Fix mypy type errors in reporting module

.dockerignore

@@ -0,0 +1,50 @@
+# Git
+.git
+.gitignore
+.gitea
+
+# Python
+__pycache__
+*.py[cod]
+*$py.class
+*.so
+.Python
+*.egg-info
+.eggs
+dist
+build
+.pytest_cache
+.mypy_cache
+.ruff_cache
+.coverage
+htmlcov
+
+# Tests
+tests/
+pytest.ini
+
+# Documentation
+docs/
+*.md
+!README.md
+
+# Development
+.vscode
+.idea
+*.swp
+*.swo
+*~
+
+# Environment
+.env
+.env.*
+venv
+.venv
+
+# Data (will be created fresh in container)
+data/
+*.db
+*.parquet
+
+# CI/CD
+.gitea/

CHANGELOG.md

@@ -8,6 +8,10 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 ## [Unreleased]
 
 ### Added
+- Fly.io deployment configuration for public demo
+  - Dockerfile with Python 3.11-slim and WeasyPrint dependencies
+  - fly.toml with scale-to-zero configuration (London region)
+  - .dockerignore to exclude tests, docs, and development files
 - PDF Report Generation (Sprint 18)
   - Professional PDF reports from test results with charts and styling
   - `ReportGenerator` class orchestrating data gathering, chart generation, and PDF output

Dockerfile

@@ -0,0 +1,39 @@
+FROM python:3.11-slim
+
+WORKDIR /app
+
+# Install system dependencies for WeasyPrint (PDF generation)
+RUN apt-get update && apt-get install -y --no-install-recommends \
+    libpango-1.0-0 \
+    libpangocairo-1.0-0 \
+    libgdk-pixbuf2.0-0 \
+    libffi-dev \
+    shared-mime-info \
+    && rm -rf /var/lib/apt/lists/*
+
+# Copy project files
+COPY pyproject.toml .
+COPY src/ src/
+COPY config/ config/
+
+# Install package with reports dependencies (for PDF export)
+RUN pip install --no-cache-dir -e ".[reports]"
+
+# Create data directory for SQLite and measurements
+RUN mkdir -p /app/data/measurements /app/data/reports
+
+# Streamlit configuration
+RUN mkdir -p ~/.streamlit
+RUN echo '[server]\n\
+headless = true\n\
+address = "0.0.0.0"\n\
+port = 8080\n\
+enableXsrfProtection = false\n\
+enableCORS = false\n\
+\n\
+[browser]\n\
+gatherUsageStats = false\n' > ~/.streamlit/config.toml
+
+EXPOSE 8080
+
+CMD ["streamlit", "run", "src/py_dvt_ate/app/dashboard/app.py"]

docs/05_sprint_18_report_generation.md

@@ -0,0 +1,460 @@
+# Sprint 18: PDF Report Generation
+
+| Document ID | DEV-002 |
+|-------------|---------|
+| Version | 1.0.0 |
+| Status | Draft |
+| Author | Kai Chappell |
+| Created | 2026-01-29 |
+| Last Updated | 2026-01-29 |
+
+---
+
+## Purpose
+
+This document defines **Sprint 18** of py-dvt-ate development: automated PDF report generation from test results. Reports are designed to be professional and well-presented for recruiters/clients evaluating the simulation platform.
+
+For project context, see:
+- `01_requirements.md` - What the system must do
+- `02_technical_specification.md` - How to implement
+- `03_architecture_decisions.md` - Why decisions were made
+- `04_development_plan.md` - Phase 1 MVP sprints (1-17)
+
+---
+
+## Feature Overview
+
+Add automated PDF report generation with:
+- Professional, well-presented layout suitable for external stakeholders
+- Clean UX with easy download from CLI and dashboard
+- Test metadata, results table with pass/fail status, and measurement charts
+- Configurable company branding
+
+---
+
+## Design Principles
+
+Following existing project patterns:
+
+1. **Small, Focused Commits** - Each task = 1 commit, ~50-150 lines changed
+2. **Stubs First** - Define interfaces/types before implementation
+3. **Test Alongside** - Write tests immediately after implementation
+4. **UK English** - characterisation, behaviour, colour
+5. **Minimal Context** - Each task completable with knowledge of 1-3 files
+
+---
+
+## Task Breakdown
+
+### Task 18.1: Add reporting dependencies to pyproject.toml
+
+- Add `matplotlib>=3.8` to reports optional dependency group
+- Verify jinja2 and weasyprint already present
+- **Files:** `pyproject.toml`
+- **Commit:** "Add matplotlib to reports dependencies"
+
+---
+
+### Task 18.2: Create report data models
+
+- Create `src/py_dvt_ate/reporting/models.py`
+- Define `ReportConfig` dataclass:
+  - `company_name: str` - Company name for header
+  - `logo_path: Path | None` - Optional logo image path
+  - `include_charts: bool` - Whether to include charts
+  - `chart_dpi: int` - Chart resolution
+- Define `ReportData` dataclass:
+  - `run: TestRun` - Test run metadata
+  - `results: list[TestResult]` - Scalar results with limits
+  - `measurements: pd.DataFrame | None` - Time-series data
+  - `charts: dict[str, str]` - Chart name to base64 PNG
+- **Files:** `src/py_dvt_ate/reporting/models.py`
+- **Commit:** "Add report data models"
+
+---
+
+### Task 18.3: Create reporting exceptions
+
+- Create `src/py_dvt_ate/reporting/exceptions.py`
+- Define exception hierarchy:
+  - `ReportingError` - Base exception
+  - `ReportGenerationError` - General generation failure
+  - `TemplateRenderError` - HTML rendering failure
+  - `PDFConversionError` - HTML to PDF conversion failure
+  - `ChartGenerationError` - Chart generation failure
+- **Files:** `src/py_dvt_ate/reporting/exceptions.py`
+- **Commit:** "Add reporting exception classes"
+
+---
+
+### Task 18.4: Create CSS stylesheet for reports
+
+- Create `src/py_dvt_ate/reporting/templates/styles.css`
+- Professional styling:
+  - A4 page setup with margins
+  - Header with company branding
+  - Footer with page numbers
+  - Data tables with borders
+  - Status badges (pass=green, fail=red, info=blue)
+  - Summary cards with colour coding
+  - Chart containers
+  - Print-optimised with page breaks
+- **Files:** `src/py_dvt_ate/reporting/templates/styles.css`
+- **Commit:** "Add professional CSS stylesheet for reports"
+
+---
+
+### Task 18.5: Create base HTML template
+
+- Create `src/py_dvt_ate/reporting/templates/base.html`
+- Jinja2 base template with:
+  - `<head>` with CSS include
+  - Header block with company name, logo, report metadata
+  - Content block (for child templates)
+  - Footer block with confidentiality notice, page numbers
+- WeasyPrint `@page` rules for PDF pagination
+- **Files:** `src/py_dvt_ate/reporting/templates/base.html`
+- **Commit:** "Add base HTML report template"
+
+---
+
+### Task 18.6: Create test report template
+
+- Create `src/py_dvt_ate/reporting/templates/test_report.html`
+- Extends `base.html` with sections:
+  - **Test Overview**: name, description, status, timestamps, duration, operator
+  - **Results Summary**: total/pass/fail cards with counts
+  - **Results Table**: parameter, value, unit, limits, pass/fail badge
+  - **Charts**: voltage vs temperature (if available)
+  - **Configuration**: test config JSON (optional)
+- Jinja2 filters for formatting (floats, dates)
+- **Files:** `src/py_dvt_ate/reporting/templates/test_report.html`
+- **Commit:** "Add test report HTML template"
+
+---
+
+### Task 18.7: Implement HTML renderer
+
+- Create `src/py_dvt_ate/reporting/renderers/__init__.py`
+- Create `src/py_dvt_ate/reporting/renderers/html.py`
+- `HTMLRenderer` class:
+  - Constructor takes `ReportConfig`
+  - Uses `jinja2.Environment` with `PackageLoader`
+  - `render(report_data: ReportData) -> str` method
+  - Custom filters for number formatting
+- Template loading from `py_dvt_ate.reporting.templates` package
+- **Files:** `src/py_dvt_ate/reporting/renderers/html.py`, `src/py_dvt_ate/reporting/renderers/__init__.py`
+- **Commit:** "Implement HTML renderer with Jinja2"
+
+---
+
+### Task 18.8: Implement PDF renderer
+
+- Create `src/py_dvt_ate/reporting/renderers/pdf.py`
+- `PDFRenderer` class:
+  - `render_to_file(html: str, output_path: Path) -> None`
+  - `render_to_bytes(html: str) -> bytes`
+- Use WeasyPrint `HTML(string=html).write_pdf()`
+- Handle WeasyPrint warnings gracefully
+- **Files:** `src/py_dvt_ate/reporting/renderers/pdf.py`
+- **Commit:** "Implement PDF renderer with WeasyPrint"
+
+---
+
+### Task 18.9: Implement chart generator
+
+- Create `src/py_dvt_ate/reporting/charts/__init__.py`
+- Create `src/py_dvt_ate/reporting/charts/matplotlib_charts.py`
+- `ChartGenerator` class:
+  - Constructor takes `ReportConfig` (for DPI)
+  - `_setup_style()` - Configure matplotlib for professional appearance
+  - `generate_voltage_vs_temperature(measurements: DataFrame) -> str`
+    - Scatter plot with trend line
+    - Calculate and display slope (ppm/C)
+    - Return base64-encoded PNG
+  - `generate_all(run, results, measurements) -> dict[str, str]`
+    - Dispatch to appropriate chart methods based on test type
+- Use `matplotlib.use('Agg')` for non-interactive backend
+- **Files:** `src/py_dvt_ate/reporting/charts/matplotlib_charts.py`, `src/py_dvt_ate/reporting/charts/__init__.py`
+- **Commit:** "Implement matplotlib chart generator"
+
+---
+
+### Task 18.10: Implement ReportGenerator class
+
+- Create `src/py_dvt_ate/reporting/generator.py`
+- `IReportGenerator` Protocol:
+  - `generate(run_id: UUID, output_path: Path | None) -> Path`
+  - `generate_bytes(run_id: UUID) -> bytes`
+- `ReportGenerator` class:
+  - Constructor: `repository`, `config`, `output_dir`
+  - Private: `_html_renderer`, `_pdf_renderer`, `_chart_generator`
+  - `_gather_data(run_id: UUID) -> ReportData`
+    - Fetch run, results, measurements from repository
+    - Generate charts if measurements available
+  - `_generate_output_path(run: TestRun) -> Path`
+    - Format: `{test_name}_{run_id_short}_{timestamp}.pdf`
+  - Error handling with appropriate exception types
+- **Files:** `src/py_dvt_ate/reporting/generator.py`
+- **Commit:** "Implement ReportGenerator class"
+
+---
+
+### Task 18.11: Update reporting module exports
+
+- Update `src/py_dvt_ate/reporting/__init__.py`
+- Export public API:
+  - `ReportGenerator`, `IReportGenerator`
+  - `ReportConfig`, `ReportData`
+  - All exception classes
+- Add module docstring with usage example
+- Lazy imports to handle missing optional dependencies
+- **Files:** `src/py_dvt_ate/reporting/__init__.py`
+- **Commit:** "Update reporting module public API"
+
+---
+
+### Task 18.12: Add ReportingConfig to app config
+
+- Update `src/py_dvt_ate/app/config.py`
+- Add `ReportingConfig` Pydantic model:
+  - `company_name: str = "DVT Engineering"`
+  - `logo_path: str | None = None`
+  - `include_charts: bool = True`
+  - `chart_dpi: int = 150`
+- Add `reporting: ReportingConfig` to `AppConfig`
+- **Files:** `src/py_dvt_ate/app/config.py`
+- **Commit:** "Add ReportingConfig to application config"
+
+---
+
+### Task 18.13: Add reporting section to default.yaml
+
+- Update `config/default.yaml`
+- Add `reporting:` section with all options
+- Document each option with comments
+- **Files:** `config/default.yaml`
+- **Commit:** "Add reporting configuration to default.yaml"
+
+---
+
+### Task 18.14: Add list-runs CLI command
+
+- Update `src/py_dvt_ate/app/cli.py`
+- Add `list-runs` command:
+  - `--limit` option (default 10)
+  - `--config` option for config file
+- Output format: `{id:8}  {test_name:15}  {status:8}  {timestamp}`
+- Load repository from config
+- **Files:** `src/py_dvt_ate/app/cli.py`
+- **Commit:** "Add list-runs CLI command"
+
+---
+
+### Task 18.15: Add export-report CLI command
+
+- Update `src/py_dvt_ate/app/cli.py`
+- Add `export-report` command:
+  - `run_id` argument (required)
+  - `--output` / `-o` option for output path
+  - `--company` option for company name override
+  - `--config` option for config file
+- Support short (8-char) and full UUID lookup
+- Display progress and result path
+- **Files:** `src/py_dvt_ate/app/cli.py`
+- **Commit:** "Add export-report CLI command"
+
+---
+
+### Task 18.16: Add PDF download to dashboard
+
+- Update `src/py_dvt_ate/app/dashboard/app.py`
+- In results viewer page, add:
+  - "Generate PDF Report" button (primary)
+  - `st.download_button` for PDF download
+  - Progress spinner during generation
+  - Error handling for missing dependencies
+- Store generated PDF in `st.session_state`
+- **Files:** `src/py_dvt_ate/app/dashboard/app.py`
+- **Commit:** "Add PDF download button to dashboard"
+
+---
+
+### Task 18.17: Add reporting unit tests
+
+- Create `tests/unit/reporting/__init__.py`
+- Create `tests/unit/reporting/test_models.py`
+  - Test ReportConfig and ReportData creation
+  - Test default values
+- Create `tests/unit/reporting/test_html_renderer.py`
+  - Test template rendering with mock data
+  - Test custom filters
+- Create `tests/unit/reporting/test_chart_generator.py`
+  - Test chart generation produces valid base64
+  - Test with sample DataFrame
+- **Files:** `tests/unit/reporting/`
+- **Commit:** "Add reporting unit tests"
+
+---
+
+### Task 18.18: Add reporting integration test
+
+- Create `tests/integration/test_report_generation.py`
+- End-to-end test:
+  - Create test run with sample results in repository
+  - Generate PDF report
+  - Verify PDF file created and non-empty
+  - Optionally verify PDF structure (page count)
+- Use pytest fixtures for repository setup
+- **Files:** `tests/integration/test_report_generation.py`
+- **Commit:** "Add report generation integration test"
+
+---
+
+### Task 18.19: Update CHANGELOG
+
+- Update `CHANGELOG.md`
+- Add `## [Unreleased]` section if not present
+- Document:
+  - New `export-report` CLI command
+  - New `list-runs` CLI command
+  - Dashboard PDF download feature
+  - Reporting module with PDF/HTML generation
+- **Files:** `CHANGELOG.md`
+- **Commit:** "Update CHANGELOG with report generation feature"
+
+---
+
+## File Structure (New Files)
+
+```
+src/py_dvt_ate/reporting/
+├── __init__.py              # Task 18.11 - Public API
+├── models.py                # Task 18.2 - ReportConfig, ReportData
+├── exceptions.py            # Task 18.3 - Exception hierarchy
+├── generator.py             # Task 18.10 - ReportGenerator
+├── renderers/
+│   ├── __init__.py          # Task 18.7
+│   ├── html.py              # Task 18.7 - HTMLRenderer
+│   └── pdf.py               # Task 18.8 - PDFRenderer
+├── charts/
+│   ├── __init__.py          # Task 18.9
+│   └── matplotlib_charts.py # Task 18.9 - ChartGenerator
+└── templates/
+    ├── styles.css           # Task 18.4 - CSS
+    ├── base.html            # Task 18.5 - Base template
+    └── test_report.html     # Task 18.6 - Report template
+
+tests/unit/reporting/
+├── __init__.py              # Task 18.17
+├── test_models.py           # Task 18.17
+├── test_html_renderer.py    # Task 18.17
+└── test_chart_generator.py  # Task 18.17
+
+tests/integration/
+└── test_report_generation.py # Task 18.18
+```
+
+---
+
+## Files to Modify
+
+| File | Tasks | Changes |
+|------|-------|---------|
+| `pyproject.toml` | 18.1 | Add matplotlib to reports deps |
+| `src/py_dvt_ate/app/config.py` | 18.12 | Add ReportingConfig |
+| `config/default.yaml` | 18.13 | Add reporting section |
+| `src/py_dvt_ate/app/cli.py` | 18.14, 18.15 | Add list-runs, export-report |
+| `src/py_dvt_ate/app/dashboard/app.py` | 18.16 | Add PDF download |
+| `CHANGELOG.md` | 18.19 | Document new features |
+
+---
+
+## Dependencies
+
+| Package | Version | Purpose |
+|---------|---------|---------|
+| jinja2 | >=3.1 | HTML template rendering |
+| weasyprint | >=60.0 | HTML to PDF conversion |
+| matplotlib | >=3.8 | Chart generation |
+
+All in `[project.optional-dependencies] reports` group.
+
+Install with: `pip install py-dvt-ate[reports]`
+
+---
+
+## Verification
+
+### CLI Verification
+
+```bash
+# List recent test runs
+py-dvt-ate list-runs
+
+# Generate PDF report
+py-dvt-ate export-report <run_id>
+
+# With options
+py-dvt-ate export-report <run_id> -o ./my_report.pdf --company "Acme Corp"
+
+# View generated PDF
+xdg-open ./data/reports/*.pdf
+```
+
+### Dashboard Verification
+
+```bash
+# Start dashboard
+streamlit run src/py_dvt_ate/app/dashboard/app.py
+
+# In browser:
+# 1. Navigate to Results Viewer
+# 2. Select a test run
+# 3. Click "Generate PDF Report"
+# 4. Click "Download PDF Report"
+# 5. Open downloaded PDF
+```
+
+### Test Verification
+
+```bash
+# Run unit tests
+pytest tests/unit/reporting/ -v
+
+# Run integration test
+pytest tests/integration/test_report_generation.py -v
+
+# Check coverage
+pytest tests/unit/reporting/ --cov=py_dvt_ate.reporting --cov-report=term-missing
+```
+
+---
+
+## Task Progress
+
+| Task | Status | Description |
+|------|--------|-------------|
+| 18.1 | pending | Add matplotlib dependency |
+| 18.2 | pending | Report data models |
+| 18.3 | pending | Reporting exceptions |
+| 18.4 | pending | CSS stylesheet |
+| 18.5 | pending | Base HTML template |
+| 18.6 | pending | Test report template |
+| 18.7 | pending | HTML renderer |
+| 18.8 | pending | PDF renderer |
+| 18.9 | pending | Chart generator |
+| 18.10 | pending | ReportGenerator class |
+| 18.11 | pending | Module exports |
+| 18.12 | pending | App config update |
+| 18.13 | pending | default.yaml update |
+| 18.14 | pending | list-runs CLI |
+| 18.15 | pending | export-report CLI |
+| 18.16 | pending | Dashboard download |
+| 18.17 | pending | Unit tests |
+| 18.18 | pending | Integration test |
+| 18.19 | pending | CHANGELOG update |
+
+---
+
+**End of Sprint 18 Plan**

fly.toml

@@ -0,0 +1,16 @@
+app = "py-dvt-ate"
+primary_region = "lhr"
+
+[build]
+
+[http_service]
+  internal_port = 8080
+  force_https = true
+  auto_stop_machines = "stop"
+  auto_start_machines = true
+  min_machines_running = 0
+
+[[vm]]
+  cpu_kind = "shared"
+  cpus = 1
+  memory_mb = 512

pyproject.toml

@@ -84,6 +84,8 @@ disallow_incomplete_defs = true
 module = [
     "streamlit.*",
     "plotly.*",
+    "weasyprint.*",
+    "matplotlib.*",
 ]
 ignore_missing_imports = true
 

src/py_dvt_ate/reporting/charts/matplotlib_charts.py

@@ -6,6 +6,7 @@ Charts are rendered to base64-encoded PNG images for embedding in HTML/PDF.
 
 import base64
 from io import BytesIO
+from typing import Any
 
 import pandas as pd
 
@@ -27,9 +28,9 @@ class ChartGenerator:
             dpi: Resolution for chart images (dots per inch).
         """
         self.dpi = dpi
-        self._plt: type | None = None
+        self._plt: tuple[Any, Any] | None = None
 
-    def _get_matplotlib(self) -> tuple:
+    def _get_matplotlib(self) -> tuple[Any, Any]:
         """Lazy-load matplotlib to avoid import errors when not installed.
 
         Returns:

src/py_dvt_ate/reporting/renderers/pdf.py

@@ -75,7 +75,8 @@ class PDFRenderer:
         """
         try:
             HTML = self._get_weasyprint()
-            return HTML(string=html).write_pdf()
+            result: bytes = HTML(string=html).write_pdf()
+            return result
         except PDFConversionError:
             raise
         except Exception as e: