    debug!(
+                        "Edge fused vitals from {src}: node={} br={:.1} hr={:.1} \
+                         mmwave_targets={} fusion_conf={}",
+                        fused.node_id, fused.breathing_rate_bpm, fused.heartrate_bpm,
+                        fused.mmwave_targets, fused.fusion_confidence,
+                    );
+                    let s = state.write().await;
+                    if let Ok(json) = serde_json::to_string(&serde_json::json!({
+                        "type": "edge_fused_vitals",
+                        "node_id": fused.node_id,
+                        "breathing_rate_bpm": fused.breathing_rate_bpm,
+                        "heartrate_bpm": fused.heartrate_bpm,
+                        "n_persons": fused.n_persons,
+                        "fusion_confidence": fused.fusion_confidence,
+                        "mmwave": {
+                            "hr_bpm": fused.mmwave_hr_bpm,
+                            "br_bpm": fused.mmwave_br_bpm,
+                            "distance_cm": fused.mmwave_distance_cm,
+                            "targets": fused.mmwave_targets,
+                            "confidence": fused.mmwave_confidence,
+                            "type": fused.mmwave_type,
+                        },
+                        "motion_energy": fused.motion_energy,
+                        "presence_score": fused.presence_score,
+                        "timestamp_ms": fused.timestamp_ms,
+                    })) {
+                        let _ = s.tx.send(json);
+                    }
+                    continue;
+                }
+
+                // ADR-040: Try WASM output packet (magic 0xC511_0007 post-#928).
                 if let Some(wasm_output) = parse_wasm_output(&buf[..len]) {
                     debug!(
                         "WASM output from {src}: node={} module={} events={}",
@@ -5619,6 +5839,16 @@ fn diagnose_model_load_error(path: &std::path::Path, data: &[u8], err: &str) ->
     )
 }
 
+/// Whether `--export-rvf` should emit the placeholder container-format demo.
+///
+/// It must only do so **standalone**. Combined with `--train`/`--pretrain` the
+/// real model is produced by the training pipeline, so short-circuiting here
+/// would silently skip training and write placeholder weights — the #894 bug
+/// where the documented `--train … --export-rvf` workflow produced a fake model.
+fn export_emits_placeholder_demo(export_set: bool, train: bool, pretrain: bool) -> bool {
+    export_set && !train && !pretrain
+}
+
 // ── Main ─────────────────────────────────────────────────────────────────────
 
 /// If `--ui-path` points nowhere (wrong cwd), try common repo layouts relative to cwd.
@@ -5662,9 +5892,24 @@ async fn main() {
         return;
     }
 
-    // Handle --export-rvf mode: build an RVF container package and exit
-    if let Some(ref rvf_path) = args.export_rvf {
-        eprintln!("Exporting RVF container package...");
+    // Handle --export-rvf: writes a CONTAINER-FORMAT DEMO with placeholder
+    // weights — it is NOT a trained model. Only short-circuit when standalone:
+    // combined with --train/--pretrain the real model is exported by the
+    // training pipeline, and short-circuiting here would silently skip training
+    // and write placeholder weights (#894 — the documented `--train …
+    // --export-rvf` workflow produced a placeholder and never trained).
+    if export_emits_placeholder_demo(args.export_rvf.is_some(), args.train, args.pretrain) {
+        let rvf_path = args
+            .export_rvf
+            .as_ref()
+            .expect("export_emits_placeholder_demo implies export_rvf is set");
+        eprintln!(
+            "WARNING: --export-rvf writes a CONTAINER-FORMAT DEMO with placeholder \
+             weights — it is NOT a trained model. Train one with \
+             `--train --dataset <DIR>` (which exports a calibrated .rvf to the \
+             models/ directory), or download a pretrained encoder. See issue #894."
+        );
+        eprintln!("Exporting RVF container package (placeholder weights)...");
         use rvf_pipeline::RvfModelBuilder;
 
         let mut builder = RvfModelBuilder::new("wifi-densepose", "1.0.0");
@@ -5713,6 +5958,13 @@ async fn main() {
             }
         }
         return;
+    } else if args.export_rvf.is_some() {
+        // --export-rvf alongside --train/--pretrain: don't emit a placeholder.
+        // Fall through so training runs; it exports the real calibrated model.
+        eprintln!(
+            "Note: --export-rvf is ignored in training mode — the trained model \
+             is exported by the training pipeline to the models/ directory."
+        );
     }
 
     // Handle --pretrain mode: self-supervised contrastive pretraining (ADR-024)
@@ -7310,3 +7562,29 @@ mod model_load_diagnostic_tests {
         assert!(msg.contains("wifi-densepose-train"), "{msg}");
     }
 }
+
+#[cfg(test)]
+mod export_rvf_mode_tests {
+    use super::export_emits_placeholder_demo;
+
+    #[test]
+    fn standalone_export_emits_placeholder() {
+        // --export-rvf alone → the container-format demo (placeholder weights).
+        assert!(export_emits_placeholder_demo(true, false, false));
+    }
+
+    #[test]
+    fn export_with_train_does_not_short_circuit() {
+        // #894: `--train --export-rvf` must NOT emit a placeholder + skip
+        // training — it must fall through to the real training pipeline.
+        assert!(!export_emits_placeholder_demo(true, true, false));
+        assert!(!export_emits_placeholder_demo(true, false, true));
+        assert!(!export_emits_placeholder_demo(true, true, true));
+    }
+
+    #[test]
+    fn no_export_flag_never_emits() {
+        assert!(!export_emits_placeholder_demo(false, false, false));
+        assert!(!export_emits_placeholder_demo(false, true, false));
+    }
+}