fix: Ensure auto-start works correctly (#40)

* fix: Ensure auto-start works correctly

* fix: Correct auto-start functionality for Bridge

* fix: general improvements

CLAUDE.md

@@ -1009,6 +1009,43 @@ FreeCAD can run in two modes:
 1. **GUI mode**: Full graphical interface with 3D view, accessed via `FreeCAD.app` or `freecad`
 1. **Headless mode**: Console-only, no GUI, accessed via `FreeCADCmd` or `freecadcmd`
 
+### FreeCAD Workbench Addon Loading (Critical)
+
+**CRITICAL**: For FreeCAD **workbench addons**, `Init.py` does **NOT** run at FreeCAD startup. Only `InitGui.py` module-level code runs when FreeCAD GUI starts.
+
+| File         | When It Runs                                       | Use Case                                 |
+| ------------ | -------------------------------------------------- | ---------------------------------------- |
+| `Init.py`    | Only when workbench is **selected** by user        | Workbench-specific initialization        |
+| `InitGui.py` | **Module-level code** runs at FreeCAD GUI startup  | Auto-start features, status bar setup    |
+| `InitGui.py` | `Initialize()` method runs when workbench selected | Toolbar/menu setup, command registration |
+
+**Why this matters for auto-start:**
+
+If you put auto-start logic in `Init.py`, it will only run when the user manually selects the workbench - NOT when FreeCAD starts. To auto-start the MCP bridge at FreeCAD startup:
+
+1. Put auto-start code in `InitGui.py` **module-level code** (outside any class/method)
+2. Use `QTimer.singleShot()` to defer execution until GUI is fully ready
+3. The `Initialize()` method is too late - it only runs when workbench is selected
+
+**Example pattern in InitGui.py:**
+
+```python
+# Module-level code - runs at FreeCAD GUI startup
+try:
+    from PySide2 import QtCore
+except ImportError:
+    from PySide6 import QtCore
+
+def _deferred_auto_start() -> None:
+    """Auto-start bridge after GUI is fully ready."""
+    # ... auto-start logic here ...
+
+# Schedule auto-start after GUI initializes (3 second delay)
+QtCore.QTimer.singleShot(3000, _deferred_auto_start)
+```
+
+**This is different from regular Python packages** where `__init__.py` runs on import. FreeCAD workbenches have special loading behavior.
+
 ### Detecting GUI Availability
 
 **CRITICAL**: Always use `FreeCAD.GuiUp` to check if the GUI is available. **Never** check for Qt/PySide availability as a proxy for GUI mode.
@@ -1031,7 +1068,7 @@ else:
 
 When FreeCAD starts in GUI mode, there's a timing window where:
 
-1. `Init.py` runs when `FreeCAD.GuiUp = False` (GUI not yet initialized)
+1. `InitGui.py` module-level code runs when `FreeCAD.GuiUp = False` (GUI not yet initialized)
 2. Qt/PySide is available (can import successfully)
 3. The bridge starts, sees `GuiUp = False`, and starts a background thread for queue processing
 4. FreeCAD GUI finishes initializing (`GuiUp` becomes `True`)
@@ -1044,28 +1081,59 @@ When FreeCAD starts in GUI mode, there's a timing window where:
 - Integration tests pass initial connection, then crash on first document operation
 - Thread check shows `is_main_thread: False` with `thread_name: 'MCP-QueueProcessor'` even when `gui_up: True`
 
-**The Fix (in `Init.py`):**
+**The Fix (in `InitGui.py` or `startup_bridge.py`):**
 
-When Qt is available but `FreeCAD.GuiUp` is `False`, use a repeating timer to wait for `GuiUp` to become `True` before starting the bridge:
+Use `QTimer.singleShot()` to defer bridge startup until after GUI is ready:
 
 ```python
-# WRONG - starts bridge immediately, will use background thread
-elif QtCore is not None:
+# WRONG - starts bridge immediately, GUI may not be ready
 _auto_start_bridge()
 
-# CORRECT - wait for GUI to be ready
-elif QtCore is not None:
-    _auto_start_timer = QtCore.QTimer()
-    _auto_start_timer.setSingleShot(False)  # Repeating
-    _auto_start_timer.timeout.connect(_wait_for_gui_and_start)
-    _auto_start_timer.start(100)  # Check every 100ms
+# CORRECT - wait for GUI to be ready (use sufficient delay)
+QtCore.QTimer.singleShot(3000, _deferred_auto_start)
 ```
 
-**Note:** This QTimer wait pattern is **only for GUI startup scenarios**. In headless mode (`freecadcmd`), the bridge starts directly without waiting because there is no Qt event loop to wait for. The three startup paths are:
+For `startup_bridge.py`, use `GuiWaiter` to poll for `FreeCAD.GuiUp`:
 
-1. **GUI already up** (`FreeCAD.GuiUp = True`): Start bridge immediately
-2. **GUI starting** (Qt available, `GuiUp = False`): Use QTimer to wait for GUI
-3. **Headless** (no Qt): Start bridge immediately with background thread
+```python
+# Wait for GuiUp to become True before starting
+from bridge_utils import GuiWaiter
+_gui_waiter = GuiWaiter(callback=_start_bridge, log_prefix="Startup Bridge")
+_gui_waiter.start()
+```
+
+**Note:** This QTimer wait pattern is **only for GUI startup scenarios**. In headless mode (`freecadcmd`), the bridge starts directly without waiting because there is no Qt event loop to wait for. The four startup paths are:
+
+1. **GUI already up** (`FreeCAD.GuiUp = True`): Start bridge immediately with Qt timer
+2. **True headless** (`QCoreApplication` exists but is NOT a `QApplication`): Start directly with background thread
+3. **GUI starting** (Qt available but no app yet, or `QApplication` initializing): Use GuiWaiter to wait for GUI
+4. **No Qt available** (unusual state): Start directly
+
+**IMPORTANT - Detecting True Headless vs Early GUI Startup:**
+
+Simply checking `QApplication.instance() is None` is NOT sufficient because:
+
+- In true headless mode (`freecadcmd`): `QCoreApplication` exists but NOT `QApplication`
+- In early GUI startup: No application exists yet, but GUI will be available soon
+
+The correct detection uses `isinstance` to distinguish these cases:
+
+```python
+# Check for QApplication first
+qapp = QtWidgets.QApplication.instance()
+if qapp is not None:
+    # QApplication exists - GUI is available or starting
+    _has_qapp = True
+else:
+    # No QApplication - check if QCoreApplication exists
+    qcore_app = QtCore.QCoreApplication.instance()
+    if qcore_app is not None and not isinstance(qcore_app, QtWidgets.QApplication):
+        # QCoreApplication exists but is NOT a QApplication = true headless
+        _is_true_headless = True
+    # If no app at all, assume early GUI startup (will use GuiWaiter)
+```
+
+This logic is implemented in both `Init.py` and `startup_bridge.py` and MUST be kept in sync.
 
 **Testing:**
 
@@ -1077,6 +1145,43 @@ An integration test in `tests/integration/test_thread_safety.py` verifies that:
 
 **Key Lesson:** Never assume Qt availability means GUI is ready. Always check `FreeCAD.GuiUp` before doing operations that depend on the Qt event loop running on the main thread.
 
+### Keeping Startup Scripts in Sync (Critical)
+
+**CRITICAL**: The MCP bridge can be started from THREE different entry points. They must use compatible detection logic:
+
+| File                                             | Purpose                                          |
+| ------------------------------------------------ | ------------------------------------------------ |
+| `addon/FreecadRobustMCPBridge/InitGui.py`        | Auto-start at FreeCAD GUI startup (if enabled)   |
+| `addon/FreecadRobustMCPBridge/Init.py`           | Fallback auto-start when workbench selected      |
+| `addon/.../freecad_mcp_bridge/startup_bridge.py` | Manual start via `just freecad::run-gui`         |
+
+**When modifying startup logic in one file, you MUST update the others to match.**
+
+All files must have compatible logic for:
+
+1. **QApplication detection** - Use `QApplication.instance()` to detect GUI vs headless
+2. **GuiWaiter usage** - Wait for `GuiUp` before starting in GUI mode
+3. **Headless detection** - Start directly when no QApplication exists
+4. **Diagnostic logging** - Log `GuiUp`, `QtCore`, and `QApp` state
+5. **Already running check** - Skip start if bridge already running
+
+**Why these files exist:**
+
+- `InitGui.py` module-level code runs at FreeCAD GUI startup (primary auto-start location)
+- `Init.py` runs when workbench is selected (fallback if InitGui didn't auto-start)
+- `startup_bridge.py` is passed as a command-line argument for `just freecad::run-gui`
+- All check if a bridge is already running to avoid conflicts
+
+**Test command to verify both work:**
+
+```bash
+# Test headless mode (uses blocking_bridge.py)
+just testing::integration-headless-release
+
+# Test GUI mode (uses startup_bridge.py, InitGui.py auto-start may also be active)
+just testing::integration-gui-release
+```
+
 ### Why NOT to Check for PySide/Qt
 
 **WRONG** - Do not use Qt availability to detect GUI mode:

addon/FreecadRobustMCPBridge/Init.py

@@ -13,13 +13,16 @@ must run on the main thread.
 
 from __future__ import annotations
 
-from typing import TYPE_CHECKING, Any
+# Import FreeCAD first so we can log early
+import FreeCAD
+
+FreeCAD.Console.PrintMessage("Robust MCP Bridge: Init.py loaded\n")
+
+from typing import TYPE_CHECKING, Any  # noqa: E402
 
 if TYPE_CHECKING:
     from freecad_mcp_bridge.bridge_utils import GuiWaiter
 
-import FreeCAD
-
 FreeCAD.Console.PrintMessage("Robust MCP Bridge: Init loaded\n")
 
 # Global reference to GuiWaiter and auto-start timer to prevent garbage collection
@@ -83,15 +86,22 @@ def _auto_start_bridge() -> None:
 
     except Exception as e:
         FreeCAD.Console.PrintError(f"Failed to auto-start MCP Bridge: {e}\n")
+        import traceback
+
+        FreeCAD.Console.PrintError(f"Traceback: {traceback.format_exc()}\n")
 
 
 # Schedule auto-start after FreeCAD finishes loading
 # Strategy:
 # - If FreeCAD.GuiUp is True: Qt event loop is running, use timer for deferred start
-# - If FreeCAD.GuiUp is False but Qt is available: FreeCAD GUI is initializing.
+# - If FreeCAD.GuiUp is False but QApplication exists: FreeCAD GUI is initializing.
 #   Use GuiWaiter to wait for GuiUp to become True before starting.
 #   This ensures the bridge uses Qt timer (not background thread) for queue processing.
-# - If Qt is not available: Pure headless mode, start bridge directly
+# - If no QApplication: True headless mode, start bridge directly
+#
+# IMPORTANT: We check for QApplication.instance() rather than just QtCore availability
+# because FreeCAD bundles PySide even in headless mode (freecadcmd), but there's no
+# Qt event loop running. Without a QApplication, Qt timers will never fire.
 #
 # CRITICAL: We must wait for FreeCAD.GuiUp to be True before starting the bridge
 # in GUI mode. If we start when GuiUp is False, the bridge's _start_queue_processor()
@@ -100,19 +110,59 @@ def _auto_start_bridge() -> None:
 try:
     from preferences import get_auto_start
 
-    if get_auto_start():
-        # Try to import Qt
+    _auto_start_enabled = get_auto_start()
+    FreeCAD.Console.PrintMessage(
+        f"Robust MCP Bridge: Auto-start preference = {_auto_start_enabled}\n"
+    )
+
+    if _auto_start_enabled:
+        # Try to import Qt and check for running QApplication
         import contextlib
 
         QtCore = None
+        QtWidgets = None
+        _has_qapp = False
+        _is_true_headless = False
+
         try:
-            from PySide2 import QtCore  # type: ignore[assignment, no-redef]
+            from PySide2 import QtCore, QtWidgets  # type: ignore[assignment, no-redef]
         except ImportError:
             with contextlib.suppress(ImportError):
-                from PySide6 import QtCore  # type: ignore[assignment, no-redef]
+                from PySide6 import (  # type: ignore[assignment, no-redef]
+                    QtCore,
+                    QtWidgets,
+                )
+
+        # Detect GUI mode vs true headless mode
+        # - True headless (freecadcmd): QCoreApplication exists but NOT QApplication
+        # - GUI mode early startup: No app yet, or QApplication being initialized
+        # - GUI mode ready: FreeCAD.GuiUp is True
+        if QtWidgets is not None and QtCore is not None:
+            qapp = QtWidgets.QApplication.instance()
+            if qapp is not None:
+                _has_qapp = True
+            else:
+                # No QApplication - check if QCoreApplication exists
+                # If QCoreApplication exists but is NOT a QApplication, it's true headless
+                qcore_app = QtCore.QCoreApplication.instance()
+                if qcore_app is not None and not isinstance(
+                    qcore_app, QtWidgets.QApplication
+                ):
+                    _is_true_headless = True
+                # If no app at all, assume early GUI startup (will use GuiWaiter)
+
+        FreeCAD.Console.PrintMessage(
+            f"Robust MCP Bridge: GuiUp={FreeCAD.GuiUp}, "
+            f"QtCore={'available' if QtCore else 'unavailable'}, "
+            f"QApp={'running' if _has_qapp else 'none'}, "
+            f"headless={_is_true_headless}\n"
+        )
 
         if FreeCAD.GuiUp:
             # GUI is already up - use timer for deferred start
+            FreeCAD.Console.PrintMessage(
+                "Robust MCP Bridge: GUI already up, scheduling deferred start...\n"
+            )
             if QtCore is not None:
                 _auto_start_timer = QtCore.QTimer()
                 _auto_start_timer.setSingleShot(True)
@@ -121,9 +171,21 @@ try:
             else:
                 # GUI is up but Qt import failed - start directly
                 _auto_start_bridge()
+        elif _is_true_headless:
+            # True headless mode - QCoreApplication exists but not QApplication
+            # No Qt event loop for GUI, so start bridge directly with background thread
+            FreeCAD.Console.PrintMessage(
+                "Robust MCP Bridge: True headless mode (QCoreApplication only), "
+                "starting directly...\n"
+            )
+            _auto_start_bridge()
         elif QtCore is not None:
-            # GUI not ready yet, but Qt is available (FreeCAD starting in GUI mode)
+            # GUI not ready yet (either QApplication exists or no app yet)
             # Use GuiWaiter to wait for GuiUp to become True before starting
+            # This ensures the bridge uses Qt timer (not background thread) for queue
+            FreeCAD.Console.PrintMessage(
+                "Robust MCP Bridge: GUI not ready, using GuiWaiter...\n"
+            )
             from freecad_mcp_bridge.bridge_utils import GuiWaiter
 
             _gui_waiter = GuiWaiter(
@@ -136,7 +198,13 @@ try:
             )
             _gui_waiter.start()
         else:
-            # True headless mode - no Qt, no GUI
+            # No Qt available at all - unusual state, start directly
+            FreeCAD.Console.PrintMessage(
+                "Robust MCP Bridge: No Qt available, starting directly...\n"
+            )
             _auto_start_bridge()
 except Exception as e:
     FreeCAD.Console.PrintWarning(f"Could not set up auto-start: {e}\n")
+    import traceback
+
+    FreeCAD.Console.PrintWarning(f"Traceback: {traceback.format_exc()}\n")

addon/FreecadRobustMCPBridge/InitGui.py

@@ -178,6 +178,72 @@ try:
     FreeCAD.Console.PrintMessage(
         "Robust MCP Bridge: Status bar sync scheduled from InitGui (2s)\n"
     )
+
+    # Auto-start the MCP bridge if configured in preferences
+    # This runs at FreeCAD GUI startup (InitGui.py module-level code)
+    # Note: Init.py does NOT run at startup for workbench addons, so auto-start
+    # must be triggered from here instead.
+    def _deferred_auto_start() -> None:
+        """Auto-start bridge after GUI is fully ready."""
+        try:
+            from preferences import get_auto_start
+
+            if not get_auto_start():
+                return
+
+            # Check if bridge is already running
+            from commands import is_bridge_running
+
+            if is_bridge_running():
+                FreeCAD.Console.PrintMessage(
+                    "Robust MCP Bridge: Bridge already running, skipping auto-start\n"
+                )
+                return
+
+            FreeCAD.Console.PrintMessage(
+                "Robust MCP Bridge: Auto-starting from InitGui...\n"
+            )
+
+            # Import and start the bridge
+            from freecad_mcp_bridge.bridge_utils import register_mcp_plugin
+            from freecad_mcp_bridge.server import FreecadMCPPlugin
+            from preferences import get_socket_port, get_xmlrpc_port
+
+            xmlrpc_port = get_xmlrpc_port()
+            socket_port = get_socket_port()
+
+            plugin = FreecadMCPPlugin(
+                host="localhost",
+                port=socket_port,
+                xmlrpc_port=xmlrpc_port,
+                enable_xmlrpc=True,
+            )
+            plugin.start()
+
+            # Register plugin with commands module
+            register_mcp_plugin(plugin, xmlrpc_port, socket_port)
+
+            # Sync status bar now that bridge is running
+            try:
+                from status_widget import sync_status_with_bridge
+
+                sync_status_with_bridge()
+            except Exception as status_err:
+                FreeCAD.Console.PrintWarning(
+                    f"Could not sync status bar after auto-start: {status_err}\n"
+                )
+        except Exception as e:
+            FreeCAD.Console.PrintError(f"Robust MCP Bridge: Auto-start failed: {e}\n")
+            import traceback
+
+            FreeCAD.Console.PrintError(traceback.format_exc())
+
+    # Schedule auto-start after a short delay to ensure GUI is fully ready
+    # Use a longer delay than status bar sync to avoid race conditions
+    QtCore.QTimer.singleShot(3000, _deferred_auto_start)
+    FreeCAD.Console.PrintMessage(
+        "Robust MCP Bridge: Auto-start scheduled from InitGui (3s)\n"
+    )
 except Exception as e:
     FreeCAD.Console.PrintWarning(
         f"Robust MCP Bridge: Could not schedule status bar sync: {e}\n"

addon/FreecadRobustMCPBridge/RELEASE_NOTES.md

@@ -2,7 +2,7 @@
 
 ## Version 0.6.2 (2026-01-18)
 
-No changes to the workbench code itself. This release reflects the repository restructuring.
+This release fixes some auto-start issues and improves the overall startup experience across all supported modes.
 
 ### Added
 
@@ -11,10 +11,13 @@ No changes to the workbench code itself. This release reflects the repository re
 ### Changed
 
 - **Repository restructured**: This addon now focuses solely on the MCP Bridge Workbench. Standalone macros have been moved to dedicated repositories for independent release cycles.
+- **Cleaner startup messages**: Removed duplicate success messages when bridge auto-starts.
 
 ### Fixed
 
-- No bug fixes in this release.
+- **Auto-start not working at FreeCAD startup**: Fixed bug where auto-start only worked when manually selecting the workbench. For FreeCAD workbench addons, `Init.py` does NOT run at startup - only `InitGui.py` module-level code runs. Auto-start logic has been moved to `InitGui.py`.
+- **Status bar not appearing after auto-start**: The status bar widget now syncs immediately after the bridge starts, instead of on a timer that ran before the bridge was ready.
+- **Integration test crashes**: Fixed race condition where the bridge could start before `FreeCAD.GuiUp` was `True`, causing Qt operations to run on a background thread and crash FreeCAD.
 
 ### Note
 

addon/FreecadRobustMCPBridge/freecad_mcp_bridge/startup_bridge.py

@@ -128,31 +128,76 @@ def _start_bridge() -> None:
 # Schedule bridge start after FreeCAD finishes loading
 # Strategy:
 # - If FreeCAD.GuiUp is True: Qt event loop is running, start bridge directly
-# - If FreeCAD.GuiUp is False but Qt is available: FreeCAD GUI is initializing.
+# - If FreeCAD.GuiUp is False but QApplication exists: FreeCAD GUI is initializing.
 #   Use GuiWaiter to wait for GuiUp to become True before starting.
 #   This ensures the bridge uses Qt timer (not background thread) for queue processing.
-# - If Qt is not available: Pure headless mode, start bridge directly
+# - If no QApplication: True headless mode, start bridge directly
+#
+# IMPORTANT: We check for QApplication.instance() rather than just QtCore availability
+# because FreeCAD bundles PySide even in headless mode (freecadcmd), but there's no
+# Qt event loop running. Without a QApplication, Qt timers will never fire.
 #
 # CRITICAL: We must wait for FreeCAD.GuiUp to be True before starting the bridge
 # in GUI mode. If we start when GuiUp is False, the bridge's _start_queue_processor()
 # will see GuiUp=False and use a background thread. Later, code executed on that
 # thread will try to do Qt operations, causing crashes (SIGABRT in QCocoaWindow).
 try:
-    # Try to import Qt
+    # Try to import Qt and check for running QApplication
     QtCore = None
+    QtWidgets = None
+    _has_qapp = False
+    _is_true_headless = False
+
     try:
-        from PySide2 import QtCore  # type: ignore[assignment, no-redef]
+        from PySide2 import QtCore, QtWidgets  # type: ignore[assignment, no-redef]
     except ImportError:
         with contextlib.suppress(ImportError):
-            from PySide6 import QtCore  # type: ignore[assignment, no-redef]
+            from PySide6 import QtCore, QtWidgets  # type: ignore[assignment, no-redef]
+
+    # Detect GUI mode vs true headless mode
+    # - True headless (freecadcmd): QCoreApplication exists but NOT QApplication
+    # - GUI mode early startup: No app yet, or QApplication being initialized
+    # - GUI mode ready: FreeCAD.GuiUp is True
+    if QtWidgets is not None and QtCore is not None:
+        qapp = QtWidgets.QApplication.instance()
+        if qapp is not None:
+            _has_qapp = True
+        else:
+            # No QApplication - check if QCoreApplication exists
+            # If QCoreApplication exists but is NOT a QApplication, it's true headless
+            qcore_app = QtCore.QCoreApplication.instance()
+            if qcore_app is not None and not isinstance(
+                qcore_app, QtWidgets.QApplication
+            ):
+                _is_true_headless = True
+            # If no app at all, assume early GUI startup (will use GuiWaiter)
+
+    FreeCAD.Console.PrintMessage(
+        f"Startup Bridge: GuiUp={FreeCAD.GuiUp}, "
+        f"QtCore={'available' if QtCore else 'unavailable'}, "
+        f"QApp={'running' if _has_qapp else 'none'}, "
+        f"headless={_is_true_headless}\n"
+    )
 
     if FreeCAD.GuiUp:
         # GUI is already up - start bridge directly
         FreeCAD.Console.PrintMessage("Startup Bridge: GUI already up, starting...\n")
         _start_bridge()
+    elif _is_true_headless:
+        # True headless mode - QCoreApplication exists but not QApplication
+        # No Qt event loop for GUI, so start bridge directly with background thread
+        FreeCAD.Console.PrintMessage(
+            "Startup Bridge: True headless mode (QCoreApplication only), "
+            "starting directly...\n"
+        )
+        _start_bridge()
     elif QtCore is not None:
-        # GUI not ready yet, but Qt is available (FreeCAD starting in GUI mode)
+        # GUI not ready yet (either QApplication exists or no app yet)
         # Use GuiWaiter to wait for GuiUp to become True before starting
+        # This ensures the bridge uses Qt timer (not background thread) for queue
+        FreeCAD.Console.PrintMessage(
+            "Startup Bridge: GUI not ready, using GuiWaiter...\n"
+        )
         from bridge_utils import GuiWaiter
 
         _gui_waiter = GuiWaiter(
@@ -165,10 +210,11 @@ try:
         )
         _gui_waiter.start()
     else:
-        # True headless mode - no Qt, no GUI
+        # No Qt available at all - unusual state, start directly
         FreeCAD.Console.PrintMessage(
-            "Startup Bridge: Headless mode, starting directly...\n"
+            "Startup Bridge: No Qt available, starting directly...\n"
         )
         _start_bridge()
 except Exception as e:
     FreeCAD.Console.PrintError(f"Startup Bridge: Failed to initialize: {e}\n")
+    FreeCAD.Console.PrintError(traceback.format_exc())

tests/unit/addon/test_addon_autostart.py

@@ -0,0 +1,340 @@
+"""Tests for the FreeCAD Robust MCP workbench auto-start logic.
+
+These tests verify that the auto-start logic in Init.py is correctly
+implemented with proper diagnostic logging and all code paths covered.
+
+This test suite was added after discovering a bug where auto-start wasn't
+working because the code flow wasn't properly logging which path was taken,
+making it difficult to debug.
+"""
+
+import ast
+from pathlib import Path
+
+import pytest
+
+# Get the addon directory path
+ADDON_DIR = (
+    Path(__file__).parent.parent.parent.parent / "addon" / "FreecadRobustMCPBridge"
+)
+
+
+class TestAutoStartPreferences:
+    """Tests for auto-start preference functions."""
+
+    @pytest.fixture
+    def preferences_code(self) -> str:
+        """Load preferences.py content."""
+        return (ADDON_DIR / "preferences.py").read_text()
+
+    def test_get_auto_start_function_exists(self, preferences_code: str) -> None:
+        """preferences.py should have get_auto_start function."""
+        assert "def get_auto_start" in preferences_code
+
+    def test_set_auto_start_function_exists(self, preferences_code: str) -> None:
+        """preferences.py should have set_auto_start function."""
+        assert "def set_auto_start" in preferences_code
+
+    def test_auto_start_default_is_false(self, preferences_code: str) -> None:
+        """Default auto-start should be False for safety."""
+        assert "DEFAULT_AUTO_START = False" in preferences_code
+
+    def test_auto_start_uses_param_path(self, preferences_code: str) -> None:
+        """Auto-start should use FreeCAD parameter system."""
+        assert "PARAM_PATH" in preferences_code
+        assert "RobustMCPBridge" in preferences_code
+
+    def test_get_auto_start_returns_bool(self, preferences_code: str) -> None:
+        """get_auto_start should return a bool."""
+        # Check for GetBool call
+        assert "GetBool" in preferences_code
+        # Use AST to verify return type annotation
+        tree = ast.parse(preferences_code)
+        for node in ast.walk(tree):
+            if isinstance(node, ast.FunctionDef) and node.name == "get_auto_start":
+                assert node.returns is not None, (
+                    "get_auto_start should have return annotation"
+                )
+                # Check if return annotation is 'bool'
+                if isinstance(node.returns, ast.Name):
+                    assert node.returns.id == "bool", "Return type should be bool"
+                elif isinstance(node.returns, ast.Constant):
+                    # Python 3.9+ may use Constant for some annotations
+                    assert node.returns.value == "bool", "Return type should be bool"
+                else:
+                    pytest.fail(
+                        f"Unexpected return annotation type: {type(node.returns)}"
+                    )
+                return
+        pytest.fail("get_auto_start function not found in preferences.py")
+
+
+class TestAutoStartInitLogic:
+    """Tests for auto-start logic in Init.py."""
+
+    @pytest.fixture
+    def init_code(self) -> str:
+        """Load Init.py content."""
+        return (ADDON_DIR / "Init.py").read_text()
+
+    def test_imports_get_auto_start(self, init_code: str) -> None:
+        """Init.py should import get_auto_start from preferences."""
+        assert "from preferences import get_auto_start" in init_code
+
+    def test_checks_auto_start_preference(self, init_code: str) -> None:
+        """Init.py should check the auto_start preference value."""
+        # Should call get_auto_start() and store/check the result
+        assert "get_auto_start()" in init_code
+
+    def test_logs_auto_start_preference_value(self, init_code: str) -> None:
+        """Init.py should log whether auto-start is enabled.
+
+        This diagnostic logging helps debug auto-start issues by showing
+        what value was read from preferences.
+        """
+        # Should log the actual preference value
+        assert "Auto-start preference" in init_code
+
+    def test_logs_gui_state(self, init_code: str) -> None:
+        """Init.py should log GuiUp, QtCore, and QApp availability.
+
+        This diagnostic logging helps debug which code path is taken.
+        """
+        assert "GuiUp=" in init_code
+        assert "QtCore=" in init_code
+        assert "QApp=" in init_code
+
+    def test_handles_gui_already_up_path(self, init_code: str) -> None:
+        """Init.py should handle the case when GUI is already up."""
+        # Should check FreeCAD.GuiUp and log accordingly
+        assert "GUI already up" in init_code
+
+    def test_handles_gui_not_ready_path(self, init_code: str) -> None:
+        """Init.py should handle the case when GUI is not yet ready."""
+        # Should use GuiWaiter when GUI is not ready but Qt is available
+        assert "GUI not ready" in init_code
+        assert "GuiWaiter" in init_code
+
+    def test_handles_headless_path(self, init_code: str) -> None:
+        """Init.py should handle true headless mode (QCoreApplication only)."""
+        # Should detect and handle true headless mode
+        assert "True headless mode" in init_code or "headless" in init_code.lower()
+        # Should check QCoreApplication to detect true headless
+        assert "QCoreApplication" in init_code
+        # Should use isinstance to distinguish QCoreApplication from QApplication
+        assert "isinstance" in init_code
+
+    def test_imports_gui_waiter(self, init_code: str) -> None:
+        """Init.py should import GuiWaiter for waiting on GUI."""
+        assert "from freecad_mcp_bridge.bridge_utils import GuiWaiter" in init_code
+
+    def test_uses_single_shot_timer_for_gui_up(self, init_code: str) -> None:
+        """When GUI is up, should use single-shot timer for deferred start."""
+        assert "setSingleShot(True)" in init_code
+
+    def test_exception_handling_with_traceback(self, init_code: str) -> None:
+        """Auto-start setup should catch exceptions and log traceback.
+
+        Without traceback logging, failures are silent and hard to debug.
+        """
+        assert "except Exception" in init_code
+        # Should log the traceback, not just the exception message
+        assert "traceback" in init_code.lower()
+
+    @pytest.mark.parametrize(
+        "var_name",
+        ["_auto_start_timer", "_gui_waiter"],
+        ids=["timer_reference", "gui_waiter_reference"],
+    )
+    def test_global_references_prevent_gc(self, init_code: str, var_name: str) -> None:
+        """Global references should be stored at module level to prevent GC.
+
+        Both _auto_start_timer and _gui_waiter must be defined at module level
+        (not indented) to prevent garbage collection of Qt timers and callbacks.
+        """
+        assert var_name in init_code, f"{var_name} should be present in Init.py"
+        # Verify module-level definition (line starts with var name, not indented)
+        lines = init_code.split("\n")
+        for line in lines:
+            if line.startswith(var_name):
+                # Found module-level definition (not indented)
+                return
+        pytest.fail(f"{var_name} should be defined at module level (not indented)")
+
+
+class TestAutoStartBridgeFunction:
+    """Tests for the _auto_start_bridge function."""
+
+    @pytest.fixture
+    def init_code(self) -> str:
+        """Load Init.py content."""
+        return (ADDON_DIR / "Init.py").read_text()
+
+    def test_auto_start_bridge_function_exists(self, init_code: str) -> None:
+        """_auto_start_bridge function should exist."""
+        assert "def _auto_start_bridge" in init_code
+
+    def test_auto_start_bridge_checks_preference_again(self, init_code: str) -> None:
+        """_auto_start_bridge should re-check preference before starting.
+
+        This handles the case where preference changed between Init.py load
+        and the deferred timer firing.
+        """
+        # Parse the function body
+        tree = ast.parse(init_code)
+        for node in ast.walk(tree):
+            if isinstance(node, ast.FunctionDef) and node.name == "_auto_start_bridge":
+                # Convert function body back to source for analysis
+                func_code = ast.unparse(node)
+                assert "get_auto_start" in func_code
+                return
+        pytest.fail("_auto_start_bridge function not found")
+
+    def test_auto_start_bridge_checks_if_already_running(self, init_code: str) -> None:
+        """_auto_start_bridge should check if bridge is already running."""
+        # Should check _mcp_plugin.is_running or similar
+        assert "is_running" in init_code
+
+    def test_auto_start_bridge_logs_start_message(self, init_code: str) -> None:
+        """_auto_start_bridge should log when auto-starting."""
+        assert "Auto-starting MCP Bridge" in init_code
+
+    def test_auto_start_bridge_creates_plugin(self, init_code: str) -> None:
+        """_auto_start_bridge should create a FreecadMCPPlugin instance."""
+        assert "FreecadMCPPlugin" in init_code
+
+    def test_auto_start_bridge_registers_plugin(self, init_code: str) -> None:
+        """_auto_start_bridge should register plugin with commands module."""
+        assert "register_mcp_plugin" in init_code
+
+    def test_auto_start_bridge_handles_exceptions(self, init_code: str) -> None:
+        """_auto_start_bridge should catch and log exceptions."""
+        # Parse the function and check for try/except
+        tree = ast.parse(init_code)
+        for node in ast.walk(tree):
+            if isinstance(node, ast.FunctionDef) and node.name == "_auto_start_bridge":
+                # Check if function has try/except
+                for child in ast.walk(node):
+                    if isinstance(child, ast.Try):
+                        return  # Found try/except
+        pytest.fail("_auto_start_bridge should have try/except for error handling")
+
+
+class TestGuiWaiterUsage:
+    """Tests for GuiWaiter class usage in auto-start."""
+
+    @pytest.fixture
+    def bridge_utils_code(self) -> str:
+        """Load bridge_utils.py content."""
+        return (ADDON_DIR / "freecad_mcp_bridge" / "bridge_utils.py").read_text()
+
+    def test_gui_waiter_class_exists(self, bridge_utils_code: str) -> None:
+        """GuiWaiter class should exist in bridge_utils.py."""
+        assert "class GuiWaiter" in bridge_utils_code
+
+    def test_gui_waiter_has_start_method(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should have a start method."""
+        assert "def start(self)" in bridge_utils_code
+
+    def test_gui_waiter_checks_gui_up(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should check FreeCAD.GuiUp."""
+        assert "GuiUp" in bridge_utils_code
+
+    def test_gui_waiter_uses_repeating_timer(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should use a repeating timer to poll GUI state."""
+        # setSingleShot(False) means repeating
+        assert "setSingleShot(False)" in bridge_utils_code
+
+    def test_gui_waiter_has_timeout(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should have a timeout to prevent infinite waiting."""
+        assert "max_retries" in bridge_utils_code or "timeout" in bridge_utils_code
+
+    def test_gui_waiter_defers_callback(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should defer callback after GUI is ready.
+
+        This prevents starting the bridge too early when FreeCAD is still
+        initializing, which could cause race conditions.
+        """
+        # Check for specific defer-related patterns to avoid false positives
+        # Look for the defer timer, defer_ms parameter, or deferring log message
+        has_defer_timer = "_defer_timer" in bridge_utils_code
+        has_defer_ms = "defer_ms" in bridge_utils_code
+        has_deferring_message = "deferring" in bridge_utils_code.lower()
+        assert any([has_defer_timer, has_defer_ms, has_deferring_message]), (
+            "GuiWaiter should have defer functionality "
+            "(expected _defer_timer, defer_ms, or 'deferring' in code)"
+        )
+
+    def test_gui_waiter_logs_waiting_message(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should log when it starts waiting."""
+        assert "Waiting for GUI" in bridge_utils_code
+
+    def test_gui_waiter_logs_ready_message(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should log when GUI becomes ready."""
+        assert "GUI ready" in bridge_utils_code
+
+    def test_gui_waiter_logs_timeout_error(self, bridge_utils_code: str) -> None:
+        """GuiWaiter should log error on timeout."""
+        assert "did not become ready" in bridge_utils_code
+
+
+class TestAutoStartCodePaths:
+    """Tests to verify all auto-start code paths are properly handled."""
+
+    @pytest.fixture
+    def init_code(self) -> str:
+        """Load Init.py content."""
+        return (ADDON_DIR / "Init.py").read_text()
+
+    def test_four_startup_scenarios_documented(self, init_code: str) -> None:
+        """Init.py should document the four startup scenarios.
+
+        1. GUI already up - use timer for deferred start
+        2. True headless (QCoreApplication only) - start directly with background thread
+        3. GUI not ready but Qt available - use GuiWaiter
+        4. No Qt available - start directly (unusual state)
+        """
+        # Check for documentation of scenarios
+        assert "GuiUp is True" in init_code or "GUI is already up" in init_code
+        assert "QCoreApplication" in init_code  # True headless detection
+        assert "GUI not ready" in init_code
+        assert "No Qt available" in init_code or "headless" in init_code.lower()
+
+    def test_all_paths_have_logging(self, init_code: str) -> None:
+        """Each code path should have diagnostic logging."""
+        # Count distinct log messages for different paths
+        log_patterns = [
+            "GUI already up",
+            "True headless mode",
+            "GUI not ready",
+            "No Qt available",
+        ]
+        found = sum(1 for pattern in log_patterns if pattern in init_code)
+        assert found >= 4, f"Expected 4 code paths with logging, found {found}"
+
+    def test_pyside_fallback_from_2_to_6(self, init_code: str) -> None:
+        """Should try PySide2 first, then fall back to PySide6."""
+        # Check for both imports
+        assert "PySide2" in init_code
+        assert "PySide6" in init_code
+        # PySide2 should be tried first (common pattern)
+        pyside2_pos = init_code.find("PySide2")
+        pyside6_pos = init_code.find("PySide6")
+        assert pyside2_pos < pyside6_pos, "Should try PySide2 before PySide6"
+
+    def test_true_headless_detection_via_isinstance(self, init_code: str) -> None:
+        """Should use isinstance to detect true headless mode.
+
+        True headless mode is when QCoreApplication exists but is NOT a
+        QApplication. This happens with freecadcmd (headless FreeCAD).
+
+        In GUI mode during early startup, there may be no application yet,
+        or a QApplication that's being initialized. We need to wait for
+        FreeCAD.GuiUp in those cases.
+        """
+        # Should check QCoreApplication.instance()
+        assert "QCoreApplication.instance()" in init_code
+        # Should use isinstance to check if it's a QApplication
+        assert "isinstance" in init_code
+        # Should have a variable tracking true headless state
+        assert "_is_true_headless" in init_code