fix(flight-finder): require fresh search evidence and improve PDF layout

skills/flight-finder/SKILL.md

@@ -9,6 +9,12 @@ Use this skill instead of the old `docs/prompts/dfw-blq-2026.md` prompt when the
 
 The deliverable target is always a PDF report plus email delivery when the report is complete.
 
+Freshness rule:
+
+- Never reuse cached flight-search captures, prior same-day report payloads, earlier workspace artifacts, or previously rendered PDFs as the primary evidence for a new run.
+- Every flight-finder run must execute a fresh bounded search before ranking, PDF render, or email delivery.
+- If a fresh search cannot be completed, say so clearly and stop with a degraded/incomplete outcome instead of silently reusing old captures.
+
 ## Inputs
 
 Accept either:
@@ -62,6 +68,7 @@ Follow the same operational style as `property-assessor`:
 - missing required input should trigger a direct question, not an invented assumption
 - `update?`, `status?`, `and?`, and similar nudges mean “report status and keep going”
 - a silent helper/source path is a failed path and should be abandoned quickly
+- previously saved workspace captures are not a fallback; they are stale evidence and must not be reused for a new report
 - keep progress state by phase so a dropped session can resume or at least report the last completed phase
 - do not start email-tool exploration before the report payload is complete and the PDF is ready to render
 - if PDF render fails, return the completed report summary in chat and report delivery failure separately
@@ -83,6 +90,7 @@ Rules:
 - keep the bounded search phase observable with concise updates
 - normalize compared prices to USD before ranking
 - do not claim market-localized pricing succeeded unless VPN connect and post-connect verification succeeded
+- do not inspect prior `workspace/reports` flight artifacts as reusable search input for a new run
 
 ## VPN / market-country rules
 
@@ -118,6 +126,7 @@ Rules:
 - `normalize-request` should report missing search inputs separately from delivery-only email gaps
 - `report-status` should expose whether the run is ready to search, ready for a chat summary, ready to render a PDF, or ready to email
 - `render-report` must reject incomplete report payloads
+- `render-report` must reject payloads that are not explicitly marked as the output of a fresh search run
 - `delivery-plan` must stay on the Luke sender path and must not silently fall back to another sender
 
 ## Prompt migration rule

skills/flight-finder/examples/dfw-blq-2026-report-payload.json

@@ -73,6 +73,16 @@
       "normalizeCurrencyTo": "USD"
     }
   },
+  "searchExecution": {
+    "freshSearch": true,
+    "startedAt": "2026-03-30T21:00:00Z",
+    "completedAt": "2026-03-30T21:20:00Z",
+    "artifactsRoot": "/Users/stefano/.openclaw/workspace/reports/dfw-blq-flight-report-2026-03-30-exec",
+    "notes": [
+      "Fresh bounded Thailand-market search executed for this report payload.",
+      "Prior workspace captures must not be reused across flight-finder runs."
+    ]
+  },
   "sourceFindings": [
     {
       "source": "kayak",

skills/flight-finder/src/report-pdf.ts

@@ -4,7 +4,13 @@ import PDFDocument from "pdfkit";
 
 import { getFlightReportStatus } from "./report-status.js";
 import { normalizeFlightReportRequest } from "./request-normalizer.js";
-import type { FlightReportPayload } from "./types.js";
+import type {
+  FlightLegWindow,
+  FlightPassengerGroup,
+  FlightQuote,
+  FlightRecommendationOption,
+  FlightReportPayload
+} from "./types.js";
 
 export class ReportValidationError extends Error {}
 
@@ -12,14 +18,194 @@ function bulletLines(value: string[] | undefined, fallback = "Not provided."): s
   return value?.length ? value : [fallback];
 }
 
+function asLegLabelMap(legs: FlightLegWindow[]): Map<string, string> {
+  return new Map(legs.map((leg) => [leg.id, leg.label || `${leg.origin} -> ${leg.destination}`]));
+}
+
+function asPassengerGroupLabelMap(groups: FlightPassengerGroup[]): Map<string, string> {
+  return new Map(
+    groups.map((group) => [group.id, group.label || `${group.adults} adult${group.adults === 1 ? "" : "s"}`])
+  );
+}
+
+function formatUsd(value: number): string {
+  return new Intl.NumberFormat("en-US", {
+    style: "currency",
+    currency: "USD",
+    maximumFractionDigits: 0
+  }).format(value);
+}
+
+function formatDateWindow(leg: FlightLegWindow): string {
+  if (leg.earliest && leg.latest) {
+    return leg.earliest === leg.latest ? leg.earliest : `${leg.earliest} to ${leg.latest}`;
+  }
+  if (leg.relativeToLegId) {
+    const min = leg.minDaysAfter ?? "?";
+    const max = leg.maxDaysAfter ?? "?";
+    return `${min}-${max} days after ${leg.relativeToLegId}`;
+  }
+  return "Not provided";
+}
+
+function drawSectionHeader(doc: PDFKit.PDFDocument, title: string): void {
+  const x = doc.page.margins.left;
+  const y = doc.y;
+  const width = doc.page.width - doc.page.margins.left - doc.page.margins.right;
+  const height = 18;
+
+  doc.save();
+  doc.roundedRect(x, y, width, height, 3).fill("#10384E");
+  doc
+    .fillColor("white")
+    .font("Helvetica-Bold")
+    .fontSize(12)
+    .text(title, x + 8, y + 4, { width: width - 16 });
+  doc.restore();
+  doc.moveDown(1.2);
+}
+
+function drawBulletList(doc: PDFKit.PDFDocument, items: string[] | undefined, fallback = "Not provided."): void {
+  const lines = bulletLines(items, fallback);
+  for (const line of lines) {
+    const startY = doc.y;
+    doc.circle(doc.page.margins.left + 4, startY + 6, 1.5).fill("#10384E");
+    doc
+      .fillColor("#1E2329")
+      .font("Helvetica")
+      .fontSize(10.5)
+      .text(line, doc.page.margins.left + 14, startY, {
+        width: doc.page.width - doc.page.margins.left - doc.page.margins.right - 14,
+        lineGap: 2
+      });
+    doc.moveDown(0.35);
+  }
+  doc.moveDown(0.2);
+}
+
+function drawKeyValueTable(doc: PDFKit.PDFDocument, rows: Array<[string, string]>): void {
+  const left = doc.page.margins.left;
+  const totalWidth = doc.page.width - doc.page.margins.left - doc.page.margins.right;
+  const keyWidth = 170;
+  const valueWidth = totalWidth - keyWidth;
+
+  for (const [key, value] of rows) {
+    const startY = doc.y;
+    const keyHeight = doc.heightOfString(key, { width: keyWidth - 12 });
+    const valueHeight = doc.heightOfString(value, { width: valueWidth - 12 });
+    const rowHeight = Math.max(keyHeight, valueHeight) + 12;
+
+    doc.save();
+    doc.rect(left, startY, keyWidth, rowHeight).fill("#EEF3F7");
+    doc.rect(left + keyWidth, startY, valueWidth, rowHeight).fill("#FFFFFF");
+    doc
+      .lineWidth(0.5)
+      .strokeColor("#C7D0D9")
+      .rect(left, startY, totalWidth, rowHeight)
+      .stroke();
+    doc.moveTo(left + keyWidth, startY).lineTo(left + keyWidth, startY + rowHeight).stroke();
+    doc.restore();
+
+    doc
+      .fillColor("#1E2329")
+      .font("Helvetica-Bold")
+      .fontSize(9.5)
+      .text(key, left + 6, startY + 6, { width: keyWidth - 12 });
+    doc
+      .fillColor("#1E2329")
+      .font("Helvetica")
+      .fontSize(9.5)
+      .text(value, left + keyWidth + 6, startY + 6, { width: valueWidth - 12 });
+    doc.y = startY + rowHeight;
+  }
+  doc.moveDown(0.8);
+}
+
+function ensureFreshSearch(payload: FlightReportPayload): void {
+  const searchExecution = payload.searchExecution;
+  if (!searchExecution?.freshSearch) {
+    throw new ReportValidationError(
+      "The flight report payload must come from a fresh search run. Cached or previously captured results are not allowed."
+    );
+  }
+
+  const startedAt = Date.parse(searchExecution.startedAt);
+  const completedAt = Date.parse(searchExecution.completedAt);
+  if (!Number.isFinite(startedAt) || !Number.isFinite(completedAt) || completedAt < startedAt) {
+    throw new ReportValidationError(
+      "The flight report payload must include a valid fresh-search time window."
+    );
+  }
+
+  if (!String(searchExecution.artifactsRoot || "").trim()) {
+    throw new ReportValidationError(
+      "The flight report payload must include the artifacts root for the fresh search run."
+    );
+  }
+}
+
+function drawItineraryCard(
+  doc: PDFKit.PDFDocument,
+  option: FlightRecommendationOption,
+  quotesById: Map<string, FlightQuote>,
+  legLabels: Map<string, string>,
+  passengerLabels: Map<string, string>
+): void {
+  const left = doc.page.margins.left;
+  const width = doc.page.width - doc.page.margins.left - doc.page.margins.right;
+  const top = doc.y;
+  const badge = option.backup ? "Backup" : "Primary";
+  const quoteLines = option.quoteIds.flatMap((quoteId) => {
+    const quote = quotesById.get(quoteId);
+    if (!quote) return [`Missing quote reference: ${quoteId}`];
+    const passengerLine = quote.passengerGroupIds
+      .map((groupId) => passengerLabels.get(groupId) || groupId)
+      .join(", ");
+    const legLine = legLabels.get(quote.legId) || quote.legId;
+    return [
+      `${legLine}: ${quote.itinerarySummary} (${quote.displayPriceUsd})`,
+      `Passengers: ${passengerLine}`,
+      `Timing: ${quote.departureTimeLocal || "?"} -> ${quote.arrivalTimeLocal || "?"}; ${quote.stopsText || "stops?"}; ${quote.totalDurationText || "duration?"}`,
+      ...(quote.notes || []).map((note) => `Note: ${note}`)
+    ];
+  });
+  const bodyLines = [
+    `Why it ranked here: ${option.rationale}`,
+    ...quoteLines
+  ];
+  const bodyText = bodyLines.join("\n");
+  const bodyHeight = doc.heightOfString(bodyText, { width: width - 20, lineGap: 2 }) + 24;
+
+  doc.save();
+  doc.roundedRect(left, top, width, 24, 4).fill(option.backup ? "#586E75" : "#1E6B52");
+  doc
+    .fillColor("white")
+    .font("Helvetica-Bold")
+    .fontSize(11)
+    .text(`${badge}: ${option.title} (${formatUsd(option.totalPriceUsd)})`, left + 10, top + 7, {
+      width: width - 20
+    });
+  doc
+    .roundedRect(left, top + 24, width, bodyHeight, 4)
+    .fillAndStroke("#F8FAFC", "#C7D0D9");
+  doc
+    .fillColor("#1E2329")
+    .font("Helvetica")
+    .fontSize(10)
+    .text(bodyText, left + 10, top + 34, {
+      width: width - 20,
+      lineGap: 2
+    });
+  doc.restore();
+  doc.y = top + 24 + bodyHeight + 10;
+}
+
 export async function renderFlightReportPdf(
   payload: FlightReportPayload,
   outputPath: string
 ): Promise<string> {
-  const status = getFlightReportStatus(
-    normalizeFlightReportRequest(payload.request),
-    payload
-  );
+  const normalizedRequest = normalizeFlightReportRequest(payload.request);
+  const status = getFlightReportStatus(normalizedRequest, payload);
 
   if (!status.pdfReady) {
     throw new ReportValidationError(
@@ -27,56 +213,89 @@ export async function renderFlightReportPdf(
     );
   }
 
+  ensureFreshSearch(payload);
+
   await fs.promises.mkdir(path.dirname(outputPath), { recursive: true });
 
   const doc = new PDFDocument({
     size: "LETTER",
-    margin: 50
+    margin: 50,
+    info: {
+      Title: payload.request.tripName || "Flight report",
+      Author: "OpenClaw flight-finder"
+    }
   });
 
   const stream = fs.createWriteStream(outputPath);
   doc.pipe(stream);
 
+  const request = normalizedRequest.request;
+  const legLabels = asLegLabelMap(request.legs);
+  const passengerLabels = asPassengerGroupLabelMap(request.passengerGroups);
+  const quotesById = new Map(payload.quotes.map((quote) => [quote.id, quote]));
+
   try {
-    doc.fontSize(20).text(payload.request.tripName || "Flight report", {
-      align: "left"
-    });
-    doc.moveDown(0.25);
-    doc.fontSize(10).fillColor("#555").text(`Generated: ${payload.generatedAt}`);
-    doc.fillColor("#000");
-    doc.moveDown();
-
-    doc.fontSize(14).text("Executive Summary");
-    bulletLines(payload.executiveSummary).forEach((line) => {
-      doc.fontSize(10).text(`• ${line}`);
-    });
-
-    doc.moveDown();
-    doc.fontSize(14).text("Recommended Options");
-    payload.rankedOptions.forEach((option) => {
-      doc.fontSize(11).text(
-        `${option.backup ? "Backup" : "Primary"}: ${option.title} — $${option.totalPriceUsd.toFixed(2)}`
+    doc.fillColor("#10384E").font("Helvetica-Bold").fontSize(22).text(request.tripName || "Flight report");
+    doc.moveDown(0.2);
+    doc
+      .fillColor("#4F5B66")
+      .font("Helvetica")
+      .fontSize(10)
+      .text(`Generated: ${payload.generatedAt}`);
+    doc
+      .fillColor("#4F5B66")
+      .font("Helvetica")
+      .fontSize(10)
+      .text(
+        `Market: ${payload.marketCountryUsed || "Default market"} | Fresh search: ${payload.searchExecution.completedAt}`
       );
-      doc.fontSize(10).text(option.rationale);
-      doc.moveDown(0.5);
-    });
-
     doc.moveDown();
-    doc.fontSize(14).text("Source Findings");
+
+    drawSectionHeader(doc, "Trip Snapshot");
+    drawKeyValueTable(doc, [
+      ["Recipient", request.recipientEmail || "Missing"],
+      ["Passenger groups", request.passengerGroups.map((group) => group.label || `${group.adults} adults`).join(" | ")],
+      ["Preferences", [
+        request.preferences.flexibleDates ? "Flexible dates" : "Fixed dates",
+        request.preferences.maxStops != null ? `Max stops ${request.preferences.maxStops}` : "Stops not capped",
+        request.preferences.maxLayoverHours != null ? `Layover <= ${request.preferences.maxLayoverHours}h` : "Layover open"
+      ].join(" | ")],
+      ["Market-country mode", request.preferences.marketCountry || "Off"],
+      ["Search artifacts", payload.searchExecution.artifactsRoot]
+    ]);
+
+    drawSectionHeader(doc, "Legs And Travelers");
+    for (const leg of request.legs) {
+      const assignedGroups = request.legAssignments
+        .find((assignment) => assignment.legId === leg.id)
+        ?.passengerGroupIds.map((groupId) => passengerLabels.get(groupId) || groupId)
+        .join(", ") || "Not assigned";
+      drawKeyValueTable(doc, [
+        ["Leg", leg.label || leg.id],
+        ["Route", `${leg.origin} -> ${leg.destination}`],
+        ["Window", formatDateWindow(leg)],
+        ["Travelers", assignedGroups]
+      ]);
+    }
+
+    drawSectionHeader(doc, "Executive Summary");
+    drawBulletList(doc, payload.executiveSummary);
+
+    drawSectionHeader(doc, "Recommended Options");
+    payload.rankedOptions.forEach((option) => drawItineraryCard(doc, option, quotesById, legLabels, passengerLabels));
+
+    drawSectionHeader(doc, "Source Findings");
     payload.sourceFindings.forEach((finding) => {
-      doc.fontSize(11).text(`${finding.source}: ${finding.status}`);
-      bulletLines(finding.notes).forEach((line) => doc.fontSize(10).text(`• ${line}`));
-      doc.moveDown(0.25);
+      drawKeyValueTable(doc, [
+        ["Source", finding.source],
+        ["Status", finding.status],
+        ["Checked", finding.checkedAt]
+      ]);
+      drawBulletList(doc, finding.notes, "No source notes.");
     });
 
-    doc.moveDown();
-    doc.fontSize(14).text("Warnings And Degraded Conditions");
-    bulletLines(
-      [...payload.reportWarnings, ...payload.degradedReasons],
-      "No additional warnings."
-    ).forEach((line) => {
-      doc.fontSize(10).text(`• ${line}`);
-    });
+    drawSectionHeader(doc, "Warnings And Degraded Conditions");
+    drawBulletList(doc, [...payload.reportWarnings, ...payload.degradedReasons], "No additional warnings.");
 
     doc.end();
 

skills/flight-finder/src/types.ts

@@ -149,6 +149,13 @@ export type NormalizedFlightReportRequest = {
 
 export type FlightReportPayload = {
   request: FlightReportRequest;
+  searchExecution: {
+    freshSearch: boolean;
+    startedAt: string;
+    completedAt: string;
+    artifactsRoot: string;
+    notes?: string[];
+  };
   sourceFindings: FlightSearchSourceFinding[];
   quotes: FlightQuote[];
   rankedOptions: FlightRecommendationOption[];

skills/flight-finder/tests/report-pdf.test.ts

@@ -14,6 +14,13 @@ import {
 function samplePayload(): FlightReportPayload {
   return {
     request: normalizeFlightReportRequest(DFW_BLQ_2026_PROMPT_DRAFT).request,
+    searchExecution: {
+      freshSearch: true,
+      startedAt: "2026-03-30T20:45:00Z",
+      completedAt: "2026-03-30T21:00:00Z",
+      artifactsRoot: "/Users/stefano/.openclaw/workspace/reports/dfw-blq-flight-report-2026-03-30-exec",
+      notes: ["Fresh bounded search executed for this report."]
+    },
     sourceFindings: [
       {
         source: "kayak",
@@ -74,3 +81,21 @@ test("renderFlightReportPdf rejects incomplete report payloads", async () => {
     ReportValidationError
   );
 });
+
+test("renderFlightReportPdf rejects payloads that are not marked as fresh-search output", async () => {
+  const outputPath = path.join(os.tmpdir(), `flight-finder-stale-${Date.now()}.pdf`);
+  await assert.rejects(
+    () =>
+      renderFlightReportPdf(
+        {
+          ...samplePayload(),
+          searchExecution: {
+            ...samplePayload().searchExecution,
+            freshSearch: false
+          }
+        },
+        outputPath
+      ),
+    ReportValidationError
+  );
+});