diff --git a/src/components/FileUpload/FileUpload.tsx b/src/components/FileUpload/FileUpload.tsx
index 991cd12..da0ec2e 100644
--- a/src/components/FileUpload/FileUpload.tsx
+++ b/src/components/FileUpload/FileUpload.tsx
@@ -20,7 +20,7 @@ import {
   usePatternRotationUpload,
   usePatternValidation,
 } from "@/hooks";
-import { useDisplayFilename } from "../../hooks/domain/useDisplayFilename";
+import { getDisplayFilename } from "../../utils/displayFilename";
 import { PatternInfoSkeleton } from "../SkeletonLoader";
 import { PatternInfo } from "../PatternInfo";
 import { DocumentTextIcon } from "@heroicons/react/24/solid";
@@ -105,7 +105,7 @@ export function FileUpload() {
   // Use prop pesData if available (from cached pattern), otherwise use local state
   const pesData = pesDataProp || localPesData;
   // Use currentFileName from App state, or local fileName, or resumeFileName for display
-  const displayFileName = useDisplayFilename({
+  const displayFileName = getDisplayFilename({
     currentFileName,
     localFileName: fileName,
     resumeFileName,
@@ -229,6 +229,7 @@ export function FileUpload() {
             isConnected={isConnected}
             isUploading={isUploading}
             uploadProgress={uploadProgress}
+            boundsFits={boundsCheck.fits}
             boundsError={boundsCheck.error}
             onUpload={handleUpload}
             patternUploaded={patternUploaded}
diff --git a/src/components/FileUpload/PyodideProgress.tsx b/src/components/FileUpload/PyodideProgress.tsx
index d6a6538..e8c3868 100644
--- a/src/components/FileUpload/PyodideProgress.tsx
+++ b/src/components/FileUpload/PyodideProgress.tsx
@@ -25,7 +25,7 @@ export function PyodideProgress({
     <div className="mb-3">
       <div className="flex justify-between items-center mb-1.5">
         <span className="text-xs font-medium text-gray-600 dark:text-gray-400">
-          {isFileLoading && !pyodideReady
+          {isFileLoading
             ? "Please wait - initializing Python environment..."
             : pyodideLoadingStep || "Initializing Python environment..."}
         </span>
@@ -35,7 +35,7 @@ export function PyodideProgress({
       </div>
       <Progress value={pyodideProgress} className="h-2.5" />
       <p className="text-xs text-gray-500 dark:text-gray-400 mt-1.5 italic">
-        {isFileLoading && !pyodideReady
+        {isFileLoading
           ? "File dialog will open automatically when ready"
           : "This only happens once on first use"}
       </p>
diff --git a/src/components/FileUpload/UploadButton.tsx b/src/components/FileUpload/UploadButton.tsx
index f933729..22d7912 100644
--- a/src/components/FileUpload/UploadButton.tsx
+++ b/src/components/FileUpload/UploadButton.tsx
@@ -17,6 +17,7 @@ interface UploadButtonProps {
   isConnected: boolean;
   isUploading: boolean;
   uploadProgress: number;
+  boundsFits: boolean;
   boundsError: string | null;
   onUpload: () => Promise<void>;
   patternUploaded: boolean;
@@ -28,6 +29,7 @@ export function UploadButton({
   isConnected,
   isUploading,
   uploadProgress,
+  boundsFits,
   boundsError,
   onUpload,
   patternUploaded,
@@ -43,7 +45,7 @@ export function UploadButton({
   return (
     <Button
       onClick={onUpload}
-      disabled={!isConnected || isUploading || !!boundsError}
+      disabled={!isConnected || isUploading || !boundsFits}
       className="flex-1"
       aria-label={
         isUploading
diff --git a/src/components/ProgressMonitor/ColorBlockItem.tsx b/src/components/ProgressMonitor/ColorBlockItem.tsx
index fb21fcd..a85a57a 100644
--- a/src/components/ProgressMonitor/ColorBlockItem.tsx
+++ b/src/components/ProgressMonitor/ColorBlockItem.tsx
@@ -12,18 +12,7 @@ import {
 } from "@heroicons/react/24/solid";
 import { Progress } from "@/components/ui/progress";
 import { formatThreadMetadata } from "../../utils/threadMetadata";
-
-export interface ColorBlock {
-  colorIndex: number;
-  threadHex: string;
-  startStitch: number;
-  endStitch: number;
-  stitchCount: number;
-  threadCatalogNumber: string | null;
-  threadBrand: string | null;
-  threadDescription: string | null;
-  threadChart: string | null;
-}
+import type { ColorBlock } from "./types";
 
 interface ColorBlockItemProps {
   block: ColorBlock;
diff --git a/src/components/ProgressMonitor/ColorBlockList.tsx b/src/components/ProgressMonitor/ColorBlockList.tsx
index 0ae0df2..29a22aa 100644
--- a/src/components/ProgressMonitor/ColorBlockList.tsx
+++ b/src/components/ProgressMonitor/ColorBlockList.tsx
@@ -5,7 +5,8 @@
  */
 
 import { ScrollArea } from "@/components/ui/scroll-area";
-import { ColorBlockItem, type ColorBlock } from "./ColorBlockItem";
+import { ColorBlockItem } from "./ColorBlockItem";
+import type { ColorBlock } from "./types";
 
 interface ColorBlockListProps {
   colorBlocks: ColorBlock[];
diff --git a/src/components/ProgressMonitor/ProgressMonitor.tsx b/src/components/ProgressMonitor/ProgressMonitor.tsx
index 4947035..b15e1dc 100644
--- a/src/components/ProgressMonitor/ProgressMonitor.tsx
+++ b/src/components/ProgressMonitor/ProgressMonitor.tsx
@@ -23,7 +23,7 @@ import { ProgressStats } from "./ProgressStats";
 import { ProgressSection } from "./ProgressSection";
 import { ColorBlockList } from "./ColorBlockList";
 import { ProgressActions } from "./ProgressActions";
-import type { ColorBlock } from "./ColorBlockItem";
+import type { ColorBlock } from "./types";
 
 export function ProgressMonitor() {
   // Machine store
diff --git a/src/components/ProgressMonitor/types.ts b/src/components/ProgressMonitor/types.ts
new file mode 100644
index 0000000..103049e
--- /dev/null
+++ b/src/components/ProgressMonitor/types.ts
@@ -0,0 +1,15 @@
+/**
+ * Shared types for ProgressMonitor components
+ */
+
+export interface ColorBlock {
+  colorIndex: number;
+  threadHex: string;
+  startStitch: number;
+  endStitch: number;
+  stitchCount: number;
+  threadCatalogNumber: string | null;
+  threadBrand: string | null;
+  threadDescription: string | null;
+  threadChart: string | null;
+}
diff --git a/src/components/WorkflowStepper/StepCircle.tsx b/src/components/WorkflowStepper/StepCircle.tsx
index 4c9ab83..ba86a8d 100644
--- a/src/components/WorkflowStepper/StepCircle.tsx
+++ b/src/components/WorkflowStepper/StepCircle.tsx
@@ -28,7 +28,7 @@ export const StepCircle = forwardRef<HTMLDivElement, StepCircleProps>(
         onClick={onClick}
         className={`
           w-8 h-8 lg:w-10 lg:h-10 rounded-full flex items-center justify-center font-bold text-xs transition-all duration-300 border-2 shadow-md
-          ${stepId <= (isCurrent ? stepId : isComplete ? stepId : stepId - 1) ? "cursor-pointer hover:scale-110" : "cursor-not-allowed"}
+          ${isComplete || isCurrent ? "cursor-pointer hover:scale-110" : "cursor-not-allowed"}
           ${isComplete ? "bg-success-500 dark:bg-success-600 border-success-400 dark:border-success-500 text-white shadow-success-500/30 dark:shadow-success-600/30" : ""}
           ${isCurrent ? "bg-primary-600 dark:bg-primary-700 border-primary-500 dark:border-primary-600 text-white scale-105 lg:scale-110 shadow-primary-600/40 dark:shadow-primary-700/40 ring-2 ring-primary-300 dark:ring-primary-500 ring-offset-2 dark:ring-offset-gray-900" : ""}
           ${isUpcoming ? "bg-primary-700 dark:bg-primary-800 border-primary-500/30 dark:border-primary-600/30 text-primary-200/70 dark:text-primary-300/70" : ""}
diff --git a/src/components/WorkflowStepper/StepPopover.tsx b/src/components/WorkflowStepper/StepPopover.tsx
index 711fe8a..d625fae 100644
--- a/src/components/WorkflowStepper/StepPopover.tsx
+++ b/src/components/WorkflowStepper/StepPopover.tsx
@@ -98,18 +98,20 @@ export const StepPopover = forwardRef<HTMLDivElement, StepPopoverProps>(
                 <ul
                   className={`list-disc list-inside text-sm ${listColorClasses[content.type]} space-y-1`}
                 >
-                  {content.items.map((item, index) => (
-                    <li
-                      key={index}
-                      className="pl-2"
-                      dangerouslySetInnerHTML={{
-                        __html: item.replace(
-                          /\*\*(.*?)\*\*/g,
-                          "<strong>$1</strong>",
-                        ),
-                      }}
-                    />
-                  ))}
+                  {content.items.map((item, index) => {
+                    // Parse **text** markdown syntax into React elements safely
+                    const parts = item.split(/(\*\*.*?\*\*)/);
+                    return (
+                      <li key={index} className="pl-2">
+                        {parts.map((part, i) => {
+                          if (part.startsWith("**") && part.endsWith("**")) {
+                            return <strong key={i}>{part.slice(2, -2)}</strong>;
+                          }
+                          return part;
+                        })}
+                      </li>
+                    );
+                  })}
                 </ul>
               )}
             </div>
diff --git a/src/constants/workflowSteps.ts b/src/constants/workflowSteps.ts
index 63b7864..264ccea 100644
--- a/src/constants/workflowSteps.ts
+++ b/src/constants/workflowSteps.ts
@@ -3,9 +3,9 @@
  */
 
 export interface WorkflowStep {
-  id: number;
-  label: string;
-  description: string;
+  readonly id: number;
+  readonly label: string;
+  readonly description: string;
 }
 
 export const WORKFLOW_STEPS: readonly WorkflowStep[] = [
diff --git a/src/hooks/domain/useDisplayFilename.ts b/src/utils/displayFilename.ts
similarity index 84%
rename from src/hooks/domain/useDisplayFilename.ts
rename to src/utils/displayFilename.ts
index f239ed2..39cae3c 100644
--- a/src/hooks/domain/useDisplayFilename.ts
+++ b/src/utils/displayFilename.ts
@@ -1,5 +1,5 @@
 /**
- * useDisplayFilename Hook
+ * getDisplayFilename Utility
  *
  * Determines which filename to display based on priority:
  * 1. currentFileName (from pattern store)
@@ -8,7 +8,7 @@
  * 4. Empty string
  */
 
-export function useDisplayFilename(options: {
+export function getDisplayFilename(options: {
   currentFileName: string | null;
   localFileName: string;
   resumeFileName: string | null;
diff --git a/src/utils/threadMetadata.ts b/src/utils/threadMetadata.ts
index 5433b10..0854573 100644
--- a/src/utils/threadMetadata.ts
+++ b/src/utils/threadMetadata.ts
@@ -1,6 +1,54 @@
 /**
- * Format thread metadata for display
+ * Format thread metadata for display.
+ *
  * Combines brand, catalog number, chart, and description into a readable string
+ * using the following rules:
+ *
+ * - The primary part consists of the brand and catalog number:
+ *   - The brand (if present) appears first.
+ *   - The catalog number (if present) is prefixed with `#` and appended after
+ *     the brand, separated by a single space (e.g. `"DMC #310"`).
+ * - The secondary part consists of the chart and description:
+ *   - The chart is omitted if it is `null`/empty or exactly equal to
+ *     `threadCatalogNumber`.
+ *   - The chart (when shown) and the description are joined with a single
+ *     space (e.g. `"Anchor 24-colour Black"`).
+ * - The primary and secondary parts are joined with `" • "` (space, bullet,
+ *   space). If either part is empty, only the non-empty part is returned.
+ *
+ * Examples:
+ *
+ * - Brand and catalog only:
+ *   - Input:
+ *     - `threadBrand: "DMC"`
+ *     - `threadCatalogNumber: "310"`
+ *     - `threadChart: null`
+ *     - `threadDescription: null`
+ *   - Output: `"DMC #310"`
+ *
+ * - Brand, catalog, and description:
+ *   - Input:
+ *     - `threadBrand: "DMC"`
+ *     - `threadCatalogNumber: "310"`
+ *     - `threadChart: null`
+ *     - `threadDescription: "Black"`
+ *   - Output: `"DMC #310 • Black"`
+ *
+ * - Brand, catalog, chart (different from catalog), and description:
+ *   - Input:
+ *     - `threadBrand: "Anchor"`
+ *     - `threadCatalogNumber: "403"`
+ *     - `threadChart: "24-colour"`
+ *     - `threadDescription: "Black"`
+ *   - Output: `"Anchor #403 • 24-colour Black"`
+ *
+ * - Chart equal to catalog number (chart omitted):
+ *   - Input:
+ *     - `threadBrand: "DMC"`
+ *     - `threadCatalogNumber: "310"`
+ *     - `threadChart: "310"`
+ *     - `threadDescription: "Black"`
+ *   - Output: `"DMC #310 • Black"`
  */
 
 interface ThreadMetadata {