fix(display): draw text 1-bit, so glyphs stay crisp on the LED grid (#521)

An LED panel has no partial brightness. PIL defaults ImageDraw's fontmode to
"L", which anti-aliases TrueType glyphs into a grey fringe the panel can only
round off -- a 4px glyph arrives smeared into 3px.

DisplayManager creates its shared `draw` in six places and set fontmode at
none of them, while _load_fonts loads extra_small_font as 4x6-font.ttf at
size 6. Measured at draw time, that face at that size puts 74% of its lit
pixels at partial coverage. Every plugin drawing small text through the
shared draw inherited the blur; geochron was the case that surfaced it.

The harness's VisualDisplayManager had the same gap, which mattered more than
it looks: goldens were recording anti-aliased text that production would not
produce, so the harness could not have caught this. Fixing only production
left geochron still blurry under the harness -- that is how the second site
was found.

Both are set to "1" so the harness renders what the panel renders.


Claude-Session: https://claude.ai/code/session_014RRtqXDCnvnY6EQwhT5CV9

Co-authored-by: Claude Opus 5 (1M context) <noreply@anthropic.com>

src/common/sports_card.py

@@ -17,10 +17,13 @@ deliberate difference is `crisp_size`, which takes the seven-plugin guard
 the extra guard only stops a None size raising TypeError.
 """
 
+import logging
 from datetime import datetime, timezone
 from typing import Any, Dict, Optional, Tuple
 from zoneinfo import ZoneInfo
 
+logger = logging.getLogger(__name__)
+
 __all__ = [
     "ELEMENT_FOR_FONT", "FAVORITE_RESULT_COLOR_DEFAULTS", "FONT_NAME_ALIASES",
     "FONT_PIXEL_GRID", "MONTH_ABBR", "WEEKDAY_ABBR",
@@ -395,7 +398,14 @@ def schema_font_size(schema_path: str, element_key) -> Optional[int]:
                 size = spec.get('properties', {}).get('font_size', {}).get('default')
                 if size is not None:
                     cache[key] = int(size)
-        except Exception:
+        except Exception as exc:
+            # See sports_shared._schema_font_size: an unreadable schema
+            # silently disables the pixel-grid snap for every element.
+            # Built once per schema path, so this cannot repeat per frame.
+            logger.warning(
+                "could not read %s (%s: %s); font sizes will skip their "
+                "pixel grid snap and may render a pixel narrow",
+                schema_path, type(exc).__name__, exc)
             cache = {}
         _SCHEMA_FONT_SIZE_CACHE[schema_path] = cache
     return cache.get(element_key)

src/common/sports_shared.py

@@ -288,7 +288,23 @@ class SportsCoreSharedMixin:
                     size = spec.get('properties', {}).get('font_size', {}).get('default')
                     if size is not None:
                         cache[key] = int(size)
-            except Exception:
+            except Exception as exc:
+                # Say so. An unreadable schema is not cosmetic: every element's
+                # configured size then stops matching "the schema default", is
+                # treated as a deliberate user choice, and skips the snap to the
+                # font's pixel grid -- which renders 4x6-font.ttf at 6 instead
+                # of 7, a 3px-wide glyph instead of 4px. That shipped once,
+                # silently, and was found by a user counting pixels on a photo
+                # of the panel.
+                #
+                # Logged, not raised: a missing schema must not stop a plugin
+                # rendering. The cache is built once per class, so this cannot
+                # repeat per frame.
+                logger.warning(
+                    "%s: could not read config_schema.json (%s: %s); every font "
+                    "size will be treated as user-chosen and will skip its pixel "
+                    "grid snap. Font sizes may render a pixel narrow.",
+                    type(self).__name__, type(exc).__name__, exc)
                 cache = {}
             self.__class__._SCHEMA_FONT_SIZES = cache
         return cache.get(element_key)

src/display_manager.py

@@ -364,6 +364,7 @@ class DisplayManager:
             # Create image with the (logical) display dimensions
             self.image = Image.new('RGB', (self.matrix.width, self.matrix.height))
             self.draw = ImageDraw.Draw(self.image)
+            self.draw.fontmode = "1"  # 1-bit text: the panel has no partial brightness, so AA only smears glyphs.
             logger.info(f"Image canvas created with dimensions: {self.matrix.width}x{self.matrix.height}")
             
             # Initialize font with Press Start 2P
@@ -403,6 +404,7 @@ class DisplayManager:
 
             self.image = Image.new('RGB', (fallback_width, fallback_height))
             self.draw = ImageDraw.Draw(self.image)
+            self.draw.fontmode = "1"  # 1-bit text: the panel has no partial brightness, so AA only smears glyphs.
             # Simple fallback visualization so web UI shows a realistic canvas
             try:
                 self.draw.rectangle([0, 0, fallback_width - 1, fallback_height - 1], outline=(255, 0, 0))
@@ -705,6 +707,7 @@ class DisplayManager:
             # self.image, so swapping the buffer below is enough on its own.
             self.image = Image.new('RGB', (target_w, target_h))
             self.draw = ImageDraw.Draw(self.image)
+            self.draw.fontmode = "1"  # 1-bit text: the panel has no partial brightness, so AA only smears glyphs.
             yield
         finally:
             self.matrix = real_matrix
@@ -814,6 +817,7 @@ class DisplayManager:
                 
                 self.image = Image.new('RGB', (width, height))
                 self.draw = ImageDraw.Draw(self.image)
+                self.draw.fontmode = "1"  # 1-bit text: the panel has no partial brightness, so AA only smears glyphs.
                 logger.debug("Cleared display in fallback mode")
                 return
                 
@@ -825,6 +829,7 @@ class DisplayManager:
             # Create a new black image
             self.image = Image.new('RGB', (self.matrix.width, self.matrix.height))
             self.draw = ImageDraw.Draw(self.image)
+            self.draw.fontmode = "1"  # 1-bit text: the panel has no partial brightness, so AA only smears glyphs.
 
             if not self._capture_mode_active:
                 # Clear both canvases and the underlying matrix to ensure no artifacts.
@@ -1258,6 +1263,7 @@ class DisplayManager:
             try:
                 self.image = Image.new('RGB', (self.width, self.height))
                 self.draw = ImageDraw.Draw(self.image)
+                self.draw.fontmode = "1"  # 1-bit text: the panel has no partial brightness, so AA only smears glyphs.
             except (OSError, RuntimeError, ValueError, MemoryError):
                 logger.debug("Canvas reset during cleanup failed", exc_info=True)
         # Reset the singleton state when cleaning up

src/plugin_system/testing/visual_display_manager.py

@@ -70,6 +70,7 @@ class VisualTestDisplayManager:
         # Canvas
         self.image = Image.new('RGB', (width, height), (0, 0, 0))
         self.draw = ImageDraw.Draw(self.image)
+        self.draw.fontmode = "1"  # Match production: 1-bit text, so goldens show what the panel shows.
 
         # Matrix proxy (plugins access display_manager.matrix.width/height)
         self.matrix = _MatrixProxy(width, height)
@@ -184,6 +185,7 @@ class VisualTestDisplayManager:
         self.clear_called = True
         self.image = Image.new('RGB', (self._width, self._height), (0, 0, 0))
         self.draw = ImageDraw.Draw(self.image)
+        self.draw.fontmode = "1"  # Match production: 1-bit text, so goldens show what the panel shows.
 
     def update_display(self):
         """No-op for hardware; marks that display was updated."""
@@ -211,6 +213,7 @@ class VisualTestDisplayManager:
             self.matrix = _MatrixProxy(target_w, target_h)
             self.image = Image.new('RGB', (target_w, target_h), (0, 0, 0))
             self.draw = ImageDraw.Draw(self.image)
+            self.draw.fontmode = "1"  # Match production: 1-bit text, so goldens show what the panel shows.
             yield
         finally:
             self._width, self._height = prev_w, prev_h
@@ -569,6 +572,7 @@ class VisualTestDisplayManager:
         self.draw_calls = []
         self.image = Image.new('RGB', (self._width, self._height), (0, 0, 0))
         self.draw = ImageDraw.Draw(self.image)
+        self.draw.fontmode = "1"  # Match production: 1-bit text, so goldens show what the panel shows.
         self._scrolling_state = {
             'is_scrolling': False,
             'last_scroll_activity': 0,
@@ -582,3 +586,4 @@ class VisualTestDisplayManager:
         """Clean up resources."""
         self.image = Image.new('RGB', (self._width, self._height), (0, 0, 0))
         self.draw = ImageDraw.Draw(self.image)
+        self.draw.fontmode = "1"  # Match production: 1-bit text, so goldens show what the panel shows.