feat: add load error signaling and comparison validation

src/pygui/ISC/HomePage.qml

@@ -404,7 +404,7 @@ Rectangle {
                                     id: badgeLabel
                                     anchors.centerIn: parent
                                     text: deviceController.connectionStatus || "Disconnected"
-                                    color: "#111111"
+                                    color: Theme.statusBadgeText
                                     font.pixelSize: Theme.font2xs
                                     font.bold: true
                                 }

src/pygui/ISC/Tabs/DataTab.qml

@@ -1,5 +1,6 @@
 import QtQuick
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import QtQuick.Layouts
 import ISC
 import ISC.Wafer
@@ -124,7 +125,7 @@ Item {
         Layout.fillWidth: true
         implicitHeight: 38
         radius: 4
-        color: Qt.rgba(1, 1, 1, 0.02)
+        color: Theme.cardWash
         border.color: Theme.cardBorder
         border.width: 1
 
@@ -232,7 +233,7 @@ Item {
                 Label {
                     text: slotBox.filePath !== ""
                         ? root.shortName(slotBox.filePath)
-                        : (root.activeBox === slotBox.boxIndex ? "← Select file from left panel…" : "Click to select")
+                        : (root.activeBox === slotBox.boxIndex ? "<- Select file from left panel..." : "Click to select")
                     font.pixelSize: Theme.fontXs
                     color: slotBox.filePath !== "" ? Theme.headingColor : Theme.bodyColor
                     opacity: slotBox.filePath !== "" ? 1.0 : 0.6
@@ -248,14 +249,15 @@ Item {
                 onClicked: slotBox.cleared()
                 background: Rectangle {
                     radius: Theme.radiusSm
-                    color: parent.hovered ? Qt.rgba(1, 1, 1, 0.08) : "transparent"
+                    color: parent.hovered ? Theme.flatButtonHover : "transparent"
                 }
-                contentItem: Label {
-                    text: "✕"
+                contentItem: IconImage {
+                    source: "icons/x.svg"
+                    width: 14; height: 14
+                    sourceSize.width: 14
+                    sourceSize.height: 14
                     color: Theme.bodyColor
-                    font.pixelSize: Theme.fontSm
-                    horizontalAlignment: Text.AlignHCenter
-                    verticalAlignment: Text.AlignVCenter
+                    anchors.centerIn: parent
                 }
             }
         }
@@ -291,44 +293,54 @@ Item {
 
                 background: Rectangle {
                     radius: Theme.radiusSm
-                    color: resetBtn.hovered ? Qt.rgba(1, 1, 1, 0.08) : "transparent"
+                    color: resetBtn.hovered ? Theme.flatButtonHover : "transparent"
                 }
-                contentItem: Label {
-                    text: "↺"
-                    font.pixelSize: Theme.fontLg
+                contentItem: IconImage {
+                    source: "icons/rotate-ccw.svg"
+                    width: 18; height: 18
+                    sourceSize.width: 18
+                    sourceSize.height: 18
                     color: Theme.bodyColor
-                    horizontalAlignment: Text.AlignHCenter
-                    verticalAlignment: Text.AlignVCenter
+                    anchors.centerIn: parent
                 }
                 ToolTip.visible: resetBtn.hovered
                 ToolTip.text: "Reset comparison"
             }
-
-            Label {
-                text: "Dynamic Time Warping Profile Matching"
-                font.pixelSize: Theme.fontSm
-                color: Theme.bodyColor
-            }
         }
 
         // ── Error Banner ───────────────────────────────────────────
         Rectangle {
             Layout.fillWidth: true
-            Layout.preferredHeight: errorLabel.implicitHeight + 16
+            Layout.preferredHeight: errorRow.implicitHeight + 16
             visible: root.errorMessage !== ""
-            color: Qt.rgba(0.93, 0.27, 0.27, 0.15)
-            border.color: "#ef4444"
+            color: Theme.errorSurface
+            border.color: Theme.statusErrorColor
             border.width: 1
             radius: Theme.radiusSm
 
-            Label {
-                id: errorLabel
+            RowLayout {
+                id: errorRow
                 anchors.fill: parent
                 anchors.margins: 8
-                text: "⚠  " + root.errorMessage
-                color: "#fca5a5"
-                font.pixelSize: Theme.fontSm
-                wrapMode: Text.WordWrap
+                spacing: 8
+
+                IconImage {
+                    source: "icons/triangle-alert.svg"
+                    width: 16; height: 16
+                    sourceSize.width: 16
+                    sourceSize.height: 16
+                    color: Theme.errorTextSoft
+                    Layout.alignment: Qt.AlignTop
+                }
+
+                Label {
+                    id: errorLabel
+                    text: root.errorMessage
+                    color: Theme.errorTextSoft
+                    font.pixelSize: Theme.fontSm
+                    wrapMode: Text.WordWrap
+                    Layout.fillWidth: true
+                }
             }
         }
 
@@ -402,9 +414,9 @@ Item {
                                     var plotH = height - padTop - padBottom
                                     var range = (maxV - minV) || 1
 
-                                    ctx.strokeStyle = Qt.rgba(1, 1, 1, 0.08)
+                                    ctx.strokeStyle = Theme.chartGridLine
                                     ctx.lineWidth = 1
-                                    ctx.fillStyle = Qt.rgba(1, 1, 1, 0.35)
+                                    ctx.fillStyle = Theme.chartAxisText
                                     ctx.font = "10px sans-serif"
                                     ctx.textAlign = "right"
 
@@ -507,10 +519,14 @@ Item {
                                 visible: !root.hasSeries
                                 spacing: 8
 
-                                Label {
+                                IconImage {
                                     Layout.alignment: Qt.AlignHCenter
-                                    text: root.comparing ? "" : "📊"
-                                    font.pixelSize: 32
+                                    visible: !root.comparing
+                                    source: "icons/bar-chart.svg"
+                                    width: 32; height: 32
+                                    sourceSize.width: 32
+                                    sourceSize.height: 32
+                                    color: Theme.sideMutedText
                                 }
                                 Label {
                                     Layout.alignment: Qt.AlignHCenter
@@ -655,10 +671,13 @@ Item {
                                 anchors.centerIn: parent
                                 visible: root.compareSensorLayout.length === 0 || !enableOverlapCheck.checked
                                 spacing: 4
-                                Label {
+                                IconImage {
                                     Layout.alignment: Qt.AlignHCenter
-                                    text: "🗺"
-                                    font.pixelSize: 24
+                                    source: "icons/map.svg"
+                                    width: 24; height: 24
+                                    sourceSize.width: 24
+                                    sourceSize.height: 24
+                                    color: Theme.sideMutedText
                                 }
                                 Label {
                                     Layout.alignment: Qt.AlignHCenter
@@ -864,7 +883,7 @@ Item {
                             label: "DTW ALIGNMENT DISTANCE"
                             value: root.warpingDistance >= 0 ? root.warpingDistance.toFixed(2) : "--"
                             valueColor: root.warpingDistance >= 0
-                                ? (root.warpingDistance < 50 ? "#6ee7b7" : root.warpingDistance < 100 ? "#fde047" : "#ef4444")
+                                ? (root.warpingDistance < 50 ? Theme.metricGood : root.warpingDistance < 100 ? Theme.metricWarn : Theme.metricBad)
                                 : Theme.sideMutedText
                         }
                         ReadoutCard {
@@ -878,7 +897,7 @@ Item {
                             label: "MAX SENSOR DEVIATION"
                             value: root.maxSensorDeviation >= 0 ? root.maxSensorDeviation.toFixed(2) + "°C" : "--"
                             valueColor: root.maxSensorDeviation >= 0
-                                ? (root.maxSensorDeviation < 1.0 ? "#6ee7b7" : root.maxSensorDeviation < 3.0 ? "#fde047" : "#ef4444")
+                                ? (root.maxSensorDeviation < 1.0 ? Theme.metricGood : root.maxSensorDeviation < 3.0 ? Theme.metricWarn : Theme.metricBad)
                                 : Theme.sideMutedText
                         }
                     }

src/pygui/ISC/Tabs/SelectFileDialog.qml

@@ -1,5 +1,6 @@
 import QtQuick
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import QtQuick.Layouts
 import Qt.labs.qmlmodels
 import ISC
@@ -181,10 +182,17 @@ Dialog {
             anchors.verticalCenter: parent.verticalCenter
             anchors.right: parent.right
             anchors.rightMargin: 12
-            text: "✕"
             implicitWidth: 32
             implicitHeight: 32
             onClicked: root.close()
+            contentItem: IconImage {
+                source: "icons/x.svg"
+                width: 14; height: 14
+                sourceSize.width: 14
+                sourceSize.height: 14
+                color: Theme.buttonNeutralText
+                anchors.centerIn: parent
+            }
         }
     }
 

src/pygui/ISC/Tabs/SettingsTab.qml

@@ -1,5 +1,6 @@
 import QtQuick
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import QtQuick.Layouts
 import QtQuick.Dialogs
 import ISC
@@ -123,19 +124,17 @@ Item {
                 ColorAnimation { duration: Theme.durationFast }
             }
 
-            Text {
+            IconImage {
                 anchors.centerIn: parent
-                text: "✓"
-                font.pixelSize: Theme.fontMd
-                font.bold: true
+                source: "icons/check.svg"
+                width: 12; height: 12
+                sourceSize.width: 12
+                sourceSize.height: 12
                 color: Theme.panelBackground
                 opacity: toggle.checked ? 1.0 : 0.0
                 Behavior on opacity {
                     NumberAnimation { duration: Theme.durationFast }
                 }
-                // Small nudge to center the checkmark perfectly
-                verticalAlignment: Text.AlignVCenter
-                horizontalAlignment: Text.AlignHCenter
             }
         }
 
@@ -366,7 +365,7 @@ Item {
                                 width: 22
                                 height: 22
                                 radius: height / 2
-                                color: "white"
+                                color: Theme.toggleThumb
                                 anchors.verticalCenter: parent.verticalCenter
                                 x: Theme.isDarkMode ? parent.width - width - 3 : 3
 
@@ -452,12 +451,9 @@ Item {
                 }
             }
 
-            Label {
+            Row {
                 anchors.centerIn: parent
-                text: "↓ Scroll for more"
-                font.pixelSize: Theme.fontSm
-                font.bold: true
-                color: Theme.bodyColor
+                spacing: 4
                 opacity: (settingsScroll.ScrollBar.vertical.position <= 0 && settingsScroll.contentHeight > settingsScroll.height) ? (scrollHintTimer.running ? 1 : 0) : 0
 
                 Behavior on opacity {
@@ -465,6 +461,22 @@ Item {
                         duration: 400
                     }
                 }
+
+                IconImage {
+                    anchors.verticalCenter: parent.verticalCenter
+                    source: "icons/chevron-down.svg"
+                    width: 14; height: 14
+                    sourceSize.width: 14
+                    sourceSize.height: 14
+                    color: Theme.bodyColor
+                }
+                Label {
+                    anchors.verticalCenter: parent.verticalCenter
+                    text: "Scroll for more"
+                    font.pixelSize: Theme.fontSm
+                    font.bold: true
+                    color: Theme.bodyColor
+                }
             }
         }
     }

src/pygui/ISC/Tabs/StatusTab.qml

@@ -1,6 +1,7 @@
 import QtQuick
 import QtQuick.Layouts
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import QtQuick.Dialogs
 import ISC
 
@@ -211,7 +212,7 @@ ColumnLayout {
                                     id: statusPillText
                                     anchors.centerIn: parent
                                     text: root.isConnected ? "ACTIVE" : (root.isBusy ? deviceController.connectionStatus.replace("...", "").toUpperCase() : "INACTIVE")
-                                    color: "#111111"
+                                    color: Theme.statusBadgeText
                                     font.pixelSize: Theme.fontXs
                                     font.weight: Font.Bold
                                     font.family: Theme.uiFontFamily
@@ -483,9 +484,12 @@ ColumnLayout {
                     anchors.rightMargin: Theme.panelPadding
                     spacing: 8
 
-                    Text {
-                        text: "📄"
-                        font.pixelSize: Theme.fontSm
+                    IconImage {
+                        source: "icons/file-text.svg"
+                        width: 14; height: 14
+                        sourceSize.width: 14
+                        sourceSize.height: 14
+                        color: Theme.bodyColor
                         visible: root.csvPath !== ""
                         Layout.alignment: Qt.AlignVCenter
                     }

src/pygui/ISC/Tabs/WaferMapTab.qml

@@ -1,5 +1,6 @@
 import QtQuick
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import QtQuick.Dialogs
 import QtQuick.Layouts
 import ISC
@@ -30,11 +31,23 @@ Item {
     // into the trend chart's data property. The slot parseJsonToData() is defined
     // on the Python TrendChartItem; we use it so malformed payloads are logged
     // there instead of crashing the QML binding.
+    property string loadErrorMessage: ""
     Connections {
         target: streamController
         function onTrendData(avgsJson) {
             trendChart.setDataFromJson(avgsJson);
         }
+        // A file was picked from the rail (any tab) — loadFile() switches the
+        // backend to review mode; mirror that in the toolbar toggle so a
+        // successful load is never hidden behind a stale "Live" selection.
+        function onLoadedFileChanged() {
+            root.loadErrorMessage = "";
+            if (streamController.mode === "review")
+                modeBar.currentIndex = 0;
+        }
+        function onLoadFileError(message) {
+            root.loadErrorMessage = message;
+        }
     }
 
     ColumnLayout {
@@ -118,12 +131,13 @@ Item {
             RowLayout {
                 visible: streamController.mode === "live"
                 spacing: 5
-                // WiFi icon (Unicode approximation; swap for SVG if available)
-                Label {
+                // Live status dot (matches the connection-flow indicator dot elsewhere)
+                Rectangle {
                     id: liveIndicator
-                    text: "◉"
+                    width: 8; height: 8
+                    radius: 4
+                    Layout.alignment: Qt.AlignVCenter
                     color: (deviceController.connectionStatus === "Connected" && streamController.state !== "idle") ? Theme.liveColor : Theme.bodyColor
-                    font.pixelSize: Theme.fontSm
 
                     SequentialAnimation on opacity {
                         running: deviceController.connectionStatus === "Connected" && streamController.state !== "idle"
@@ -250,6 +264,41 @@ Item {
             }
         }
 
+        // ── Load error banner ───────────────────────────────────────────
+        Rectangle {
+            Layout.fillWidth: true
+            Layout.preferredHeight: errorRow.implicitHeight + 16
+            visible: root.loadErrorMessage !== ""
+            color: Theme.errorSurface
+            border.color: Theme.statusErrorColor
+            border.width: 1
+            radius: Theme.radiusSm
+
+            RowLayout {
+                id: errorRow
+                anchors.fill: parent
+                anchors.margins: 8
+                spacing: 8
+
+                IconImage {
+                    source: "icons/triangle-alert.svg"
+                    width: 16; height: 16
+                    sourceSize.width: 16
+                    sourceSize.height: 16
+                    color: Theme.errorTextSoft
+                    Layout.alignment: Qt.AlignTop
+                }
+
+                Label {
+                    text: root.loadErrorMessage
+                    color: Theme.errorTextSoft
+                    font.pixelSize: Theme.fontSm
+                    wrapMode: Text.WordWrap
+                    Layout.fillWidth: true
+                }
+            }
+        }
+
         // ── Body: 2 columns (wafer + trend + transport | readout) ──────────
         RowLayout {
             Layout.fillWidth: true

src/pygui/ISC/Tabs/components/ReadoutPanel.qml

@@ -1,5 +1,6 @@
 import QtQuick
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import QtQuick.Layouts
 import ISC
 
@@ -32,18 +33,17 @@ ColumnLayout {
                 ColorAnimation { duration: Theme.durationFast }
             }
 
-            Text {
+            IconImage {
                 anchors.centerIn: parent
-                text: "✓"
-                font.pixelSize: Theme.fontSm
-                font.bold: true
+                source: "../icons/check.svg"
+                width: 12; height: 12
+                sourceSize.width: 12
+                sourceSize.height: 12
                 color: Theme.panelBackground
                 opacity: toggle.checked ? 1.0 : 0.0
                 Behavior on opacity {
                     NumberAnimation { duration: Theme.durationFast }
                 }
-                verticalAlignment: Text.AlignVCenter
-                horizontalAlignment: Text.AlignHCenter
             }
         }
 
@@ -205,7 +205,7 @@ ColumnLayout {
                 Item { Layout.fillWidth: true }
                 Label {
                     text: s.diff !== undefined ? s.diff : "—"
-                    color: Theme.isDarkMode ? "#A78BFA" : "#8B5CF6"
+                    color: Theme.diffAccent
                     font.family: Theme.codeFontFamily
                     font.pixelSize: Theme.fontMd
                     font.bold: true

src/pygui/ISC/Tabs/components/ReplaceSensorDialog.qml

@@ -10,6 +10,10 @@ Dialog {
     standardButtons: Dialog.NoButton
     width: 300
 
+    // Anchor to the top-left of the window instead of the default centered position.
+    x: 24
+    y: 24
+
     // called by WaferMapView's TapHandler
     property int sensorIndex: -1
     property string sensorLabel: ""
@@ -60,7 +64,7 @@ Dialog {
                     id: overrideTag
                     anchors.centerIn: parent
                     text: "OVERRIDE"
-                    color: "white"
+                    color: Theme.statusBadgeText
                     font.pixelSize: Theme.fontXs
                     font.bold: true
                     font.letterSpacing: 1

src/pygui/ISC/Tabs/components/SourcePanel.qml

@@ -122,10 +122,12 @@ ColumnLayout {
         }
         contentItem: RowLayout {
             spacing: 6
-            Label {
-                text: "▤"
+            IconImage {
+                source: "../icons/folder.svg"
+                width: 14; height: 14
+                sourceSize.width: 14
+                sourceSize.height: 14
                 color: Theme.bodyColor
-                font.pixelSize: Theme.fontSm
             }
             Label {
                 text: file_browser.currentDirectory.split("/").pop() || file_browser.currentDirectory
@@ -204,7 +206,7 @@ ColumnLayout {
             onClicked: streamController.loadFile(modelData.fileName)
 
             background: Rectangle {
-                color: fileItem.isActive ? Qt.rgba(1, 1, 1, 0.06) : fileItem.hovered ? Qt.rgba(1, 1, 1, 0.04) : "transparent"
+                color: fileItem.isActive ? Theme.listActiveBackground : fileItem.hovered ? Theme.listHoverBackground : "transparent"
                 radius: Theme.radiusSm
                 Behavior on color {
                     ColorAnimation { duration: Theme.durationFast }
@@ -225,11 +227,11 @@ ColumnLayout {
                     color: {
                         var t = modelData.waferType;
                         if (t === "A" || t === "E" || t === "P")
-                            return "#3B82F6";
+                            return Theme.familyBlueAccent;
                         if (t === "B" || t === "C" || t === "D")
-                            return "#10B981";
+                            return Theme.familyGreenAccent;
                         if (t === "Z")
-                            return "#8B5CF6";
+                            return Theme.familyVioletAccent;
                         return Theme.headingColor;
                     }
                 }
@@ -249,19 +251,36 @@ ColumnLayout {
                     color: {
                         var t = modelData.waferType;
                         if (t === "A" || t === "E" || t === "P")
-                            return "#1D4ED8";
+                            return Theme.familyBlueFill;
                         if (t === "B" || t === "C" || t === "D")
-                            return "#065F46";
+                            return Theme.familyGreenFill;
                         if (t === "Z")
-                            return "#7C3AED";
-                        return "#374151";
+                            return Theme.familyVioletFill;
+                        return Theme.familyNeutralFill;
                     }
                     Label {
                         anchors.centerIn: parent
                         text: modelData.waferType || "?"
                         font.pixelSize: Theme.fontMd
                         font.weight: Font.Bold
-                        color: "#FFFFFF"
+                        color: Theme.textOnColor
+                    }
+
+                    // Recording indicator dot — distinguishes a live-recorded CSV
+                    // (SessionController.startRecording) from a read-memory dump
+                    // (DeviceController.parseAndSaveData).
+                    Rectangle {
+                        visible: modelData.isRecording === true
+                        width: 10
+                        height: 10
+                        radius: 5
+                        color: Theme.recordColor
+                        border.color: Theme.subtleSectionBackground
+                        border.width: 1.5
+                        anchors.top: parent.top
+                        anchors.right: parent.right
+                        anchors.topMargin: -2
+                        anchors.rightMargin: -2
                     }
                 }
 
@@ -270,14 +289,38 @@ ColumnLayout {
                     spacing: 1
                     Layout.fillWidth: true
 
-                    // Primary: wafer type + serial number
-                    Label {
-                        text: modelData.serialNumber ? (modelData.waferType + modelData.serialNumber) : modelData.baseName
-                        color: Theme.headingColor
-                        font.pixelSize: Theme.fontMd
-                        font.weight: Font.Bold
-                        elide: Text.ElideRight
+                    // Primary: wafer type + serial number, plus a REC badge for recordings
+                    RowLayout {
                         Layout.fillWidth: true
+                        spacing: 6
+
+                        Label {
+                            text: modelData.serialNumber ? (modelData.waferType + modelData.serialNumber) : modelData.baseName
+                            color: Theme.headingColor
+                            font.pixelSize: Theme.fontMd
+                            font.weight: Font.Bold
+                            elide: Text.ElideRight
+                            Layout.fillWidth: true
+                        }
+
+                        Rectangle {
+                            visible: modelData.isRecording === true
+                            radius: 4
+                            color: Qt.alpha(Theme.recordColor, 0.18)
+                            implicitWidth: recLabel.implicitWidth + 10
+                            implicitHeight: recLabel.implicitHeight + 4
+                            Layout.alignment: Qt.AlignVCenter
+
+                            Label {
+                                id: recLabel
+                                anchors.centerIn: parent
+                                text: "REC"
+                                color: Theme.recordColor
+                                font.pixelSize: Theme.font2xs
+                                font.bold: true
+                                font.letterSpacing: 0.6
+                            }
+                        }
                     }
 
                     // Secondary: date · time

src/pygui/ISC/Tabs/components/StreamStatsDialog.qml

@@ -1,6 +1,7 @@
 import QtQuick
 import QtQuick.Layouts
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import ISC
 
 // ===== Stream Stats Dialog =====
@@ -72,7 +73,6 @@ Popup {
             }
 
             Button {
-                text: "✕"
                 flat: true
                 Layout.preferredWidth: 32
                 Layout.preferredHeight: 32
@@ -82,11 +82,13 @@ Popup {
                     radius: Theme.radiusXs
                     color: parent.hovered ? Theme.buttonNeutralHover : "transparent"
                 }
-                contentItem: Label {
-                    text: parent.text
+                contentItem: IconImage {
+                    source: "../icons/x.svg"
+                    width: 14; height: 14
+                    sourceSize.width: 14
+                    sourceSize.height: 14
                     color: Theme.bodyColor
-                    horizontalAlignment: Text.AlignHCenter
-                    verticalAlignment: Text.AlignVCenter
+                    anchors.centerIn: parent
                 }
             }
         }

src/pygui/ISC/Tabs/components/TransportBar.qml

@@ -1,5 +1,6 @@
 import QtQuick
 import QtQuick.Controls
+import QtQuick.Controls.impl
 import QtQuick.Layouts
 import ISC
 
@@ -177,8 +178,6 @@ Item {
                         implicitWidth: 56
                         implicitHeight: 56
                         hoverEnabled: true
-                        text: "⏮"
-                        font.pixelSize: 24
                         background: Rectangle {
                             radius: 8
                             color: skipStartBtn.pressed ? Theme.transportButtonHover
@@ -188,12 +187,13 @@ Item {
                                 ColorAnimation { duration: Theme.durationFast }
                             }
                         }
-                        contentItem: Text {
-                            text: parent.text
+                        contentItem: IconImage {
+                            source: "../icons/prev.svg"
+                            width: 22; height: 22
+                            sourceSize.width: 22
+                            sourceSize.height: 22
                             color: Theme.headingColor
-                            font: parent.font
-                            horizontalAlignment: Text.AlignHCenter
-                            verticalAlignment: Text.AlignVCenter
+                            anchors.centerIn: parent
                         }
                         onClicked: streamController.step(-1)
                     }
@@ -205,8 +205,6 @@ Item {
                         implicitWidth: 56
                         implicitHeight: 56
                         hoverEnabled: true
-                        text: "■"
-                        font.pixelSize: 22
                         background: Rectangle {
                             radius: 8
                             color: reviewStopBtn.pressed ? Theme.transportButtonHover
@@ -216,12 +214,13 @@ Item {
                                 ColorAnimation { duration: Theme.durationFast }
                             }
                         }
-                        contentItem: Text {
-                            text: parent.text
+                        contentItem: IconImage {
+                            source: "../icons/stop.svg"
+                            width: 20; height: 20
+                            sourceSize.width: 20
+                            sourceSize.height: 20
                             color: Theme.headingColor
-                            font: parent.font
-                            horizontalAlignment: Text.AlignHCenter
-                            verticalAlignment: Text.AlignVCenter
+                            anchors.centerIn: parent
                         }
                         onClicked: streamController.stop()
                     }
@@ -233,8 +232,6 @@ Item {
                         implicitWidth: 64
                         implicitHeight: 56
                         hoverEnabled: true
-                        text: streamController.playing ? "⏸" : "▶"
-                        font.pixelSize: 24
                         background: Rectangle {
                             radius: 8
                             color: playPauseBtn.pressed ? Theme.transportButtonHover
@@ -244,13 +241,13 @@ Item {
                                 ColorAnimation { duration: Theme.durationFast }
                             }
                         }
-                        contentItem: Text {
-                            text: parent.text
+                        contentItem: IconImage {
+                            source: streamController.playing ? "../icons/pause.svg" : "../icons/play.svg"
+                            width: 22; height: 22
+                            sourceSize.width: 22
+                            sourceSize.height: 22
                             color: Theme.headingColor
-                            font: parent.font
-                            horizontalAlignment: Text.AlignHCenter
-                            verticalAlignment: Text.AlignVCenter
-                            leftPadding: parent.text === "▶" ? 4 : 0
+                            anchors.centerIn: parent
                         }
                         onClicked: {
                             if (streamController.playing) {
@@ -268,8 +265,6 @@ Item {
                         implicitWidth: 56
                         implicitHeight: 56
                         hoverEnabled: true
-                        text: "⏭"
-                        font.pixelSize: 24
                         background: Rectangle {
                             radius: 8
                             color: skipEndBtn.pressed ? Theme.transportButtonHover
@@ -279,12 +274,13 @@ Item {
                                 ColorAnimation { duration: Theme.durationFast }
                             }
                         }
-                        contentItem: Text {
-                            text: parent.text
+                        contentItem: IconImage {
+                            source: "../icons/next.svg"
+                            width: 22; height: 22
+                            sourceSize.width: 22
+                            sourceSize.height: 22
                             color: Theme.headingColor
-                            font: parent.font
-                            horizontalAlignment: Text.AlignHCenter
-                            verticalAlignment: Text.AlignVCenter
+                            anchors.centerIn: parent
                         }
                         onClicked: streamController.step(1)
                     }

src/pygui/ISC/Tabs/components/WaferMapView.qml

@@ -29,6 +29,22 @@ Item {
         highColor: Theme.sensorHigh
         textColor: Theme.headingColor
 
+        // Grows the hovered marker smoothly; hoverScale setter triggers a repaint.
+        hoverScale: 1.0 + 0.35 * hoverPulse
+        property real hoverPulse: map.hoveredIndex >= 0 ? 1.0 : 0.0
+        Behavior on hoverPulse {
+            NumberAnimation { duration: 150; easing.type: Easing.OutQuad }
+        }
+
+        HoverHandler {
+            id: hoverHandler
+            onPointChanged: {
+                map.hoveredIndex = map.which_marker(hoverHandler.point.position.x, hoverHandler.point.position.y);
+            }
+            onHoveredChanged: if (!hoverHandler.hovered) map.hoveredIndex = -1
+            cursorShape: map.hoveredIndex >= 0 ? Qt.PointingHandCursor : Qt.ArrowCursor
+        }
+
         TapHandler {
             onTapped: ev => {
                 var idx = map.which_marker(ev.position.x, ev.position.y);

src/pygui/ISC/Tabs/icons/back.svg

@@ -0,0 +1,14 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="m12 19-7-7 7-7" />
+  <path d="M19 12H5" />
+</svg>

src/pygui/ISC/Tabs/icons/bar-chart.svg

@@ -0,0 +1,15 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <line x1="18" x2="18" y1="20" y2="10" />
+  <line x1="12" x2="12" y1="20" y2="4" />
+  <line x1="6" x2="6" y1="20" y2="14" />
+</svg>

src/pygui/ISC/Tabs/icons/check.svg

@@ -0,0 +1,13 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="M20 6 9 17l-5-5" />
+</svg>

src/pygui/ISC/Tabs/icons/chevron-down.svg

@@ -0,0 +1,13 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="m6 9 6 6 6-6" />
+</svg>

src/pygui/ISC/Tabs/icons/file-text.svg

@@ -0,0 +1,17 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="M15 2H6a2 2 0 0 0-2 2v16a2 2 0 0 0 2 2h12a2 2 0 0 0 2-2V7Z" />
+  <path d="M14 2v4a2 2 0 0 0 2 2h4" />
+  <path d="M10 9H8" />
+  <path d="M16 13H8" />
+  <path d="M16 17H8" />
+</svg>

src/pygui/ISC/Tabs/icons/folder.svg

@@ -0,0 +1,13 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="M20 20a2 2 0 0 0 2-2V8a2 2 0 0 0-2-2h-7.9a2 2 0 0 1-1.69-.9L9.6 3.9A2 2 0 0 0 7.93 3H4a2 2 0 0 0-2 2v13a2 2 0 0 0 2 2Z" />
+</svg>

src/pygui/ISC/Tabs/icons/next.svg

@@ -0,0 +1,13 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="m9 18 6-6-6-6" />
+</svg>

src/pygui/ISC/Tabs/icons/pause.svg

@@ -0,0 +1,14 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <rect x="14" y="3" width="5" height="18" rx="1" />
+  <rect x="6" y="3" width="5" height="18" rx="1" />
+</svg>

src/pygui/ISC/Tabs/icons/play.svg

@@ -0,0 +1,13 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <polygon points="6 3 20 12 6 21 6 3" />
+</svg>

src/pygui/ISC/Tabs/icons/prev.svg

@@ -0,0 +1,13 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="m15 18-6-6 6-6" />
+</svg>

src/pygui/ISC/Tabs/icons/rotate-ccw.svg

@@ -0,0 +1,14 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="M3 12a9 9 0 1 0 9-9 9.75 9.75 0 0 0-6.74 2.74L3 8" />
+  <path d="M3 3v5h5" />
+</svg>

src/pygui/ISC/Tabs/icons/stop.svg

@@ -0,0 +1,13 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <rect width="18" height="18" x="3" y="3" rx="2" />
+</svg>

src/pygui/ISC/Tabs/icons/triangle-alert.svg

@@ -0,0 +1,15 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="m21.73 18-8-14a2 2 0 0 0-3.46 0l-8 14A2 2 0 0 0 4 21h16a2 2 0 0 0 1.73-3Z" />
+  <path d="M12 9v4" />
+  <path d="M12 17h.01" />
+</svg>

src/pygui/ISC/Tabs/icons/x.svg

@@ -0,0 +1,14 @@
+<svg
+  xmlns="http://www.w3.org/2000/svg"
+  width="24"
+  height="24"
+  viewBox="0 0 24 24"
+  fill="none"
+  stroke="currentColor"
+  stroke-width="2"
+  stroke-linecap="round"
+  stroke-linejoin="round"
+>
+  <path d="M18 6 6 18" />
+  <path d="m6 6 12 12" />
+</svg>

src/pygui/ISC/Theme.qml

@@ -7,18 +7,23 @@ import QtQuick
 // =============================================================================
 //  Sections:
 //    1.  Mode flag
-//    2.  Typography
+//    2.  Typography              (families, pixel sizes, weights)
 //    3.  Motion
-//    4.  Tone palette          (raw tones; everything else derives from these)
-//    5.  Surfaces              (page / card / panel / workspace backgrounds)
+//    4.  Tone palette            (raw tones; everything else derives from these)
+//    5.  Surfaces                (page / card / panel / workspace backgrounds)
 //    6.  Borders
-//    7.  Text                  (headings, body, panel titles)
-//    8.  Controls              (fields, buttons, checkbox)
-//    9.  Tracks                (pill toggle + scrollbar)
-//   10.  Tabs                  (footer tab bar)
-//   11.  Side rail
-//   12.  Status                (success / warning / error)
-//   13.  Geometry              (radius / border width / spacing / sizing)
+//    7.  Text                    (headings, body, panel titles)
+//    8.  Controls                (fields, buttons, checkbox, toggle)
+//    9.  Interaction overlays    (hover / active washes — mode-aware)
+//   10.  Tracks                  (pill toggle + scrollbar)
+//   11.  Tabs                    (mode toggle pills)
+//   12.  Side rail
+//   13.  Transport / toolbar
+//   14.  Status & badges         (success / warning / error, badge text)
+//   15.  Sensor bands            (wafer map dots)
+//   16.  Wafer family badges     (source list avatars + accent bars)
+//   17.  Comparison & charts     (metric grading, diff accent, canvas grid)
+//   18.  Geometry                (radius / border width / spacing / sizing)
 // =============================================================================
 //  Based on Codex themes:
 //    Dark  (oscurange):  surface #0B0B0F, ink #E6E6E6
@@ -29,7 +34,10 @@ QtObject {
     // ── 1. Mode ──────────────────────────────────────────────────────────────
     property bool isDarkMode: true
 
-    // ── 2. Typography ──────────────────────────────────────────────────────
+    // ── 2. Typography ────────────────────────────────────────────────────────
+    readonly property string uiFontFamily: "Geist, Inter, system-ui, -apple-system, BlinkMacSystemFont, sans-serif"
+    readonly property string codeFontFamily: "\"Geist Mono\", ui-monospace, \"SFMono-Regular\", monospace"
+
     // pixelSize scale — map to closest token, tune globally
     readonly property int font2xs: 9   // tiny metadata
     readonly property int fontXs: 11   // captions, micro labels
@@ -44,22 +52,20 @@ QtObject {
     readonly property int fontWeightMedium: 500
     readonly property int fontWeightBold: 700
 
-    // ── 3. Motion ──────────────────────────────────────────────────────────
+    // ── 3. Motion ────────────────────────────────────────────────────────────
     readonly property int durationFast: 120   // micro-interactions (focus ring, hover flash)
     readonly property int durationBase: 180   // standard transitions (pill switch, row select)
     readonly property int durationSlow: 260   // larger transitions (panel open/close)
     readonly property var easeStandard: Easing.OutCubic
 
-    // ── 4. Tone palette (Codex theme v1 inspired) ───────────────────────────
-    readonly property string uiFontFamily: "Geist, Inter, system-ui, -apple-system, BlinkMacSystemFont, sans-serif"
-    readonly property string codeFontFamily: "\"Geist Mono\", ui-monospace, \"SFMono-Regular\", monospace"
-
+    // ── 4. Tone palette (Codex theme v1 inspired) ────────────────────────────
     readonly property color themeSurface: isDarkMode ? "#0B0B0F" : "#F9F9F7"
     readonly property color themeInk: isDarkMode ? "#E6E6E6" : "#2D2D2B"
     readonly property color themeAccent: isDarkMode ? "#F9B98C" : "#B87333"
     readonly property color themeSkill: isDarkMode ? "#479FFA" : "#3B82F6"   // blue family both modes
     readonly property color themeAdded: isDarkMode ? "#40C977" : "#00C853"
     readonly property color themeRemoved: isDarkMode ? "#FA423E" : "#FF5F38"
+    readonly property color themeViolet: isDarkMode ? "#A78BFA" : "#8B5CF6"
 
     readonly property color tone100: themeSurface
     readonly property color tone150: isDarkMode ? "#101014" : "#F3F3F1"
@@ -71,7 +77,7 @@ QtObject {
     readonly property color toneMute: isDarkMode ? "#A8A8A1" : "#85857E"
     readonly property color toneBorder: isDarkMode ? "#2D2D34" : "#D2D2CE"
 
-    // ── 3. Surfaces ──────────────────────────────────────────────────────────
+    // ── 5. Surfaces ──────────────────────────────────────────────────────────
     readonly property color pageBackground: tone100
     readonly property color cardBackground: tone150
     readonly property color panelBackground: tone150
@@ -79,7 +85,7 @@ QtObject {
     readonly property color responseBackground: tone150
     readonly property color subtleSectionBackground: tone250
 
-    // ── 4. Borders ───────────────────────────────────────────────────────────
+    // ── 6. Borders ───────────────────────────────────────────────────────────
     readonly property color cardBorder: toneBorder
     readonly property color cardSurfaceBorder: isDarkMode ? "#3A3A42" : "#C7C7C2"
     readonly property color responseBorder: toneBorder
@@ -88,14 +94,14 @@ QtObject {
     readonly property color outerFrameBorder: isDarkMode ? "#3A3A42" : "#C7C7C2"
     readonly property color softBorder: isDarkMode ? "#24242A" : "#E4E4E1"
 
-    // ── 5. Text ──────────────────────────────────────────────────────────────
+    // ── 7. Text ──────────────────────────────────────────────────────────────
     readonly property color headingColor: toneText
     readonly property color bodyColor: toneMute
     readonly property color subheadingColor: toneMute
     readonly property color panelTitleText: toneMute
     readonly property color disabledText: toneMute
 
-    // ── 6. Controls ──────────────────────────────────────────────────────────
+    // ── 8. Controls ──────────────────────────────────────────────────────────
     // Fields
     readonly property color fieldBackground: isDarkMode ? "#101014" : "#FFFFFF"
     readonly property color fieldText: toneText
@@ -111,32 +117,48 @@ QtObject {
     readonly property color primaryAccent: themeAccent
     // Checkbox
     readonly property color checkboxText: toneText
+    // Toggle switch thumb (white knob reads on both track colors)
+    readonly property color toggleThumb: "#FFFFFF"
 
-    // ── 7. Tracks (pill toggle, scrollbar thumb) ─────────────────────────────
+    // ── 9. Interaction overlays ──────────────────────────────────────────────
+    // Mode-aware washes. Never use raw Qt.rgba(1,1,1,x) in views: a white
+    // overlay is invisible on light-mode surfaces.
+    readonly property color listHoverBackground: isDarkMode ? Qt.rgba(1, 1, 1, 0.04) : Qt.rgba(0, 0, 0, 0.03)
+    readonly property color listActiveBackground: isDarkMode ? Qt.rgba(1, 1, 1, 0.06) : Qt.rgba(0, 0, 0, 0.05)
+    readonly property color flatButtonHover: isDarkMode ? Qt.rgba(1, 1, 1, 0.08) : Qt.rgba(0, 0, 0, 0.06)
+    readonly property color cardWash: isDarkMode ? Qt.rgba(1, 1, 1, 0.02) : Qt.rgba(0, 0, 0, 0.02)
+
+    // ── 10. Tracks (pill toggle, scrollbar thumb) ────────────────────────────
     readonly property color trackBackground: isDarkMode ? "#25252B" : "#E2E2DE"
 
-    // ── 8. Tabs (mode toggle pills) ──────────────────────────────────────────
+    // ── 11. Tabs (mode toggle pills) ─────────────────────────────────────────
     readonly property color tabActiveBackground: isDarkMode ? "#25252B" : "#FFFFFF"
 
-    // ── 9. Side rail ─────────────────────────────────────────────────────────
+    // ── 12. Side rail ────────────────────────────────────────────────────────
     readonly property color sideRailBackground: tone150
     readonly property color sidePanelBackground: isDarkMode ? "#151518" : "#F3F3F1"
     readonly property color sideActiveBackground: isDarkMode ? "#25252B" : "#FFFFFF"
     readonly property color sideBorder: toneBorder
     readonly property color sideMutedText: toneMute
 
-    // ── 10a. Transport / toolbar surfaces ────────────────────────────────────
+    // ── 13. Transport / toolbar surfaces ─────────────────────────────────────
     readonly property color transportButtonBg: tone250
     readonly property color transportButtonHover: tone300
     readonly property color liveColor: themeAdded
     readonly property color recordColor: themeRemoved
 
-    // ── 10. Status ───────────────────────────────────────────────────────────
+    // ── 14. Status & badges ──────────────────────────────────────────────────
     readonly property color statusSuccessColor: themeAdded
     readonly property color statusWarningColor: isDarkMode ? "#E8A817" : "#B8860B"   // amber/yellow, separate from accent
     readonly property color statusErrorColor: themeRemoved
+    // Text placed ON a filled status pill / saturated chip:
+    readonly property color statusBadgeText: "#111111"   // dark ink on bright status fills, both modes
+    readonly property color textOnColor: "#FFFFFF"       // white text on deep saturated fills (avatars etc.)
+    // Error banner (soft red surface + readable red text)
+    readonly property color errorSurface: Qt.alpha(statusErrorColor, 0.15)
+    readonly property color errorTextSoft: isDarkMode ? "#FCA5A5" : "#B91C1C"
 
-    // -- 10b. Sensor bands (wafer map dots)
+    // ── 15. Sensor bands (wafer map dots) ────────────────────────────────────
     readonly property color sensorInRange: statusSuccessColor
     // ponytail: high-temp shares error red — semantically correct (dangerous value),
     // re-hue if colorblind testing demands a different channel.
@@ -145,7 +167,31 @@ QtObject {
     readonly property color waferRingColor: toneBorder
     readonly property color waferAxisColor: softBorder
 
-    // ── 11. Geometry ─────────────────────────────────────────────────────────
+    // ── 16. Wafer family badges (SourcePanel list) ───────────────────────────
+    // Accent = left bar / outline shade; Fill = avatar circle behind textOnColor.
+    // Family grouping mirrors FileBrowser's waferType first-letter convention.
+    readonly property color familyBlueAccent: "#3B82F6"    // A / E / P
+    readonly property color familyBlueFill: "#1D4ED8"
+    readonly property color familyGreenAccent: "#10B981"   // B / C / D
+    readonly property color familyGreenFill: "#065F46"
+    readonly property color familyVioletAccent: "#8B5CF6"  // Z
+    readonly property color familyVioletFill: "#7C3AED"
+    readonly property color familyNeutralFill: "#374151"   // unknown family
+
+    // ── 17. Comparison & charts ──────────────────────────────────────────────
+    // Metric grading for DTW readout cards (good → caution → bad).
+    // Dark values are pastel (readable on tone150); light values are deepened
+    // so they still pass on near-white cards.
+    readonly property color metricGood: isDarkMode ? "#6EE7B7" : "#059669"
+    readonly property color metricWarn: isDarkMode ? "#FDE047" : "#B45309"
+    readonly property color metricBad: isDarkMode ? "#EF4444" : "#DC2626"
+    // DIFF column accent in ReadoutPanel
+    readonly property color diffAccent: themeViolet
+    // Canvas chart primitives (DTW plot grid + axis labels)
+    readonly property color chartGridLine: isDarkMode ? Qt.rgba(1, 1, 1, 0.08) : Qt.rgba(0, 0, 0, 0.10)
+    readonly property color chartAxisText: isDarkMode ? Qt.rgba(1, 1, 1, 0.35) : Qt.rgba(0, 0, 0, 0.45)
+
+    // ── 18. Geometry ─────────────────────────────────────────────────────────
     // Radius
     readonly property int radiusXs: 6   // fields, tight elements
     readonly property int radiusSm: 8   // buttons

src/pygui/backend/controllers/session_controller.py

@@ -35,6 +35,7 @@ class SessionController(QObject):
     recordingChanged = Signal()
     sensorsChanged = Signal()
     loadedFileChanged = Signal()
+    loadFileError = Signal(str)  # emitted when loadFile() fails, so QML can show why
     clusterAveragingEnabledChanged = Signal()
     settingsChanged = Signal()  # emitted when session state changes that should be persisted
     liveStatsChanged = Signal()  # emitted when receivedCount or errorCount change
@@ -275,17 +276,30 @@ class SessionController(QObject):
             try:
                 data, _ = ZWaferParser().parse(file_path)
             except (ValueError, KeyError) as exc:
-                log.warning("Could not parse %s: %s", file_path, exc)
+                msg = f"Could not parse {Path(file_path).name}: {exc}"
+                log.warning("%s", msg)
+                self.loadFileError.emit(msg)
                 return
             if data is None or not data.sensors:
-                log.warning("Could not parse %s", file_path)
+                msg = f"Could not parse {Path(file_path).name}"
+                log.warning("%s", msg)
+                self.loadFileError.emit(msg)
                 return
             records = read_data_records(file_path)
             sensors = data.sensors
             frames = frames_from_wafer_data(data, records)
 
-        if not sensors or not frames:
-            log.warning("No sensors or data in %s", file_path)
+        if not sensors:
+            msg = f"No sensor layout found in {Path(file_path).name}"
+            log.warning("%s", msg)
+            self.loadFileError.emit(msg)
+            return
+        if not frames:
+            # A well-formed header with zero data rows below it — most commonly
+            # a live recording that was stopped before any frames arrived.
+            msg = f"{Path(file_path).name} has no recorded frames"
+            log.warning("%s", msg)
+            self.loadFileError.emit(msg)
             return
 
         wafer_id = ""
@@ -304,6 +318,10 @@ class SessionController(QObject):
         self._model.reset()
         self._stats_tracker.reset()
         self._loaded_file = file_path
+        # A file was explicitly picked for review — show it regardless of
+        # whichever mode (e.g. Live) was previously active, otherwise a
+        # successful load can be invisible to the user.
+        self.setMode(MODE_REVIEW)
         self.loadedFileChanged.emit()
         self.sensorsChanged.emit()
         self._emit_current()
@@ -330,10 +348,48 @@ class SessionController(QObject):
     @slot_error_boundary
     def compareFiles(self, file_a: str, file_b: str) -> None:
         """Run DTW comparison between two CSV files and emit result."""
+        from pathlib import Path
+
         from pygui.backend.comparison import compare_runs
         from pygui.backend.data.data_records import is_official_csv, read_data_records, read_official_csv
 
         try:
+            # Recorded-live CSVs are named "live_<serial>_<timestamp>.csv" by
+            # startRecording (see FileBrowser.isRecording), distinct from the
+            # "<serial>-<timestamp>.csv" convention used for read-memory dumps.
+            # Comparing across those categories doesn't make sense (a live
+            # capture vs. a full memory readout aren't the same kind of run),
+            # so gate on that before even looking at wafer type.
+            stem_a, stem_b = Path(file_a).stem, Path(file_b).stem
+            is_recording_a = stem_a.lower().startswith("live_")
+            is_recording_b = stem_b.lower().startswith("live_")
+            if is_recording_a != is_recording_b:
+                self.comparisonResult.emit({
+                    "success": False,
+                    "error": "Cannot compare a recording file with a read-memory file"
+                })
+                return
+
+            # Gate on wafer type (family): comparing a P-wafer against an X-wafer
+            # (different sensor counts/layouts) would silently truncate the
+            # smaller sensor set and pair up unrelated physical sensors in the
+            # overlap view. Same convention as FileBrowser's waferType badge —
+            # first character of the filename stem, minus the "live_" prefix
+            # so the wafer letter is read from the serial, not the "L".
+            def _wafer_type(stem: str, is_recording: bool) -> str:
+                if is_recording:
+                    stem = stem[len("live_"):]
+                return stem[0].upper() if stem else ""
+
+            type_a = _wafer_type(stem_a, is_recording_a)
+            type_b = _wafer_type(stem_b, is_recording_b)
+            if type_a and type_b and type_a != type_b:
+                self.comparisonResult.emit({
+                    "success": False,
+                    "error": f"Cannot compare different wafer types: {type_a} vs {type_b}"
+                })
+                return
+
             if is_official_csv(file_a):
                 _, recs_a = read_official_csv(file_a)
             else:
@@ -350,8 +406,10 @@ class SessionController(QObject):
                 })
                 return
 
-            # Use first 100 frames of each for comparison (avoid O(n²) blowup)
-            max_frames = min(100, len(recs_a), len(recs_b))
+            # Compare the full overlapping length of both runs. DTW's O(n*m) cost
+            # matrix is cheap even at a few thousand frames (~26MB at 1800x1800),
+            # so only cap against pathologically long files, not typical runs.
+            max_frames = min(5000, len(recs_a), len(recs_b))
             series_a = [recs_a[i].values[0] if recs_a[i].values else 0.0
                        for i in range(max_frames)]
             series_b = [recs_b[i].values[0] if recs_b[i].values else 0.0
@@ -380,10 +438,8 @@ class SessionController(QObject):
                         max_sensor_deviation = diff
 
             # Sensor layout + per-sensor diff for the wafer overlap view. Reuses the
-            # same sensor-parsing branch as loadFile() (file_a is assumed representative
-            # of both files' wafer type).
-            from pathlib import Path
-
+            # same sensor-parsing branch as loadFile(); file_a and file_b are now
+            # guaranteed to share a wafer type by the gate above.
             from pygui.backend.data.data_records import is_official_csv, read_official_csv
             from pygui.backend.wafer.wafer_layouts import resolve_shape_and_size
             from pygui.backend.wafer.zwafer_parser import ZWaferParser

src/pygui/backend/data/file_browser.py

@@ -119,6 +119,11 @@ class FileBrowser(QObject):
             return
 
         for csv_path in sorted(self._current_directory.glob("*.csv")):
+            # Recorded-live CSVs are named "live_<serial>_<timestamp>.csv" by
+            # SessionController.startRecording (see WaferMapTab's Record button),
+            # distinct from the "<serial>-<timestamp>.csv" convention used by
+            # DeviceController.parseAndSaveData for read-memory dumps.
+            is_recording = csv_path.stem.lower().startswith("live_")
             try:
                 metadata = self._load_metadata(csv_path)
                 wafer_type = metadata.get_wafer_type().upper() or (csv_path.stem[0].upper() if csv_path.stem else "")
@@ -146,6 +151,7 @@ class FileBrowser(QObject):
                         "masterType": master_state.get(str(csv_path), "") or metadata.master_type,
                         "fileName": str(csv_path),
                         "highlight": wafer_type in {"A", "B", "C"},
+                        "isRecording": is_recording,
                     }
                 )
             except Exception:
@@ -169,6 +175,7 @@ class FileBrowser(QObject):
                         "masterType": master_state.get(str(csv_path), ""),
                         "fileName": str(csv_path),
                         "highlight": False,
+                        "isRecording": is_recording,
                     }
                 )
 

src/pygui/backend/visualization/wafer_map_item.py

@@ -52,6 +52,8 @@ class WaferMapItem(QQuickPaintedItem):
     sizeChanged     = Signal()
     thicknessChanged = Signal()
     showThicknessChanged = Signal()
+    hoveredIndexChanged = Signal()
+    hoverScaleChanged = Signal()
 
 
     def __init__(self, parent=None):
@@ -68,6 +70,10 @@ class WaferMapItem(QQuickPaintedItem):
         self._thickness_data: list[float] = []
         self._show_thickness: bool = False
         self._thickness_heatmap:QImage | None = None
+        # Hover highlight: index of the marker under the pointer (-1 = none)
+        # and a 1.0->~1.5 grow factor driven by a QML Behavior for a smooth animation.
+        self._hovered_index: int = -1
+        self._hover_scale: float = 1.0
 
         # Dark-theme color defaults (match Theme.qml tokens)
         self._ring_color     = QColor("#2A3441")   # waferRingColor  (toneBorder)
@@ -81,6 +87,12 @@ class WaferMapItem(QQuickPaintedItem):
         self._markers: dict[int, tuple[int, int]] = {}  # sensor index → (px, py)
         self._marker_r: int = 4
         self._heatmap:  QImage | None = None
+        # Size the markers/heatmap were last computed against. On first activation
+        # (e.g. a freshly-created Loader item) width()/height() can still be 0/stale
+        # when `sensors` is first set, computing degenerate marker positions that
+        # never get retried. paint() re-checks this every frame so geometry that
+        # settles after property assignment still gets picked up.
+        self._last_draw_size: int = -1
 
         self.widthChanged.connect(self._on_resize)
         self.heightChanged.connect(self._on_resize)
@@ -213,6 +225,29 @@ class WaferMapItem(QQuickPaintedItem):
         self.showThicknessChanged.emit()
         self.update()
 
+    @Property(int, notify=hoveredIndexChanged)
+    def hoveredIndex(self) -> int:
+        return self._hovered_index
+
+    @hoveredIndex.setter
+    def hoveredIndex(self, val: int) -> None:
+        val = int(val)
+        if val == self._hovered_index:
+            return
+        self._hovered_index = val
+        self.hoveredIndexChanged.emit()
+        self.update()
+
+    @Property(float, notify=hoverScaleChanged)
+    def hoverScale(self) -> float:
+        return self._hover_scale
+
+    @hoverScale.setter
+    def hoverScale(self, val: float) -> None:
+        self._hover_scale = float(val)
+        self.hoverScaleChanged.emit()
+        self.update()
+
     # Colour properties — QML can bind these to Theme tokens
     @Property(QColor, notify=colorsChanged)
     def ringColor(self) -> QColor: return self._ring_color
@@ -440,7 +475,15 @@ class WaferMapItem(QQuickPaintedItem):
     # ── paint ─────────────────────────────────────────────────────────────
 
     def paint(self, painter: QPainter) -> None:
-        ds   = self._draw_size()
+        ds = self._draw_size()
+        if ds != self._last_draw_size:
+            # Geometry settled (or changed) since markers/heatmap were last built
+            # against a stale size — recompute now, at actual paint time.
+            self._last_draw_size = ds
+            self._compute_markers()
+            self._rebuild_heatmap()
+            self._rebuild_thickness()
+
         r_px = int(ds / 2 - 4)
         cx, cy = self._center()
 
@@ -544,10 +587,22 @@ class WaferMapItem(QQuickPaintedItem):
                 self._bands[i] if i < len(self._bands) else "in_range",
                 self._in_range_color,
             )
+            is_hovered = i == self._hovered_index
+            marker_r = int(round(r * self._hover_scale)) if is_hovered else r
+
+            if is_hovered:
+                # Soft glow ring behind the marker, growing with hoverScale.
+                glow_r = int(round(marker_r * 1.9))
+                glow_color = QColor(color)
+                glow_color.setAlpha(70)
+                painter.setPen(Qt.PenStyle.NoPen)
+                painter.setBrush(QBrush(glow_color))
+                painter.drawEllipse(px - glow_r, py - glow_r, 2 * glow_r, 2 * glow_r)
+
             # Filled circle with thin dark outline for contrast over heatmap
             painter.setPen(QPen(QColor(0, 0, 0, 100), 1))
             painter.setBrush(QBrush(color))
-            painter.drawEllipse(px - r, py - r, 2 * r, 2 * r)
+            painter.drawEllipse(px - marker_r, py - marker_r, 2 * marker_r, 2 * marker_r)
 
             if self._show_labels:
                 has_temp = i < len(self._values)
@@ -557,7 +612,6 @@ class WaferMapItem(QQuickPaintedItem):
                 ox = getattr(s, "offset_x", 0.0) * r
                 oy = getattr(s, "offset_y", 0.0) * r
 
-                # Pre-compute metrics using current scaled fonts
                 painter.setFont(id_font)
                 id_fm = painter.fontMetrics()
                 id_line_h = id_fm.height()

tests/test_file_browser.py

@@ -0,0 +1,30 @@
+from pathlib import Path
+
+from pygui.backend.data.file_browser import FileBrowser
+
+
+def _write_csv(path, wafer_id="P00001"):
+    path.write_text(
+        f"Wafer ID={wafer_id}\n"
+        "Acquisition Date=03/26/2025\n"
+        "Label,1,2,3\n"
+        "X (mm),0,10,-10\n"
+        "Y (mm),10,-10,-10\n"
+        "data\n"
+        "0.0,149.0,148.5,150.6\n"
+    )
+
+
+def test_recorded_live_file_flagged_as_recording(qapp, tmp_path):
+    """Files named live_<serial>_<timestamp>.csv (SessionController.startRecording)
+    must be distinguishable in the browser from read-memory dumps."""
+    _write_csv(tmp_path / "live_P00001_20260706_143022.csv")
+    _write_csv(tmp_path / "P00002-20260706_143500.csv")
+
+    browser = FileBrowser()
+    browser._set_current_directory(tmp_path)
+    browser.refreshFiles()
+
+    files_by_name = {Path(row["fileName"]).name: row for row in browser.files}
+    assert files_by_name["live_P00001_20260706_143022.csv"]["isRecording"] is True
+    assert files_by_name["P00002-20260706_143500.csv"]["isRecording"] is False

tests/test_session_controller.py

@@ -47,6 +47,36 @@ def test_pause_stop_timer(controller):
     controller.stop()
     assert controller.frameIndex == 0
 
+def test_load_file_emits_error_for_empty_recording(controller, tmp_path):
+    """A recording with a valid header but zero data rows (e.g. Record was
+    started/stopped without any live frames arriving) must surface a clear
+    loadFileError instead of silently doing nothing."""
+    empty_recording = tmp_path / "live_A00001_20260706_120427.csv"
+    empty_recording.write_text(
+        "Wafer ID=A00001\n"
+        "Acquisition Date=07/06/2026\n"
+        "Label,1,2\n"
+        "X (mm),0.0,10.0\n"
+        "Y (mm),10.0,-10.0\n"
+        "data\n"
+    )
+
+    mock_slot = MagicMock()
+    controller.loadFileError.connect(mock_slot)
+    controller.loadFile(str(empty_recording))
+
+    assert mock_slot.call_count == 1
+    assert "no recorded frames" in mock_slot.call_args[0][0]
+    assert controller.loadedFile == ""
+
+def test_load_file_switches_to_review_mode(controller):
+    """Loading a file for playback must always land in review mode, even if
+    the controller was left in live mode from a previous session — otherwise
+    a successful load can be invisible behind a stale Live toggle."""
+    controller._mode = "live"
+    controller.loadFile("tests/fixtures/sample_stream.csv")
+    assert controller.mode == "review"
+
 def test_compare_files_integration(controller):
     # Mock the comparisonResult signal
     mock_slot = MagicMock()
@@ -65,6 +95,96 @@ def test_compare_files_integration(controller):
     assert "series_b" in args
     assert args["frame_offset"] == 0
 
+def test_compare_files_uses_full_run_not_first_100_frames(controller, tmp_path):
+    """compareFiles must score the whole run, not just an initial 100-frame window.
+
+    Regression test: max_frames used to be hard-capped at 100, so a >100-frame
+    run's soak/cool phases were silently excluded from the DTW comparison.
+    """
+    num_frames = 150
+    csv_path = tmp_path / "long_run.csv"
+    lines = ["Wafer ID=A12", "Acquisition Date=03/26/2025", "Label,1,2,3",
+             "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data"]
+    for i in range(num_frames):
+        t = i * 0.5
+        lines.append(f"{t},{149.0 + i * 0.01},{148.5 + i * 0.01},{150.6 + i * 0.01}")
+    csv_path.write_text("\n".join(lines) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(csv_path), str(csv_path))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is True
+    assert len(result["series_a"]) == num_frames
+    assert len(result["series_b"]) == num_frames
+
+def test_compare_files_rejects_mismatched_wafer_types(controller, tmp_path):
+    """compareFiles must refuse to compare two different wafer families.
+
+    Otherwise the overlap view silently truncates to min(sensor_count) and
+    pairs up unrelated physical sensors between the two wafer types.
+    """
+    header = ["Wafer ID=A12", "Acquisition Date=03/26/2025", "Label,1,2,3",
+              "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data",
+              "0.0,149.0,148.5,150.6"]
+    file_a = tmp_path / "A00055-20250326.csv"
+    file_b = tmp_path / "X00108-20250326.csv"
+    file_a.write_text("\n".join(header) + "\n")
+    file_b.write_text("\n".join(header) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(file_a), str(file_b))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is False
+    assert "A" in result["error"] and "X" in result["error"]
+
+def test_compare_files_rejects_recording_vs_read_mem(controller, tmp_path):
+    """A live_-prefixed recording must not be compared against a read-memory
+    dump. Regression: stem[0] on "live_P0001_..." is "L", which used to be
+    misreported as a wafer-type mismatch ("L vs P") instead of this clearer
+    recording-vs-read-mem error.
+    """
+    header = ["Wafer ID=P0001", "Acquisition Date=03/26/2025", "Label,1,2,3",
+              "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data",
+              "0.0,149.0,148.5,150.6"]
+    recording = tmp_path / "live_P0001_20260706_143022.csv"
+    read_mem = tmp_path / "P0001-20260706_143500.csv"
+    recording.write_text("\n".join(header) + "\n")
+    read_mem.write_text("\n".join(header) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(recording), str(read_mem))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is False
+    assert result["error"] == "Cannot compare a recording file with a read-memory file"
+
+def test_compare_files_allows_two_recordings_of_same_wafer_type(controller, tmp_path):
+    """Two live recordings of the same wafer family should compare fine —
+    the "live_" prefix must not be mistaken for the wafer type letter."""
+    header = ["Wafer ID=P0001", "Acquisition Date=03/26/2025", "Label,1,2,3",
+              "X (mm),0,10,-10", "Y (mm),10,-10,-10", "data",
+              "0.0,149.0,148.5,150.6"]
+    file_a = tmp_path / "live_P0001_20260706_143022.csv"
+    file_b = tmp_path / "live_P0002_20260706_150000.csv"
+    file_a.write_text("\n".join(header) + "\n")
+    file_b.write_text("\n".join(header) + "\n")
+
+    mock_slot = MagicMock()
+    controller.comparisonResult.connect(mock_slot)
+    controller.compareFiles(str(file_a), str(file_b))
+
+    assert mock_slot.call_count == 1
+    result = mock_slot.call_args[0][0]
+    assert result["success"] is True
+
 def test_comparison_result_reaches_qml(qapp, controller):
     """The result dict must arrive in QML as a real JS object with fields.