fix: stop mic hardware immediately when idle, make HUD always on top, and dual-layer hotkey listener

src/AppDelegate.swift

@@ -82,8 +82,8 @@ public final class AppDelegate: NSObject, NSApplicationDelegate {
         // Pre-warm the background WebSocket session for 0ms startup delay
         SonioxSessionPool.shared.prewarmNextSession()
         
-        // Pre-warm audio hardware capture pipeline for instant 0ms recording
-        try? audioRecorder.ensureSessionRunning()
+        // Pre-configure audio hardware capture graph (kept STOPPED until key is pressed)
+        try? audioRecorder.ensureSessionConfigured()
         
         // Check permissions on start
         checkInitialPermissions()
@@ -119,7 +119,11 @@ public final class AppDelegate: NSObject, NSApplicationDelegate {
     }
     
     public func startRecording() {
-        if audioRecorder.isRecording || isBusyFinalizing { return }
+        if audioRecorder.isRecording { return }
+        if isBusyFinalizing {
+            print("AppDelegate: isBusyFinalizing was active when startRecording invoked. Clearing stale lock.")
+            isBusyFinalizing = false
+        }
         
         isNetworkDegraded = false
         lastRecordedAudio.removeAll()
@@ -219,6 +223,9 @@ public final class AppDelegate: NSObject, NSApplicationDelegate {
         DispatchQueue.main.asyncAfter(deadline: .now() + 2.5) { [weak self] in
             guard let self = self, self.isBusyFinalizing else { return }
             print("AppDelegate: Finalize safety watchdog triggered — recovering transcript.")
+            self.isBusyFinalizing = false
+            self.statusBarController.updateIcon(state: .idle)
+            HUDOverlayController.shared.hide()
             self.activeSession?.completeWithCurrentText()
         }
         

src/AudioRecorder.swift

@@ -58,8 +58,8 @@ public final class AudioRecorder: NSObject, AVCaptureAudioDataOutputSampleBuffer
         return AVCaptureDevice.default(for: .audio) ?? all.first
     }
 
-    public func ensureSessionRunning() throws {
-        if let session = captureSession, session.isRunning {
+    public func ensureSessionConfigured() throws {
+        if captureSession != nil {
             return
         }
         guard let device = resolveCaptureDevice() else {
@@ -77,8 +77,7 @@ public final class AudioRecorder: NSObject, AVCaptureAudioDataOutputSampleBuffer
         }
         self.captureSession = session
         self.audioOutput = output
-        session.startRunning()
-        print("AudioRecorder: Pre-warmed audio session primed with device:", device.localizedName)
+        print("AudioRecorder: Capture session graph configured for device:", device.localizedName)
     }
 
     public func startRecording() throws {
@@ -88,9 +87,12 @@ public final class AudioRecorder: NSObject, AVCaptureAudioDataOutputSampleBuffer
         if isRecording { return }
         pcmBuffer.removeAll()
         
-        try ensureSessionRunning()
+        try ensureSessionConfigured()
+        if let session = captureSession, !session.isRunning {
+            session.startRunning()
+        }
         isRecording = true
-        print("AudioRecorder: Instant 0ms recording started.")
+        print("AudioRecorder: Fast recording started (mic hardware ON).")
     }
     
     public func captureOutput(_ output: AVCaptureOutput, didOutput sampleBuffer: CMSampleBuffer, from connection: AVCaptureConnection) {
@@ -178,8 +180,9 @@ public final class AudioRecorder: NSObject, AVCaptureAudioDataOutputSampleBuffer
         if !isRecording { return pcmBuffer }
         isRecording = false
         
-        // Keep captureSession running so subsequent presses start in 0ms!
-        print("AudioRecorder: Stopped. Total PCM captured: \(pcmBuffer.count) bytes (\(Double(pcmBuffer.count)/32000.0) seconds). Audio engine kept hot.")
+        // Immediately stop hardware capture so macOS orange mic indicator turns OFF
+        captureSession?.stopRunning()
+        print("AudioRecorder: Stopped. Microphone hardware OFF. Total PCM captured: \(pcmBuffer.count) bytes.")
         return pcmBuffer
     }
 }

src/HUDOverlay.swift

@@ -35,7 +35,7 @@ public final class HUDOverlayController {
         )
         panel.isOpaque = false
         panel.backgroundColor = .clear
-        panel.level = .floating
+        panel.level = .statusBar
         panel.collectionBehavior = [.canJoinAllSpaces, .fullScreenAuxiliary, .stationary]
         panel.hasShadow = false
         panel.ignoresMouseEvents = true
@@ -54,7 +54,7 @@ public final class HUDOverlayController {
     }
     
     private func reposition() {
-        guard let window = self.window, let screen = NSScreen.main else { return }
+        guard let window = self.window, let screen = NSScreen.main ?? NSScreen.screens.first else { return }
         let screenRect = screen.visibleFrame
         // Center horizontally, positioned comfortably higher above dock
         let x = screenRect.midX - (canvasSize / 2.0)
@@ -76,17 +76,17 @@ public final class HUDOverlayController {
                 self.hide()
                 
             case .recording(let level, let isLagging, let pingQuality):
-                if !self.isVisible {
+                if !self.isVisible || window.alphaValue < 0.95 {
                     window.orderFrontRegardless()
-                    window.animator().alphaValue = 1.0
+                    window.alphaValue = 1.0
                     self.isVisible = true
                 }
                 orb.updateAudioLevel(level, isLagging: isLagging, pingQuality: pingQuality)
                 
             case .retrying:
-                if !self.isVisible {
+                if !self.isVisible || window.alphaValue < 0.95 {
                     window.orderFrontRegardless()
-                    window.animator().alphaValue = 1.0
+                    window.alphaValue = 1.0
                     self.isVisible = true
                 }
                 orb.showRetryState()
@@ -112,13 +112,15 @@ public final class HUDOverlayController {
     public func hide() {
         DispatchQueue.main.async { [weak self] in
             guard let self = self, let window = self.window, self.isVisible else { return }
+            self.isVisible = false
             NSAnimationContext.runAnimationGroup({ context in
-                context.duration = 0.18
+                context.duration = 0.15
                 window.animator().alphaValue = 0.0
             }, completionHandler: {
+                if !self.isVisible {
                     window.orderOut(nil)
-                self.isVisible = false
                     self.orbView?.reset()
+                }
             })
         }
     }

src/HotkeyManager.swift

@@ -148,13 +148,29 @@ public final class HotkeyManager {
         // 2. Global Event Tap for high-priority interception (Microphone Key, Option, CapsLock, Fn/Globe)
         setupEventTap()
         
-        // 3. Fallback NSEvent monitor
+        // 3. Dual-layer fallback NSEvent monitor (catches flagsChanged/Option even after wake/sleep)
         setupGlobalMonitor()
+        
+        // 4. Watch for system and display sleep/wake to ensure event tap is always alive
+        NotificationCenter.default.removeObserver(self, name: NSWorkspace.didWakeNotification, object: nil)
+        NSWorkspace.shared.notificationCenter.addObserver(forName: NSWorkspace.didWakeNotification, object: nil, queue: .main) { [weak self] _ in
+            print("HotkeyManager: System woke from sleep. Re-registering hotkeys...")
+            self?.registerHotkeys()
+        }
+        NotificationCenter.default.removeObserver(self, name: NSWorkspace.screensDidWakeNotification, object: nil)
+        NSWorkspace.shared.notificationCenter.addObserver(forName: NSWorkspace.screensDidWakeNotification, object: nil, queue: .main) { [weak self] _ in
+            print("HotkeyManager: Screens woke. Verifying hotkey event tap...")
+            if let tap = self?.eventTapPort {
+                CGEvent.tapEnable(tap: tap, enable: true)
+            } else {
+                self?.registerHotkeys()
+            }
+        }
     }
     
     private func triggerAction() {
         let now = Date().timeIntervalSince1970
-        guard (now - lastTriggerTime) > 0.25 else { return }
+        guard (now - lastTriggerTime) > 0.10 else { return }
         lastTriggerTime = now
         DispatchQueue.main.async { [weak self] in
             self?.onHotkeyPressed?()
@@ -169,6 +185,15 @@ public final class HotkeyManager {
             guard let refcon = refcon else { return Unmanaged.passRetained(event) }
             let manager = Unmanaged<HotkeyManager>.fromOpaque(refcon).takeUnretainedValue()
             
+            // Auto-recover if macOS disabled tap on timeout or user input
+            if type == .tapDisabledByTimeout || type == .tapDisabledByUserInput {
+                print("HotkeyManager: EventTap was disabled by OS (\(type.rawValue)). Re-enabling now...")
+                if let tap = manager.eventTapPort {
+                    CGEvent.tapEnable(tap: tap, enable: true)
+                }
+                return Unmanaged.passRetained(event)
+            }
+            
             let flags = event.flags.rawValue
             let keyCode = event.getIntegerValueField(.keyboardEventKeycode)
             
@@ -294,12 +319,49 @@ public final class HotkeyManager {
     }
     
     private func setupGlobalMonitor() {
-        globalMonitor = NSEvent.addGlobalMonitorForEvents(matching: [.keyDown, .flagsChanged]) { [weak self] event in
-            guard let self = self, self.eventTapPort == nil else { return }
+        if let mon = globalMonitor {
+            NSEvent.removeMonitor(mon)
+            self.globalMonitor = nil
+        }
         
-            if self.currentPreset == .controlSpace {
-                if event.keyCode == 49 && event.modifierFlags.contains(.control) {
+        // Active backup monitor that never dies on sleep/wake
+        globalMonitor = NSEvent.addGlobalMonitorForEvents(matching: [.flagsChanged, .keyDown, .keyUp]) { [weak self] event in
+            guard let self = self else { return }
+            
+            let flags = event.modifierFlags
+            let keyCode = event.keyCode
+            
+            if self.currentPreset == .option {
+                if keyCode == 58 || keyCode == 61 { // Left or Right Option
+                    let isAlt = flags.contains(.option)
+                    if isAlt != self.isOptionPhysicallyDown {
+                        self.isOptionPhysicallyDown = isAlt
+                        if isAlt {
                             self.triggerAction()
+                        } else if self.currentMode == .pushToTalk {
+                            DispatchQueue.main.async {
+                                self.onHotkeyReleased?()
+                            }
+                        }
+                    }
+                }
+            } else if self.currentPreset == .controlSpace {
+                if keyCode == 49 && flags.contains(.control) {
+                    self.triggerAction()
+                }
+            } else if self.currentPreset == .capsLock {
+                if keyCode == 57 {
+                    let isCaps = flags.contains(.capsLock)
+                    if isCaps != self.isCapsLockPhysicallyDown {
+                        self.isCapsLockPhysicallyDown = isCaps
+                        if isCaps {
+                            self.triggerAction()
+                        } else if self.currentMode == .pushToTalk {
+                            DispatchQueue.main.async {
+                                self.onHotkeyReleased?()
+                            }
+                        }
+                    }
                 }
             }
         }