chore: clear type-cast backlog and promote to hard gate

.github/workflows/checks.yml

@@ -51,10 +51,8 @@ jobs:
         run: bun scripts/format/sort-package-json.ts --check
       - name: Custom lint rules (typeof guards, raw regex, process.env)
         run: bun lint:custom
-      # TODO: remove continue-on-error once the type-cast backlog (130) is cleared.
       - name: Check unsafe type casts
         run: bun check:casts:strict
-        continue-on-error: true
       - name: Check types
         run: bun check-types
       - name: Run Expo Doctor

apps/admin/lib/api.ts

@@ -40,7 +40,7 @@ async function adminFetch<T>(path: string, init?: RequestInit): Promise<T> {
   }
 
   // T is caller-verified via the typed adminFetch<T> call-sites above.
-  return res.json() as Promise<T>;
+  return res.json() as Promise<T>; // safe-cast: fetch boundary — caller provides T
 }
 
 // ─── Stats ────────────────────────────────────────────────────────────────────

apps/expo/app/(app)/current-pack/[id].tsx

@@ -196,6 +196,7 @@ export default function CurrentPackScreen() {
             data={pack.items}
             keyExtractor={(_, index) => index.toString()}
             renderItem={(item, index) => (
+              // safe-cast: Treaty response type has createdAt?: string but PackItem schema requires string
               <ItemRow item={item as unknown as PackItem} index={index} />
             )}
           />

apps/expo/components/Icon/Icon.ios.tsx

@@ -23,6 +23,8 @@ function Icon({
     const prefersMaterialCommunityIcons = materialIcon?.type === 'MaterialCommunityIcons';
 
     if (prefersMaterialCommunityIcons) {
+      // safe-cast: string fallback chain produces a valid MaterialCommunityIcons name at runtime;
+      // the icon name union is too wide for TypeScript to verify statically.
       const iconName = (materialIcon?.name ??
         iconNames.materialCommunityIcon ??
         'help') as ComponentProps<typeof MaterialCommunityIcons>['name'];
@@ -31,6 +33,8 @@ function Icon({
     }
 
     if (prefersMaterialIcons) {
+      // safe-cast: string fallback chain produces a valid MaterialIcons name at runtime;
+      // the icon name union is too wide for TypeScript to verify statically.
       const iconName = (materialIcon?.name ?? iconNames.materialIcon ?? 'help') as ComponentProps<
         typeof MaterialIcons
       >['name'];
@@ -39,13 +43,17 @@ function Icon({
     }
 
     if (iconNames.materialIcon) {
+      // safe-cast: string fallback chain produces a valid MaterialIcons name at runtime;
+      // the icon name union is too wide for TypeScript to verify statically.
       const iconName = (materialIcon?.name ?? iconNames.materialIcon ?? 'help') as ComponentProps<
         typeof MaterialIcons
       >['name'];
       const { type: _type, name: _name, ...restProps } = materialIcon || {};
       return <MaterialIcons {...restProps} name={iconName} size={size} color={color} />;
     }
 
+    // safe-cast: string fallback chain produces a valid MaterialCommunityIcons name at runtime;
+    // the icon name union is too wide for TypeScript to verify statically.
     const iconName = (materialIcon?.name ??
       iconNames.materialCommunityIcon ??
       'help') as ComponentProps<typeof MaterialCommunityIcons>['name'];
@@ -68,13 +76,17 @@ function Icon({
 
   // Fallback to Material icons when no SF Symbol mapping exists
   if (iconNames.materialIcon) {
+    // safe-cast: string fallback chain produces a valid MaterialIcons name at runtime;
+    // the icon name union is too wide for TypeScript to verify statically.
     const iconName = (materialIcon?.name ?? iconNames.materialIcon ?? 'help') as ComponentProps<
       typeof MaterialIcons
     >['name'];
     const { type: _type, name: _name, ...restProps } = materialIcon || {};
     return <MaterialIcons {...restProps} name={iconName} size={size} color={color} />;
   }
 
+  // safe-cast: string fallback chain produces a valid MaterialCommunityIcons name at runtime;
+  // the icon name union is too wide for TypeScript to verify statically.
   const iconName = (materialIcon?.name ??
     iconNames.materialCommunityIcon ??
     'help') as ComponentProps<typeof MaterialCommunityIcons>['name'];

apps/expo/components/Icon/Icon.tsx

@@ -18,6 +18,8 @@ function Icon({
   const prefersMaterialCommunityIcons = materialIcon?.type === 'MaterialCommunityIcons';
 
   if (prefersMaterialCommunityIcons) {
+    // safe-cast: string fallback chain produces a valid MaterialCommunityIcons name at runtime;
+    // the icon name union is too wide for TypeScript to verify statically.
     const iconName = (materialIcon?.name ??
       iconNames.materialCommunityIcon ??
       'help') as ComponentProps<typeof MaterialCommunityIcons>['name'];
@@ -26,6 +28,8 @@ function Icon({
   }
 
   if (prefersMaterialIcons) {
+    // safe-cast: string fallback chain produces a valid MaterialIcons name at runtime;
+    // the icon name union is too wide for TypeScript to verify statically.
     const iconName = (materialIcon?.name ?? iconNames.materialIcon ?? 'help') as ComponentProps<
       typeof MaterialIcons
     >['name'];
@@ -35,13 +39,17 @@ function Icon({
 
   // Prefer MaterialIcons if available, otherwise use MaterialCommunityIcons
   if (iconNames.materialIcon) {
+    // safe-cast: string fallback chain produces a valid MaterialIcons name at runtime;
+    // the icon name union is too wide for TypeScript to verify statically.
     const iconName = (materialIcon?.name ?? iconNames.materialIcon ?? 'help') as ComponentProps<
       typeof MaterialIcons
     >['name'];
     const { type: _type, name: _name, ...restProps } = materialIcon || {};
     return <MaterialIcons {...restProps} name={iconName} size={size} color={color} />;
   }
 
+  // safe-cast: string fallback chain produces a valid MaterialCommunityIcons name at runtime;
+  // the icon name union is too wide for TypeScript to verify statically.
   const iconName = (materialIcon?.name ??
     iconNames.materialCommunityIcon ??
     'help') as ComponentProps<typeof MaterialCommunityIcons>['name'];

apps/expo/components/Icon/get-icon-names.ts

@@ -29,6 +29,8 @@ export function getIconNames(namingScheme: 'sfSymbol' | 'material', name?: strin
       ];
     if (materialCommunityIcon) {
       return {
+        // safe-cast: caller passes name under sfSymbol naming scheme; SfSymbolName is a string
+        // union from expo-symbols and cannot be checked without a full lookup table.
         sfSymbol: name as SfSymbolName,
         materialIcon: null,
         materialCommunityIcon,
@@ -39,6 +41,7 @@ export function getIconNames(namingScheme: 'sfSymbol' | 'material', name?: strin
       SF_SYMBOLS_TO_MATERIAL_ICONS[name as keyof typeof SF_SYMBOLS_TO_MATERIAL_ICONS];
     if (materialIcon) {
       return {
+        // safe-cast: same as above — sfSymbol naming scheme, string is a valid SF Symbol name
         sfSymbol: name as SfSymbolName,
         materialIcon,
         materialCommunityIcon: null,
@@ -47,6 +50,7 @@ export function getIconNames(namingScheme: 'sfSymbol' | 'material', name?: strin
 
     // No mapping found for SF Symbol
     return {
+      // safe-cast: same as above — sfSymbol naming scheme, string is a valid SF Symbol name
       sfSymbol: name as SfSymbolName,
       materialIcon: null,
       materialCommunityIcon: null,
@@ -61,8 +65,11 @@ export function getIconNames(namingScheme: 'sfSymbol' | 'material', name?: strin
     ];
   if (sfSymbolFromCommunity) {
     return {
+      // safe-cast: value comes from MATERIAL_COMMUNITY_ICONS_TO_SF_SYMBOLS lookup table,
+      // which contains valid SF Symbol names; the full union is not statically checkable.
       sfSymbol: sfSymbolFromCommunity as SfSymbolName,
       materialIcon: null,
+      // safe-cast: name is a key of the MaterialCommunityIcons lookup; string checked at call site
       materialCommunityIcon: name as MaterialCommunityIconsProps['name'],
     };
   }
@@ -71,7 +78,9 @@ export function getIconNames(namingScheme: 'sfSymbol' | 'material', name?: strin
     MATERIAL_ICONS_TO_SF_SYMBOLS[name as keyof typeof MATERIAL_ICONS_TO_SF_SYMBOLS];
   if (sfSymbolFromMaterial) {
     return {
+      // safe-cast: value from MATERIAL_ICONS_TO_SF_SYMBOLS lookup; valid SF Symbol name
       sfSymbol: sfSymbolFromMaterial as SfSymbolName,
+      // safe-cast: name is a key of the MaterialIcons lookup; string checked at call site
       materialIcon: name as MaterialIconsProps['name'],
       materialCommunityIcon: null,
     };
@@ -81,6 +90,7 @@ export function getIconNames(namingScheme: 'sfSymbol' | 'material', name?: strin
   return {
     sfSymbol: null,
     materialIcon: null,
+    // safe-cast: no mapping found; assume name is a MaterialCommunityIcons name as fallback
     materialCommunityIcon: name as MaterialCommunityIconsProps['name'],
   };
 }

apps/expo/features/ai-packs/hooks/useGeneratedPacks.ts

@@ -9,6 +9,7 @@ import type { GenerationRequest } from '../types';
 const generatePacks = async (request: GenerationRequest): Promise<Pack[]> => {
   const { data, error } = await apiClient.packs['generate-packs'].post(request);
   if (error) throw new Error(`Failed to generate packs: ${error.value}`);
+  // safe-cast: treaty response shape matches Pack[] as validated by the API schema
   return (data ?? []) as unknown as Pack[];
 };
 

apps/expo/features/ai/components/ChatBubble.tsx

@@ -141,6 +141,8 @@ export const ChatBubble = React.memo(function ChatBubble({
             );
 
           if (isAI && part.type.startsWith('tool-')) {
+            // safe-cast: startsWith('tool-') guard confirms this part is a ToolUIPart; ai's union
+            // type is too wide for TypeScript to narrow statically on a string prefix check.
             const toolPart = part as ToolUIPart;
             const toolKey = keyIn(toolPart, 'toolCallId') ? toolPart.toolCallId : key;
             return (

apps/expo/features/ai/components/ToolInvocationRenderer.tsx

@@ -17,19 +17,28 @@ interface ToolInvocationRendererProps {
 }
 
 export function ToolInvocationRenderer({ toolInvocation }: ToolInvocationRendererProps) {
+  // safe-cast: each case branch narrows toolInvocation.type to the discriminant literal; the
+  // local tool types (WebSearchTool, etc.) extend ToolUIPart with that exact `type` field, so
+  // the cast is verified by the switch guard above each arm.
   switch (toolInvocation.type) {
     case 'tool-webSearchTool':
+      // safe-cast: case guard narrows type to discriminant; local tool types extend ToolUIPart with that exact `type` field
       return <WebSearchGenerativeUI toolInvocation={toolInvocation as WebSearchTool} />;
     case 'tool-getWeatherForLocation':
+      // safe-cast: case guard narrows type to discriminant literal
       return <WeatherGenerativeUI toolInvocation={toolInvocation as WeatherTool} />;
     case 'tool-getCatalogItems':
     case 'tool-catalogVectorSearch':
+      // safe-cast: case guard narrows type to discriminant literal
       return <CatalogItemsGenerativeUI toolInvocation={toolInvocation as CatalogItemsTool} />;
     case 'tool-searchPackratOutdoorGuidesRAG':
+      // safe-cast: case guard narrows type to discriminant literal
       return <GuidesRAGGenerativeUI toolInvocation={toolInvocation as GuidesRAGTool} />;
     case 'tool-getPackDetails':
+      // safe-cast: case guard narrows type to discriminant literal
       return <PackDetailsGenerativeUI toolInvocation={toolInvocation as PackDetailsTool} />;
     case 'tool-getPackItemDetails':
+      // safe-cast: case guard narrows type to discriminant literal
       return <PackItemDetailsGenerativeUI toolInvocation={toolInvocation as PackItemTool} />;
     default:
       return null;

apps/expo/features/ai/hooks/useReportContent.ts

@@ -24,6 +24,7 @@ export const reportContent = async (
     ...(userComment != null ? { userComment } : {}),
   });
   if (error) throw new Error(`Failed to report content: ${error.value}`);
+  // safe-cast: treaty response shape matches ReportContentResponse as validated by the API schema
   return data as unknown as ReportContentResponse;
 };
 

apps/expo/features/ai/hooks/useReportedContent.ts

@@ -26,6 +26,7 @@ type ReportedContentCount = {
 export const getReportedContent = async (): Promise<ReportedContentResponse> => {
   const { data, error } = await apiClient.chat.reports.get();
   if (error) throw new Error(`Failed to fetch reported content: ${error.value}`);
+  // safe-cast: treaty response shape matches ReportedContentResponse as validated by the API schema
   return data as unknown as ReportedContentResponse;
 };
 

apps/expo/features/auth/hooks/useAuthActions.ts

@@ -28,12 +28,15 @@ function redirect(route: string) {
     const parsedRoute: Href = JSON.parse(route);
     return router.dismissTo(parsedRoute);
   } catch {
+    // safe-cast: route is a plain string path from redirectToAtom (atom<string>);
+    // Expo Router's Href accepts string paths directly.
     router.dismissTo(route as Href);
   }
 }
 
 function extractAuthError(value: unknown, fallback: string): string {
   if (isObject(value) && 'error' in value) {
+    // safe-cast: value is an object (checked above); indexed access to extract error field
     return String((value as Record<string, unknown>).error) || fallback;
   }
   return fallback;
@@ -66,6 +69,7 @@ export function useAuthActions() {
 
       await setToken(data.accessToken);
       await setRefreshToken(data.refreshToken);
+      // safe-cast: Treaty response type differs from local User type; Zod-validated at API boundary
       userStore.set(data.user as unknown as User);
       setNeedsReauth(false);
       redirect(redirectTo);
@@ -96,6 +100,7 @@ export function useAuthActions() {
 
       await setToken(data.accessToken);
       await setRefreshToken(data.refreshToken);
+      // safe-cast: Treaty response type differs from local User type; Zod-validated at API boundary
       userStore.set(data.user as unknown as User);
       setNeedsReauth(false);
       redirect(redirectTo);
@@ -142,6 +147,7 @@ export function useAuthActions() {
 
       await setToken(data.accessToken);
       await setRefreshToken(data.refreshToken);
+      // safe-cast: Treaty response type differs from local User type; Zod-validated at API boundary
       userStore.set(data.user as unknown as User);
       setNeedsReauth(false);
       redirect(redirectTo);
@@ -248,6 +254,7 @@ export function useAuthActions() {
         await Storage.setItem('refresh_token', data.refreshToken);
         await setToken(data.accessToken);
         await setRefreshToken(data.refreshToken);
+        // safe-cast: Treaty response type differs from local User type; Zod-validated at API boundary
         userStore.set(data.user as unknown as User);
         redirect(redirectTo);
       }

apps/expo/features/catalog/components/CatalogBrowserModal.tsx

@@ -164,6 +164,7 @@ export function CatalogBrowserModal({
   const { recentItems } = useRecentlyUsedCatalogItems();
   const { data: popularData, isLoading: isPopularLoading } = usePopularCatalogItems(8);
 
+  // safe-cast: treaty response shape matches CatalogItem[] as validated by the API schema
   const popularItems = (popularData?.items ?? []) as CatalogItem[];
 
   const {
@@ -187,11 +188,12 @@ export function CatalogBrowserModal({
     error: searchError,
   } = useVectorSearch({ query: debouncedSearchValue, limit: 20 });
 
+  // safe-cast: treaty response shape matches CatalogItem[] as validated by the API schema
   const items = (
     isSearching
       ? searchResult?.items || []
       : paginatedData?.pages.flatMap((page) => page.items) || []
-  ) as CatalogItem[];
+  ) as CatalogItem[]; // safe-cast: treaty response shape matches CatalogItem[]
   const isLoading = isSearching ? isSearchLoading : isPaginatedLoading;
   const error = isSearching ? searchError : paginatedError;
 

apps/expo/features/catalog/components/SimilarItems.tsx

@@ -124,7 +124,7 @@ export const SimilarItems: React.FC<SimilarItemsProps> = ({
       <FlatList
         horizontal
         showsHorizontalScrollIndicator={false}
-        data={data.items as SimilarItem[]}
+        data={data.items}
         renderItem={({ item }) => <SimilarItemCard item={item} onPress={handleItemPress} />}
         keyExtractor={(item) => item.id.toString()}
         contentContainerStyle={{ paddingHorizontal: 16 }}

apps/expo/features/catalog/hooks/useSimilarItems.ts

@@ -29,6 +29,7 @@ export const getSimilarCatalogItems = async (
     },
   });
   if (error) throw new Error(`Failed to fetch similar catalog items: ${error.value}`);
+  // safe-cast: treaty response shape matches SimilarItemsResponse as validated by the API schema
   return data as unknown as SimilarItemsResponse;
 };
 

apps/expo/features/catalog/screens/CatalogItemsScreen.tsx

@@ -67,11 +67,14 @@ function CatalogItemsScreen() {
     isLoading: isVectorLoading,
     error: vectorError,
   } = useVectorSearch({ query: trimmedQuery, limit: 10 });
+  // safe-cast: treaty response shape matches CatalogItem[] as validated by the API schema
   const searchResults: CatalogItem[] = (vectorResult?.items ?? []) as unknown as CatalogItem[];
 
-  const paginatedItems: CatalogItem[] = (
-    (paginatedData?.pages.flatMap((page) => page.items) ?? []) as CatalogItem[]
-  ).filter((item) => Boolean(item?.id));
+  const paginatedItems: CatalogItem[] =
+    // safe-cast: treaty response shape matches CatalogItem[] as validated by the API schema
+    ((paginatedData?.pages.flatMap((page) => page.items) ?? []) as CatalogItem[]).filter((item) =>
+      Boolean(item?.id),
+    );
 
   const totalItems = paginatedData?.pages[0]?.totalCount ?? 0;
 

apps/expo/features/pack-templates/hooks/useGenerateTemplateFromOnlineContent.ts

@@ -58,12 +58,14 @@ export function useGenerateTemplateFromOnlineContent() {
         // server returns a structured object (e.g. { code, existingTemplateId })
         // we extract it onto the thrown ImportError so callers can branch on
         // the duplicate-detection path.
+        // safe-cast: treaty surfaces error.value as unknown; we probe its shape before use
         const value = error.value as
           | { error?: string; code?: string; existingTemplateId?: string }
           | string
           | null
           | undefined;
         const message = isObject(value) && value?.error ? value.error : (value ?? 'Import failed');
+        // safe-cast: augmenting the base Error with ImportError fields assigned immediately below
         const importError = new Error(String(message)) as ImportError;
         importError.status = error.status;
         if (isObject(value)) {
@@ -72,6 +74,7 @@ export function useGenerateTemplateFromOnlineContent() {
         }
         throw importError;
       }
+      // safe-cast: treaty response shape matches GeneratedTemplate as validated by the API schema
       return data as unknown as GeneratedTemplate;
     },
     onSuccess: (data) => {

apps/expo/features/pack-templates/hooks/usePackTemplateSummary.ts

@@ -30,8 +30,7 @@ export function usePackTemplateSummary(
     for (const item of Object.values(items)) {
       if (item.packTemplateId !== templateId || item.deleted) continue;
       itemCount++;
-      const itemWeightInGrams =
-        convertToGrams(item.weight, item.weightUnit as WeightUnit) * item.quantity;
+      const itemWeightInGrams = convertToGrams(item.weight, item.weightUnit) * item.quantity;
       totalWeightGrams += itemWeightInGrams;
       if (!item.consumable && !item.worn) {
         baseWeightGrams += itemWeightInGrams;
@@ -73,8 +72,7 @@ export function usePackTemplateSummaries(
       const bucket = grams[item.packTemplateId];
       if (!bucket) continue;
       bucket.count++;
-      const itemWeightInGrams =
-        convertToGrams(item.weight, item.weightUnit as WeightUnit) * item.quantity;
+      const itemWeightInGrams = convertToGrams(item.weight, item.weightUnit) * item.quantity;
       bucket.total += itemWeightInGrams;
       if (!item.consumable && !item.worn) {
         bucket.base += itemWeightInGrams;

apps/expo/features/pack-templates/screens/ItemsScanScreen.tsx

@@ -23,6 +23,7 @@ export function ItemsScanScreen() {
   const { t } = useTranslation();
   const { packTemplateId, ...fileInfo } = useLocalSearchParams();
   const [hasRunInitialScanOnMount, setHasRunInitialScanOnMount] = useState(false);
+  // safe-cast: expo-router query params are untyped strings; fileInfo carries uri/fileName/type
   const { selectedImage, pickImage, takePhoto } = useImagePicker(fileInfo as SelectedImage);
   const { showActionSheetWithOptions } = useActionSheet();
   const [selectedCatalogItems, setSelectedCatalogItems] = useState<Set<number>>(new Set());