falcon-v1.45.0 ships no falcon-flight wasm component asset (regression, recurrence of #100)

[avrabe]

Summary

falcon-v1.45.0 ships no falcon-flight-v*.wasm component asset — the wasm component (and its .sha256) is gone from the release. This is a recurrence of #100 (the v1.28–v1.32 drop, restored in v1.33).

Regression window

Release	falcon-flight-*.wasm asset
falcon-v1.33.0	✅ present (2: wasm + .sha256)
falcon-v1.34.0	✅ present
falcon-v1.44.0	✅ falcon-flight-v1.44.wasm + .sha256
falcon-v1.45.0	❌ absent (0 wasm assets)

falcon-v1.45.0 carries only the platform CLI tarballs, *.cdx.json, the rivet snapshot, and SHA256SUMS; the darwin tarball contains falcon-hello, LICENSE, CHANGELOG.md, README.md — no wasm. The CHANGELOG has no entry announcing the removal, so this looks unintentional (same signature as #100), not a deliberate distribution change.

Reproduction

gh release view falcon-v1.44.0 --repo pulseengine/relay --json assets \
  --jq '.assets[].name | select(test("wasm"))'
# → falcon-flight-v1.44.wasm
#   falcon-flight-v1.44.wasm.sha256

gh release view falcon-v1.45.0 --repo pulseengine/relay --json assets \
  --jq '[.assets[].name | select(test("wasm"))] | length'
# → 0

Impact on jess

jess's entire forward chain starts from the published falcon-flight wasm component: the wasmtime SIL gate (run-stabilization / run-position-hold), meld fusion, kiln native execution, and synth Cortex-M compilation all consume that asset. With it absent, falcon-v1.45.0 cannot be adopted — jess has to pin back to v1.44.0 or build falcon from source. Since the release-watch loop is meant to exercise each new release, a release with no consumable component artifact silently stalls the loop at the previous version.

Suggested fix

• Re-add the falcon-flight-v<ver>.wasm (+ .sha256) emission to the release workflow — likely the same job that regressed in falcon-v1.28.0 missing the falcon-flight wasm component asset (shipped in v1.27.0) #100 dropped out again on a workflow edit.
• Add a release-asset guard in CI: fail the release if falcon-flight-*.wasm is not among the uploaded assets (a one-line gh release view … | grep wasm assertion), so this can't silently recur a third time.

Happy to verify a re-cut v1.45.x the moment the asset is back.

Filed from the jess release-watch dogfooding loop (tracked as AFD-013); recurrence of #100.

[avrabe]

Status update from the jess loop: the regression has widened to 10 releases — falcon-v1.45.0 through falcon-v1.54.0 all ship zero falcon-flight-*.wasm assets (re-checked v1.54.0 today: platform CLI tarballs + cdx + rivet snapshot only). Last consumable release remains v1.44.0, which jess stays pinned to; every release since is invisible to downstream component consumers. The CI release-asset guard suggested above would have stopped this at v1.45.0 — happy to verify the moment a release re-ships the component (+ .sha256).

[avrabe]

falcon-v1.55.0 (2026-06-11): still zero wasm assets — the range is now v1.45.0 → v1.55.0 (11 releases). Repro unchanged from the issue body; jess remains pinned to v1.44.0.

[avrabe]

Resolved in falcon-v1.56.0 (just shipped).

The release now carries the falcon-flight Wasm component as a first-class asset — and the whole component family:

• falcon-flight-v1.56.wasm (+ .sha256) — the asset this issue asked for. Shipped sha256 3fb275db…a41341, clean-room verified (downloaded from the release, matches the local build byte-for-byte).
• falcon-components-v1.56.tar.gz (+ .sha256) — all 8 components (flight, iekf, ekf, attitude, rate, position, falcon-mixer, cascade).
• manifest.json + SHA256SUMS — the bundle index (name/sha256/bytes/toolchain per component).

Root cause of the 11-release gap: the release workflow only built binaries; the Wasm component build was a separate manual step never wired into a release. v1.56 generalizes it into scripts/build-components.sh and ships its output as a standard asset, so this won't regress.

jess can now unpin from v1.44.0 to v1.56.0 — that unpin + composing the cascade is the release's falsification field-test.

[avrabe]

Unpin executed and field-test green — confirming the fix from the jess side:

• falcon-flight-v1.56.wasm sha256 matches the shipped .sha256 (3fb275db…a41341) ✅
• wasmtime SIL gate: run-stabilization 0.023399856 (<0.1), run-position-hold 0.1317415 (<0.6) ✅
• Full chain, every piece individually: loom v1.1.13 optimize → behavioral differential exact; meld v0.29.0 fuse → valid; kiln v0.3.1 → stabilization == wasmtime exactly ✅
• synth v0.11.39 compile → 55 KB ELF (known open items: feat(falcon): v1.119 — GCS telemetry streaming + in-flight tuning (MAVLINK-P06) #275 dispatch, feat(failsafe): v1.103 — promote single-rotor-out reconfiguration into production FlightCore #242 VCR-RA skips — independent of this issue)

jess is now pinned to falcon-v1.56.0. The build-components.sh-in-release fix addresses the root cause; the component-family bundle + manifest is a nice upgrade beyond the restore. Thanks for closing the 11-release gap.

[avrabe]

Follow-up — the requested CI guard is now added (PR #163).

A session traceability audit flagged that this issue was closed with the asset restored + clean-room verified, but the one acceptance item that prevents recurrence — the CI release-asset guard — was never added. Without it, the "won't regress" claim rested on a manual-step convention, so a third #100→#140-style silent drop was still possible.

PR #163 closes that gap and fixes the root cause:

• The falcon-flight Wasm component is now built + attached by release.yml itself (a new flight-component job running scripts/build-components.sh) — no longer a separate manual step that can be forgotten.
• A hard guard asserts falcon-flight-*.wasm is among the release assets and fails the release workflow if absent — so a third silent recurrence is impossible (the release run goes red and visible).

This is the "additional release others can build on": every future falcon-v* release now self-attaches the component family and refuses to ship without the flight component. jess's forward chain (wasmtime SIL → meld → kiln/synth) is protected at the release boundary.