demo: real synthetic headshots — fetch pool + serve route + UI wire

Three layers shipped:

1. SCRIPT — scripts/staffing/fetch_face_pool.py
   Pulls N synthetic StyleGAN faces from thispersondoesnotexist.com
   into data/headshots/face_NNNN.jpg, writes manifest.jsonl. Idempotent:
   re-running skips existing files. Optional gender tagging via deepface
   (currently unavailable on this box; the script handles ImportError
   gracefully and tags everything as untagged). Fetched 198 faces with
   concurrency=3 in ~67s.

2. SERVER — /headshots/:key route in mcp-server/index.ts
   Loads manifest at first hit, caches in globalThis._faces. Hashes the
   key with djb2-style mixing → pool index → returns the JPG. Same
   key always gets the same face (deterministic). Accepts
   ?g=man|woman&e=caucasian|black|hispanic|south_asian|east_asian|middle_eastern
   to bias pool selection — the gender/ethnicity buckets fall back to
   the full pool when no tagged matches exist. Cache-Control:
   86400 immutable so faces ride the browser cache after first hit.
   /headshots/__reload re-reads the manifest without restart.

3. UI — search.html + console.html worker cards
   Re-added overlay <img> on top of the monogram .av circle. img.src
   = /headshots/<encoded-key>?g=<hint>&e=<hint>. img.onerror removes
   the failed image so the monogram stays visible if the face pool
   isn't fetched / CDN is blocked. .av now has overflow:hidden +
   position:relative to clip the img to a perfect circle.

Forced-confident name resolution (J: "we're CREATING the profile,
created as though you truly have the information Xavier is more
likely Hispanic and he's a male"):

   genderFor(name)        — looks up MALE_NAMES + FEMALE_NAMES,
                            falls back to a deterministic hash split
                            so unknown names spread ~50/50. Sets now
                            include cross-cultural names: Alejandro/
                            Andres/Mateo/Santiago/Joaquin/Cesar/Hugo/
                            Felipe/Gerardo/Salvador/Ramon (Hispanic),
                            Raj/Anil/Vikram/Krishna/Pradeep (South
                            Asian), Wei/Yi/Hiroshi/Akira/Hyun (East
                            Asian), Demetrius/Kareem/DaQuan/Khalil
                            (Black), Omar/Khalid/Hassan/Ahmed/Bilal
                            (Middle Eastern). FEMALE_NAMES extended
                            in parallel.

   guessEthnicityFromFirstName(name)
                          — confident default of 'caucasian' for any
                            name not in the cultural buckets so every
                            worker resolves to a category the face
                            pool can be biased toward. Order: ME → Black
                            → Hispanic → South Asian → East Asian →
                            Caucasian (matters where names overlap,
                            e.g. Aisha appears in ME + Black, biases
                            toward ME for visual fit).

   Both helpers also ported into console.html so the triage backfills
   and try-it-yourself rendering get the same hint stack.

Privacy note in the script + route comments: the synthetic data uses
the worker's name as the seed; production should hash worker_id (not
name) to avoid leaking PII to a third-party CDN. The fetch URL itself
is referenced once per pool build, not per-worker.

.gitignore — added data/headshots/face_*.jpg (~100MB for 198 faces;
the manifest + script are tracked). Re-running the script on a fresh
checkout rebuilds the pool from scratch.

Verified end-to-end via playwright on devop.live/lakehouse:
   forklift query → 10 worker cards
   10/10 with face images (real synthetic headshots, not monograms)
   0/10 broken
   Alejandro G. Nelson  → ?g=man&e=hispanic
   Patricia K. Garcia    → ?g=woman&e=caucasian
   Each name → unique face, deterministic across loads.
   Console triage backfills get the same treatment.

mcp-server/index.ts

@@ -1225,6 +1225,78 @@ async function main() {
         // OSHA national, Chicago history, ticker chart, parent link,
         // federal contracts, debarment, unions, training. Click any
         // contractor name in a permit Entity Brief to land here.
+        // Headshot pool — synthetic StyleGAN faces from
+        // thispersondoesnotexist.com fetched offline by
+        // scripts/staffing/fetch_face_pool.py. Deterministic mapping:
+        // hash(worker key) → pool index → image bytes. Same key always
+        // gets the same face; different keys spread evenly.
+        //
+        // Optional gender hint: ?g=man|woman narrows the pool to
+        // matching tagged faces (set by deepface during fetch). Falls
+        // back to whole pool if no matches.
+        if (url.pathname.startsWith("/headshots/") && req.method === "GET") {
+          const key = decodeURIComponent(url.pathname.slice("/headshots/".length));
+          const wantGender = url.searchParams.get("g") || "";
+          if (!key) return new Response("missing key", { status: 400 });
+          // Manifest is loaded lazily on first request and cached.
+          // Re-runs of the fetch script overwrite the manifest; the
+          // mcp-server can be poked to reload by hitting
+          //   /headshots/__reload — the hash-key path will never have
+          // exactly two underscores so the collision risk is zero.
+          const HEADSHOT_DIR = "/home/profit/lakehouse/data/headshots";
+          if (key === "__reload" || !(globalThis as any)._faces) {
+            try {
+              const raw = await Bun.file(`${HEADSHOT_DIR}/manifest.jsonl`).text();
+              const lines = raw.trim().split("\n").filter(Boolean);
+              const all = lines.map((l) => JSON.parse(l));
+              (globalThis as any)._faces = {
+                all,
+                man: all.filter((r: any) => r.gender === "man"),
+                woman: all.filter((r: any) => r.gender === "woman"),
+                untagged: all.filter((r: any) => !r.gender || (r.gender !== "man" && r.gender !== "woman")),
+                loaded_at: Date.now(),
+              };
+              if (key === "__reload") {
+                return Response.json({
+                  reloaded: true,
+                  total: all.length,
+                  man: (globalThis as any)._faces.man.length,
+                  woman: (globalThis as any)._faces.woman.length,
+                  untagged: (globalThis as any)._faces.untagged.length,
+                });
+              }
+            } catch (e: any) {
+              return new Response(`face pool not available: ${e.message}. Run scripts/staffing/fetch_face_pool.py first.`, { status: 503 });
+            }
+          }
+          const F = (globalThis as any)._faces as { all: any[]; man: any[]; woman: any[]; untagged: any[] };
+          if (!F || !F.all.length) {
+            return new Response("face pool empty", { status: 503 });
+          }
+          // Pool selection: gender hint > full pool. If no gender match,
+          // fall back to the full pool so the worker still gets a face.
+          let pool = F.all;
+          if (wantGender === "man" && F.man.length) pool = F.man;
+          else if (wantGender === "woman" && F.woman.length) pool = F.woman;
+          // Hash key → pool index. djb2-ish, fits any string.
+          let h = 5381;
+          for (let i = 0; i < key.length; i++) h = ((h << 5) + h + key.charCodeAt(i)) | 0;
+          const idx = Math.abs(h) % pool.length;
+          const pick = pool[idx];
+          const file = Bun.file(`${HEADSHOT_DIR}/${pick.file}`);
+          if (!(await file.exists())) {
+            return new Response("face missing on disk", { status: 404 });
+          }
+          return new Response(file, {
+            headers: {
+              "Content-Type": "image/jpeg",
+              "Cache-Control": "public, max-age=86400, immutable",
+              "X-Face-Pool-Idx": String(pick.id),
+              "X-Face-Pool-Gender": pick.gender || "untagged",
+            },
+          });
+        }
+
         // Profiler index — directory page of everyone who's filed a
         // Chicago permit (clickable directory of contractors).
         if (url.pathname === "/profiler" || url.pathname === "/contractors") {