Merge pull request 'feat(federation): outbound mTLS FederationClient (FED-M3-08)' (#508) from feat/federation-m3-client into main

- HIGH-A: resolveEntry now uses promise-cache pattern so concurrent
  callers serialize on a single in-flight build, eliminating duplicate
  key material in heap and duplicate DB round-trips
- HIGH-B: flushPeer destroys the evicted undici Agent so stale TLS
  connections close on cert rotation
- MED-C: add regression test for PEER_MISCONFIGURED when
  STEP_CA_ROOT_CERT_PATH is unset

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

apps/gateway/package.json

@@ -73,6 +73,7 @@
     "rxjs": "^7.8.0",
     "socket.io": "^4.8.0",
     "uuid": "^11.0.0",
+    "undici": "^7.24.6",
     "zod": "^4.3.6"
   },
   "devDependencies": {

apps/gateway/src/federation/__tests__/enrollment.service.spec.ts

@@ -24,10 +24,11 @@
  */
 
 import 'reflect-metadata';
-import { describe, it, expect, vi, beforeEach } from 'vitest';
+import { describe, it, expect, vi, beforeEach, beforeAll } from 'vitest';
 import { GoneException, NotFoundException } from '@nestjs/common';
 import type { Db } from '@mosaicstack/db';
 import { EnrollmentService } from '../enrollment.service.js';
+import { makeSelfSignedCert } from './helpers/test-cert.js';
 
 // ---------------------------------------------------------------------------
 // Test constants
@@ -38,10 +39,18 @@ const PEER_ID = 'p2222222-2222-2222-2222-222222222222';
 const USER_ID = 'u3333333-3333-3333-3333-333333333333';
 const TOKEN = 'a'.repeat(64); // 64-char hex
 
-const MOCK_CERT_PEM = '-----BEGIN CERTIFICATE-----\nMOCK\n-----END CERTIFICATE-----\n';
+// Real self-signed EC P-256 cert — populated once in beforeAll.
-const MOCK_CHAIN_PEM = MOCK_CERT_PEM + MOCK_CERT_PEM;
+// Required because EnrollmentService.extractCertNotAfter calls new X509Certificate(certPem)
+// with strict parsing (PR #501 HIGH-2: no silent fallback).
+let REAL_CERT_PEM: string;
+
+const MOCK_CHAIN_PEM = () => REAL_CERT_PEM + REAL_CERT_PEM;
 const MOCK_SERIAL = 'ABCD1234';
 
+beforeAll(async () => {
+  REAL_CERT_PEM = await makeSelfSignedCert();
+});
+
 // ---------------------------------------------------------------------------
 // Factory helpers
 // ---------------------------------------------------------------------------
@@ -103,11 +112,27 @@ function makeDb({
   const claimUpdateMock = vi.fn().mockReturnValue({ set: setClaimMock });
 
   // transaction(cb) — cb receives txMock; txMock has update + insert
-  const txInsertValues = vi.fn().mockResolvedValue(undefined);
+  //
-  const txInsertMock = vi.fn().mockReturnValue({ values: txInsertValues });
+  // The tx mock must support two tx.update() call patterns (CRIT-2, PR #501):
-  const txWhereUpdate = vi.fn().mockResolvedValue(undefined);
+  //   1. Grant activation:  .update().set().where().returning() → resolves to [{ id }]
+  //   2. Peer update:       .update().set().where()             → resolves to undefined
+  //
+  // We achieve this by making txWhereUpdate return an object with BOTH a thenable
+  // interface (so `await tx.update().set().where()` works) AND a .returning() method.
+  const txGrantActivatedRow = { id: GRANT_ID };
+  const txReturningMock = vi.fn().mockResolvedValue([txGrantActivatedRow]);
+  const txWhereUpdate = vi.fn().mockReturnValue({
+    // .returning() for grant activation (first tx.update call)
+    returning: txReturningMock,
+    // thenables so `await tx.update().set().where()` also works for peer update
+    then: (resolve: (v: undefined) => void) => resolve(undefined),
+    catch: () => undefined,
+    finally: () => undefined,
+  });
   const txSetMock = vi.fn().mockReturnValue({ where: txWhereUpdate });
   const txUpdateMock = vi.fn().mockReturnValue({ set: txSetMock });
+  const txInsertValues = vi.fn().mockResolvedValue(undefined);
+  const txInsertMock = vi.fn().mockReturnValue({ values: txInsertValues });
   const txMock = { update: txUpdateMock, insert: txInsertMock };
   const transactionMock = vi
     .fn()
@@ -132,6 +157,7 @@ function makeDb({
       txInsertValues,
       txInsertMock,
       txWhereUpdate,
+      txReturningMock,
       txSetMock,
       txUpdateMock,
       txMock,
@@ -146,11 +172,13 @@ function makeDb({
 
 function makeCaService() {
   return {
-    issueCert: vi.fn().mockResolvedValue({
+    // REAL_CERT_PEM is populated by beforeAll — safe to reference via closure here
-      certPem: MOCK_CERT_PEM,
+    // because makeCaService() is only called after the suite's beforeAll runs.
-      certChainPem: MOCK_CHAIN_PEM,
+    issueCert: vi.fn().mockImplementation(async () => ({
+      certPem: REAL_CERT_PEM,
+      certChainPem: MOCK_CHAIN_PEM(),
       serialNumber: MOCK_SERIAL,
-    }),
+    })),
   };
 }
 
@@ -301,29 +329,29 @@ describe('EnrollmentService.redeem — success path', () => {
     });
     caService.issueCert.mockImplementation(async () => {
       callOrder.push('issueCert');
-      return { certPem: MOCK_CERT_PEM, certChainPem: MOCK_CHAIN_PEM, serialNumber: MOCK_SERIAL };
+      return { certPem: REAL_CERT_PEM, certChainPem: MOCK_CHAIN_PEM(), serialNumber: MOCK_SERIAL };
     });
 
-    await service.redeem(TOKEN, MOCK_CERT_PEM);
+    await service.redeem(TOKEN, '---CSR---');
 
     expect(callOrder).toEqual(['claim', 'issueCert']);
   });
 
   it('calls CaService.issueCert with grantId, subjectUserId, csrPem, ttlSeconds=300', async () => {
-    await service.redeem(TOKEN, MOCK_CERT_PEM);
+    await service.redeem(TOKEN, '---CSR---');
 
     expect(caService.issueCert).toHaveBeenCalledWith(
       expect.objectContaining({
         grantId: GRANT_ID,
         subjectUserId: USER_ID,
-        csrPem: MOCK_CERT_PEM,
+        csrPem: '---CSR---',
         ttlSeconds: 300,
       }),
     );
   });
 
   it('runs activate grant + peer update + audit inside a transaction', async () => {
-    await service.redeem(TOKEN, MOCK_CERT_PEM);
+    await service.redeem(TOKEN, '---CSR---');
 
     expect(db._mocks.transactionMock).toHaveBeenCalledOnce();
     // tx.update called twice: activate grant + update peer
@@ -333,17 +361,17 @@ describe('EnrollmentService.redeem — success path', () => {
   });
 
   it('activates grant (sets status=active) inside the transaction', async () => {
-    await service.redeem(TOKEN, MOCK_CERT_PEM);
+    await service.redeem(TOKEN, '---CSR---');
 
     expect(db._mocks.txSetMock).toHaveBeenCalledWith(expect.objectContaining({ status: 'active' }));
   });
 
   it('updates the federationPeers row with certPem, certSerial, state=active inside the transaction', async () => {
-    await service.redeem(TOKEN, MOCK_CERT_PEM);
+    await service.redeem(TOKEN, '---CSR---');
 
     expect(db._mocks.txSetMock).toHaveBeenCalledWith(
       expect.objectContaining({
-        certPem: MOCK_CERT_PEM,
+        certPem: REAL_CERT_PEM,
         certSerial: MOCK_SERIAL,
         state: 'active',
       }),
@@ -351,7 +379,7 @@ describe('EnrollmentService.redeem — success path', () => {
   });
 
   it('inserts an audit log row inside the transaction', async () => {
-    await service.redeem(TOKEN, MOCK_CERT_PEM);
+    await service.redeem(TOKEN, '---CSR---');
 
     expect(db._mocks.txInsertValues).toHaveBeenCalledWith(
       expect.objectContaining({
@@ -363,11 +391,11 @@ describe('EnrollmentService.redeem — success path', () => {
   });
 
   it('returns { certPem, certChainPem } from CaService', async () => {
-    const result = await service.redeem(TOKEN, MOCK_CERT_PEM);
+    const result = await service.redeem(TOKEN, '---CSR---');
 
     expect(result).toEqual({
-      certPem: MOCK_CERT_PEM,
+      certPem: REAL_CERT_PEM,
-      certChainPem: MOCK_CHAIN_PEM,
+      certChainPem: MOCK_CHAIN_PEM(),
     });
   });
 });

apps/gateway/src/federation/__tests__/helpers/test-cert.ts

@@ -0,0 +1,138 @@
+/**
+ * Test helpers for generating real X.509 PEM certificates in unit tests.
+ *
+ * PR #501 (FED-M2-11) introduced strict `new X509Certificate(certPem)` parsing
+ * in both EnrollmentService.extractCertNotAfter and CaService.issueCert — dummy
+ * cert strings now throw `error:0680007B:asn1 encoding routines::header too long`.
+ *
+ * These helpers produce minimal but cryptographically valid self-signed EC P-256
+ * certificates via @peculiar/x509 + Node.js webcrypto, suitable for test mocks.
+ *
+ * Two variants:
+ *  - makeSelfSignedCert()          Plain cert — satisfies node:crypto X509Certificate parse.
+ *  - makeMosaicIssuedCert(opts)    Cert with custom Mosaic OID extensions — satisfies the
+ *                                  CRIT-1 OID presence + value checks in CaService.issueCert.
+ */
+
+import { webcrypto } from 'node:crypto';
+import {
+  X509CertificateGenerator,
+  Extension,
+  KeyUsagesExtension,
+  KeyUsageFlags,
+  BasicConstraintsExtension,
+  cryptoProvider,
+} from '@peculiar/x509';
+
+// ---------------------------------------------------------------------------
+// Internal helpers
+// ---------------------------------------------------------------------------
+
+/**
+ * Encode a string as an ASN.1 UTF8String TLV:
+ *   0x0C (tag) + 1-byte length (for strings ≤ 127 bytes) + UTF-8 bytes.
+ *
+ * CaService.issueCert reads the extension value as:
+ *   decoder.decode(grantIdExt.value.slice(2))
+ * i.e. it skips the tag + length byte and decodes the remainder as UTF-8.
+ * So we must produce exactly this encoding as the OCTET STRING content.
+ */
+function encodeUtf8String(value: string): Uint8Array {
+  const utf8 = new TextEncoder().encode(value);
+  if (utf8.length > 127) {
+    throw new Error('encodeUtf8String: value too long for single-byte length encoding');
+  }
+  const buf = new Uint8Array(2 + utf8.length);
+  buf[0] = 0x0c; // ASN.1 UTF8String tag
+  buf[1] = utf8.length;
+  buf.set(utf8, 2);
+  return buf;
+}
+
+// ---------------------------------------------------------------------------
+// Mosaic OID constants (must match production CaService)
+// ---------------------------------------------------------------------------
+
+const OID_MOSAIC_GRANT_ID = '1.3.6.1.4.1.99999.1';
+const OID_MOSAIC_SUBJECT_USER_ID = '1.3.6.1.4.1.99999.2';
+
+// ---------------------------------------------------------------------------
+// Public API
+// ---------------------------------------------------------------------------
+
+/**
+ * Generate a minimal self-signed EC P-256 certificate valid for 1 day.
+ * CN=harness-test, no custom extensions.
+ *
+ * Suitable for:
+ *  - EnrollmentService.extractCertNotAfter (just needs parseable PEM)
+ *  - Any mock that returns certPem / certChainPem without OID checks
+ */
+export async function makeSelfSignedCert(): Promise<string> {
+  // Ensure @peculiar/x509 uses Node.js webcrypto (available as globalThis.crypto in Node 19+,
+  // but we set it explicitly here to be safe on all Node 18+ versions).
+  cryptoProvider.set(webcrypto as unknown as Parameters<typeof cryptoProvider.set>[0]);
+
+  const alg = { name: 'ECDSA', namedCurve: 'P-256', hash: 'SHA-256' } as const;
+  const keys = await webcrypto.subtle.generateKey(alg, false, ['sign', 'verify']);
+
+  const now = new Date();
+  const tomorrow = new Date(now.getTime() + 86_400_000);
+
+  const cert = await X509CertificateGenerator.createSelfSigned({
+    serialNumber: '01',
+    name: 'CN=harness-test',
+    notBefore: now,
+    notAfter: tomorrow,
+    signingAlgorithm: alg,
+    keys,
+    extensions: [
+      new BasicConstraintsExtension(false),
+      new KeyUsagesExtension(KeyUsageFlags.digitalSignature),
+    ],
+  });
+
+  return cert.toString('pem');
+}
+
+/**
+ * Generate a self-signed EC P-256 certificate that contains the two custom
+ * Mosaic OID extensions required by CaService.issueCert's CRIT-1 check:
+ *   OID 1.3.6.1.4.1.99999.1  → mosaic_grant_id   (value = grantId)
+ *   OID 1.3.6.1.4.1.99999.2  → mosaic_subject_user_id (value = subjectUserId)
+ *
+ * The extension value encoding matches the production parser's `.slice(2)` assumption:
+ * each extension value is an OCTET STRING wrapping an ASN.1 UTF8String TLV.
+ */
+export async function makeMosaicIssuedCert(opts: {
+  grantId: string;
+  subjectUserId: string;
+}): Promise<string> {
+  // Ensure @peculiar/x509 uses Node.js webcrypto.
+  cryptoProvider.set(webcrypto as unknown as Parameters<typeof cryptoProvider.set>[0]);
+
+  const alg = { name: 'ECDSA', namedCurve: 'P-256', hash: 'SHA-256' } as const;
+  const keys = await webcrypto.subtle.generateKey(alg, false, ['sign', 'verify']);
+
+  const now = new Date();
+  const tomorrow = new Date(now.getTime() + 86_400_000);
+
+  const cert = await X509CertificateGenerator.createSelfSigned({
+    serialNumber: '01',
+    name: 'CN=mosaic-issued-test',
+    notBefore: now,
+    notAfter: tomorrow,
+    signingAlgorithm: alg,
+    keys,
+    extensions: [
+      new BasicConstraintsExtension(false),
+      new KeyUsagesExtension(KeyUsageFlags.digitalSignature),
+      // mosaic_grant_id — OID 1.3.6.1.4.1.99999.1
+      new Extension(OID_MOSAIC_GRANT_ID, false, encodeUtf8String(opts.grantId)),
+      // mosaic_subject_user_id — OID 1.3.6.1.4.1.99999.2
+      new Extension(OID_MOSAIC_SUBJECT_USER_ID, false, encodeUtf8String(opts.subjectUserId)),
+    ],
+  });
+
+  return cert.toString('pem');
+}

apps/gateway/src/federation/ca.service.spec.ts

@@ -20,9 +20,10 @@
  */
 
 import 'reflect-metadata';
-import { describe, it, expect, vi, beforeEach, type Mock } from 'vitest';
+import { describe, it, expect, vi, beforeEach, beforeAll, type Mock } from 'vitest';
 import { jwtVerify, exportJWK, generateKeyPair } from 'jose';
 import { Pkcs10CertificateRequestGenerator } from '@peculiar/x509';
+import { makeMosaicIssuedCert } from './__tests__/helpers/test-cert.js';
 
 // ---------------------------------------------------------------------------
 // Mock node:https BEFORE importing CaService so the mock is in place when
@@ -74,6 +75,11 @@ const FAKE_CA_PEM = FAKE_CERT_PEM;
 const GRANT_ID = 'a0eebc99-9c0b-4ef8-bb6d-6bb9bd380a11';
 const SUBJECT_USER_ID = 'b1ffcd00-0d1c-5f09-cc7e-7cc0ce491b22';
 
+// Real self-signed cert containing both Mosaic OID extensions — populated in beforeAll.
+// Required because CaService.issueCert performs CRIT-1 OID presence/value checks on the
+// response cert (PR #501 — strict parsing, no silent fallback).
+let realIssuedCertPem: string;
+
 // ---------------------------------------------------------------------------
 // Generate a real EC P-256 key pair and CSR for integration-style tests
 // ---------------------------------------------------------------------------
@@ -194,6 +200,15 @@ function makeHttpsMock(statusCode: number, body: unknown, errorMsg?: string): vo
 describe('CaService', () => {
   let service: CaService;
 
+  beforeAll(async () => {
+    // Generate a cert with the two Mosaic OIDs so that CaService.issueCert's
+    // CRIT-1 OID checks pass when mock step-ca returns it as `crt`.
+    realIssuedCertPem = await makeMosaicIssuedCert({
+      grantId: GRANT_ID,
+      subjectUserId: SUBJECT_USER_ID,
+    });
+  });
+
   beforeEach(() => {
     vi.clearAllMocks();
     service = new CaService();
@@ -226,9 +241,9 @@ describe('CaService', () => {
 
     // Now test that the service's validateCsr accepts it.
     // We call it indirectly via issueCert with a successful mock.
-    makeHttpsMock(200, { crt: FAKE_CERT_PEM, certChain: [FAKE_CERT_PEM, FAKE_CA_PEM] });
+    makeHttpsMock(200, { crt: realIssuedCertPem, certChain: [realIssuedCertPem, FAKE_CA_PEM] });
     const result = await service.issueCert(makeReq({ csrPem: realCsrPem }));
-    expect(result.certPem).toBe(FAKE_CERT_PEM);
+    expect(result.certPem).toBe(realIssuedCertPem);
   });
 
   it('throws INVALID_CSR for a malformed PEM-shaped CSR', async () => {
@@ -251,14 +266,14 @@ describe('CaService', () => {
   it('returns IssuedCertDto on success (certChain present)', async () => {
     if (!realCsrPem) realCsrPem = await generateRealCsr();
     makeHttpsMock(200, {
-      crt: FAKE_CERT_PEM,
+      crt: realIssuedCertPem,
-      certChain: [FAKE_CERT_PEM, FAKE_CA_PEM],
+      certChain: [realIssuedCertPem, FAKE_CA_PEM],
     });
 
     const result = await service.issueCert(makeReq());
 
-    expect(result.certPem).toBe(FAKE_CERT_PEM);
+    expect(result.certPem).toBe(realIssuedCertPem);
-    expect(result.certChainPem).toContain(FAKE_CERT_PEM);
+    expect(result.certChainPem).toContain(realIssuedCertPem);
     expect(result.certChainPem).toContain(FAKE_CA_PEM);
     expect(typeof result.serialNumber).toBe('string');
   });
@@ -270,14 +285,14 @@ describe('CaService', () => {
   it('builds certChainPem from crt+ca when certChain is absent', async () => {
     if (!realCsrPem) realCsrPem = await generateRealCsr();
     makeHttpsMock(200, {
-      crt: FAKE_CERT_PEM,
+      crt: realIssuedCertPem,
       ca: FAKE_CA_PEM,
     });
 
     const result = await service.issueCert(makeReq());
 
-    expect(result.certPem).toBe(FAKE_CERT_PEM);
+    expect(result.certPem).toBe(realIssuedCertPem);
-    expect(result.certChainPem).toContain(FAKE_CERT_PEM);
+    expect(result.certChainPem).toContain(realIssuedCertPem);
     expect(result.certChainPem).toContain(FAKE_CA_PEM);
   });
 
@@ -287,12 +302,12 @@ describe('CaService', () => {
 
   it('falls back to certPem alone when certChain and ca are absent', async () => {
     if (!realCsrPem) realCsrPem = await generateRealCsr();
-    makeHttpsMock(200, { crt: FAKE_CERT_PEM });
+    makeHttpsMock(200, { crt: realIssuedCertPem });
 
     const result = await service.issueCert(makeReq());
 
-    expect(result.certPem).toBe(FAKE_CERT_PEM);
+    expect(result.certPem).toBe(realIssuedCertPem);
-    expect(result.certChainPem).toBe(FAKE_CERT_PEM);
+    expect(result.certChainPem).toBe(realIssuedCertPem);
   });
 
   // -------------------------------------------------------------------------
@@ -398,7 +413,7 @@ describe('CaService', () => {
           statusCode: 200,
           on: (event: string, cb: (chunk?: Buffer) => void) => {
             if (event === 'data') {
-              cb(Buffer.from(JSON.stringify({ crt: FAKE_CERT_PEM })));
+              cb(Buffer.from(JSON.stringify({ crt: realIssuedCertPem })));
             }
             if (event === 'end') {
               cb();
@@ -555,7 +570,7 @@ describe('CaService', () => {
           statusCode: 200,
           on: (event: string, cb: (chunk?: Buffer) => void) => {
             if (event === 'data') {
-              cb(Buffer.from(JSON.stringify({ crt: FAKE_CERT_PEM })));
+              cb(Buffer.from(JSON.stringify({ crt: realIssuedCertPem })));
             }
             if (event === 'end') {
               cb();

apps/gateway/src/federation/client/__tests__/federation-client.service.spec.ts

@@ -0,0 +1,553 @@
+/**
+ * Unit tests for FederationClientService (FED-M3-08).
+ *
+ * HTTP mocking strategy:
+ *   undici MockAgent is used to intercept outbound HTTP requests.  The service
+ *   uses `undici.fetch` with a `dispatcher` option, so MockAgent is set as the
+ *   global dispatcher and all requests flow through it.
+ *
+ *   Because the service builds one `undici.Agent` per peer and passes it as
+ *   the dispatcher on every fetch call, we cannot intercept at the Agent level
+ *   in unit tests without significant refactoring.  Instead, we set the global
+ *   dispatcher to a MockAgent and override the service's `doRequest` indirection
+ *   by spying on the internal fetch call.
+ *
+ *   For the cert/key wiring, we use the real `sealClientKey` function from
+ *   peer-key.util.ts with a test secret — no stubs.
+ *
+ * Sealed-key setup:
+ *   Each test (or beforeAll) calls `sealClientKey(TEST_PRIVATE_KEY_PEM)` with
+ *   BETTER_AUTH_SECRET set to a deterministic test value so that
+ *   `unsealClientKey` in the service recovers the original PEM.
+ */
+
+import 'reflect-metadata';
+import { describe, it, expect, vi, beforeEach, afterEach, beforeAll, afterAll } from 'vitest';
+import { MockAgent, setGlobalDispatcher, getGlobalDispatcher } from 'undici';
+import type { Dispatcher } from 'undici';
+import { writeFileSync, unlinkSync } from 'node:fs';
+import { tmpdir } from 'node:os';
+import { join } from 'node:path';
+import type { Db } from '@mosaicstack/db';
+import { FederationClientService, FederationClientError } from '../federation-client.service.js';
+import { sealClientKey } from '../../peer-key.util.js';
+
+// ---------------------------------------------------------------------------
+// Test constants
+// ---------------------------------------------------------------------------
+
+const TEST_SECRET = 'test-secret-for-federation-client-spec-only';
+const PEER_ID = 'aaaaaaaa-aaaa-aaaa-aaaa-aaaaaaaaaaaa';
+const ENDPOINT = 'https://peer.example.com';
+
+// Minimal valid RSA/EC private key PEM — does NOT need to be a real key for
+// unit tests because we only verify it round-trips through seal/unseal, not
+// that it actually negotiates TLS (MockAgent handles that).
+const TEST_PRIVATE_KEY_PEM = `-----BEGIN PRIVATE KEY-----
+MIIEvQIBADANBgkqhkiG9w0BAQEFAASCBKcwggSjAgEAAoIBAQDummyKeyForTests
+-----END PRIVATE KEY-----`;
+
+// Minimal self-signed cert PEM (dummy — only used for mTLS Agent construction)
+const TEST_CERT_PEM = `-----BEGIN CERTIFICATE-----
+MIIBdummyCertForFederationClientTests==
+-----END CERTIFICATE-----`;
+
+const TEST_CERT_SERIAL = 'ABCDEF1234567890';
+
+// ---------------------------------------------------------------------------
+// Sealed key (computed once in beforeAll)
+// ---------------------------------------------------------------------------
+
+let SEALED_KEY: string;
+
+// Path to a stub Step-CA root cert file written in beforeAll. The cert is never
+// actually used to negotiate TLS in unit tests (MockAgent + spy on resolveEntry
+// short-circuit the network), but loadStepCaRoot() requires the file to exist.
+const STUB_CA_PEM_PATH = join(tmpdir(), 'federation-client-spec-ca.pem');
+const STUB_CA_PEM = `-----BEGIN CERTIFICATE-----
+MIIBdummyCAforFederationClientSpecOnly==
+-----END CERTIFICATE-----
+`;
+
+// ---------------------------------------------------------------------------
+// Peer row factory
+// ---------------------------------------------------------------------------
+
+function makePeerRow(overrides: Partial<Record<string, unknown>> = {}) {
+  return {
+    id: PEER_ID,
+    commonName: 'peer-example-com',
+    displayName: 'Test Peer',
+    certPem: TEST_CERT_PEM,
+    certSerial: TEST_CERT_SERIAL,
+    certNotAfter: new Date('2030-01-01T00:00:00Z'),
+    clientKeyPem: SEALED_KEY,
+    state: 'active' as const,
+    endpointUrl: ENDPOINT,
+    lastSeenAt: null,
+    createdAt: new Date('2026-01-01T00:00:00Z'),
+    revokedAt: null,
+    ...overrides,
+  };
+}
+
+// ---------------------------------------------------------------------------
+// Mock DB builder
+// ---------------------------------------------------------------------------
+
+function makeDb(selectRows: unknown[] = [makePeerRow()]): Db {
+  const limitSelect = vi.fn().mockResolvedValue(selectRows);
+  const whereSelect = vi.fn().mockReturnValue({ limit: limitSelect });
+  const fromSelect = vi.fn().mockReturnValue({ where: whereSelect });
+  const selectMock = vi.fn().mockReturnValue({ from: fromSelect });
+
+  return {
+    select: selectMock,
+    insert: vi.fn(),
+    update: vi.fn(),
+    delete: vi.fn(),
+    transaction: vi.fn(),
+  } as unknown as Db;
+}
+
+// ---------------------------------------------------------------------------
+// Helpers for MockAgent HTTP interception
+// ---------------------------------------------------------------------------
+
+/**
+ * Create a MockAgent + MockPool for the peer endpoint, set it as the global
+ * dispatcher, and return both for per-test configuration.
+ */
+function makeMockAgent() {
+  const mockAgent = new MockAgent({ connections: 1 });
+  mockAgent.disableNetConnect();
+  setGlobalDispatcher(mockAgent);
+  const pool = mockAgent.get(ENDPOINT);
+  return { mockAgent, pool };
+}
+
+/**
+ * Build a FederationClientService with a mock DB and a spy on the internal
+ * fetch so we can intercept at the HTTP layer via MockAgent.
+ *
+ * The service calls `fetch(url, { dispatcher: agent })` where `agent` is the
+ * mTLS undici.Agent built from the peer's cert+key.  To make MockAgent work,
+ * we need the fetch dispatcher to be the MockAgent, not the per-peer Agent.
+ *
+ * Strategy: we replace the private `resolveEntry` result's `agent` field with
+ * the MockAgent's pool, so fetch uses our interceptor.  We do this by spying
+ * on `resolveEntry` and returning a controlled entry.
+ */
+function makeService(db: Db, mockPool: Dispatcher): FederationClientService {
+  const svc = new FederationClientService(db);
+
+  // Override resolveEntry to inject MockAgent pool as the dispatcher
+  vi.spyOn(
+    svc as unknown as { resolveEntry: (peerId: string) => Promise<unknown> },
+    'resolveEntry',
+  ).mockImplementation(async (_peerId: string) => {
+    // Still call DB (via the real logic) to exercise peer validation,
+    // but return mock pool as the agent.
+    // For simplicity in unit tests, directly return a controlled entry.
+    return {
+      agent: mockPool,
+      endpointUrl: ENDPOINT,
+      certPem: TEST_CERT_PEM,
+      certSerial: TEST_CERT_SERIAL,
+    };
+  });
+
+  return svc;
+}
+
+// ---------------------------------------------------------------------------
+// Test setup
+// ---------------------------------------------------------------------------
+
+let originalDispatcher: Dispatcher;
+
+beforeAll(() => {
+  // Seal the test key once — requires BETTER_AUTH_SECRET
+  const saved = process.env['BETTER_AUTH_SECRET'];
+  process.env['BETTER_AUTH_SECRET'] = TEST_SECRET;
+  try {
+    SEALED_KEY = sealClientKey(TEST_PRIVATE_KEY_PEM);
+  } finally {
+    if (saved === undefined) {
+      delete process.env['BETTER_AUTH_SECRET'];
+    } else {
+      process.env['BETTER_AUTH_SECRET'] = saved;
+    }
+  }
+  writeFileSync(STUB_CA_PEM_PATH, STUB_CA_PEM, 'utf8');
+});
+
+afterAll(() => {
+  try {
+    unlinkSync(STUB_CA_PEM_PATH);
+  } catch {
+    // best-effort cleanup
+  }
+});
+
+beforeEach(() => {
+  originalDispatcher = getGlobalDispatcher();
+  process.env['BETTER_AUTH_SECRET'] = TEST_SECRET;
+  process.env['STEP_CA_ROOT_CERT_PATH'] = STUB_CA_PEM_PATH;
+});
+
+afterEach(() => {
+  setGlobalDispatcher(originalDispatcher);
+  vi.restoreAllMocks();
+  delete process.env['BETTER_AUTH_SECRET'];
+  delete process.env['STEP_CA_ROOT_CERT_PATH'];
+});
+
+// ---------------------------------------------------------------------------
+// Helpers
+// ---------------------------------------------------------------------------
+
+/** Successful list response body */
+const LIST_BODY = {
+  items: [{ id: '1', title: 'Task One' }],
+  nextCursor: undefined,
+  _partial: false,
+};
+
+/** Successful get response body */
+const GET_BODY = {
+  item: { id: '1', title: 'Task One' },
+  _partial: false,
+};
+
+/** Successful capabilities response body */
+const CAP_BODY = {
+  resources: ['tasks'],
+  excluded_resources: [],
+  max_rows_per_query: 100,
+  supported_verbs: ['list', 'get', 'capabilities'] as const,
+};
+
+// ---------------------------------------------------------------------------
+// Tests
+// ---------------------------------------------------------------------------
+
+describe('FederationClientService', () => {
+  // ─── Successful verb calls ─────────────────────────────────────────────────
+
+  describe('list()', () => {
+    it('returns parsed typed response on success', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      pool
+        .intercept({
+          path: '/api/federation/v1/list/tasks',
+          method: 'POST',
+        })
+        .reply(200, LIST_BODY, { headers: { 'content-type': 'application/json' } });
+
+      const result = await svc.list(PEER_ID, 'tasks', {});
+
+      expect(result.items).toHaveLength(1);
+      expect(result.items[0]).toMatchObject({ id: '1', title: 'Task One' });
+
+      await mockAgent.close();
+    });
+  });
+
+  describe('get()', () => {
+    it('returns parsed typed response on success', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      pool
+        .intercept({
+          path: '/api/federation/v1/get/tasks/1',
+          method: 'POST',
+        })
+        .reply(200, GET_BODY, { headers: { 'content-type': 'application/json' } });
+
+      const result = await svc.get(PEER_ID, 'tasks', '1', {});
+
+      expect(result.item).toMatchObject({ id: '1', title: 'Task One' });
+
+      await mockAgent.close();
+    });
+  });
+
+  describe('capabilities()', () => {
+    it('returns parsed capabilities response on success', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      pool
+        .intercept({
+          path: '/api/federation/v1/capabilities',
+          method: 'GET',
+        })
+        .reply(200, CAP_BODY, { headers: { 'content-type': 'application/json' } });
+
+      const result = await svc.capabilities(PEER_ID);
+
+      expect(result.resources).toContain('tasks');
+      expect(result.max_rows_per_query).toBe(100);
+
+      await mockAgent.close();
+    });
+  });
+
+  // ─── HTTP error surfaces ──────────────────────────────────────────────────
+
+  describe('non-2xx responses', () => {
+    it('surfaces 403 as FederationClientError({ status: 403, code: "FORBIDDEN" })', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      pool.intercept({ path: '/api/federation/v1/list/tasks', method: 'POST' }).reply(
+        403,
+        { error: { code: 'forbidden', message: 'Access denied' } },
+        {
+          headers: { 'content-type': 'application/json' },
+        },
+      );
+
+      await expect(svc.list(PEER_ID, 'tasks', {})).rejects.toMatchObject({
+        status: 403,
+        code: 'FORBIDDEN',
+        peerId: PEER_ID,
+      });
+
+      await mockAgent.close();
+    });
+
+    it('surfaces 404 as FederationClientError({ status: 404, code: "HTTP_404" })', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      pool.intercept({ path: '/api/federation/v1/get/tasks/999', method: 'POST' }).reply(
+        404,
+        { error: { code: 'not_found', message: 'Not found' } },
+        {
+          headers: { 'content-type': 'application/json' },
+        },
+      );
+
+      await expect(svc.get(PEER_ID, 'tasks', '999', {})).rejects.toMatchObject({
+        status: 404,
+        code: 'HTTP_404',
+        peerId: PEER_ID,
+      });
+
+      await mockAgent.close();
+    });
+  });
+
+  // ─── Network error ─────────────────────────────────────────────────────────
+
+  describe('network errors', () => {
+    it('surfaces network error as FederationClientError({ code: "NETWORK" })', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      pool
+        .intercept({ path: '/api/federation/v1/capabilities', method: 'GET' })
+        .replyWithError(new Error('ECONNREFUSED'));
+
+      await expect(svc.capabilities(PEER_ID)).rejects.toMatchObject({
+        code: 'NETWORK',
+        peerId: PEER_ID,
+      });
+
+      await mockAgent.close();
+    });
+  });
+
+  // ─── Invalid response body ─────────────────────────────────────────────────
+
+  describe('invalid response body', () => {
+    it('surfaces as FederationClientError({ code: "INVALID_RESPONSE" }) when body shape is wrong', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      // capabilities returns wrong shape (missing required fields)
+      pool
+        .intercept({ path: '/api/federation/v1/capabilities', method: 'GET' })
+        .reply(200, { totally: 'wrong' }, { headers: { 'content-type': 'application/json' } });
+
+      await expect(svc.capabilities(PEER_ID)).rejects.toMatchObject({
+        code: 'INVALID_RESPONSE',
+        peerId: PEER_ID,
+      });
+
+      await mockAgent.close();
+    });
+  });
+
+  // ─── Peer DB validation ────────────────────────────────────────────────────
+
+  describe('peer validation (without resolveEntry spy)', () => {
+    /**
+     * These tests exercise the real `resolveEntry` path — no spy on resolveEntry.
+     */
+
+    it('throws PEER_NOT_FOUND when peer is not in DB', async () => {
+      // DB returns empty array (peer not found)
+      const db = makeDb([]);
+      const svc = new FederationClientService(db);
+
+      await expect(svc.capabilities(PEER_ID)).rejects.toMatchObject({
+        code: 'PEER_NOT_FOUND',
+        peerId: PEER_ID,
+      });
+    });
+
+    it('throws PEER_INACTIVE when peer state is not "active"', async () => {
+      const db = makeDb([makePeerRow({ state: 'suspended' })]);
+      const svc = new FederationClientService(db);
+
+      await expect(svc.capabilities(PEER_ID)).rejects.toMatchObject({
+        code: 'PEER_INACTIVE',
+        peerId: PEER_ID,
+      });
+    });
+  });
+
+  // ─── Cache behaviour ───────────────────────────────────────────────────────
+
+  describe('cache behaviour', () => {
+    it('hits cache on second call — only one DB lookup happens', async () => {
+      // Verify cache by calling the private resolveEntry directly twice and
+      // asserting the DB was queried only once. This avoids the HTTP layer,
+      // which would require either a real network or per-peer Agent rewiring
+      // that the cache invariant doesn't depend on.
+      const db = makeDb();
+      const selectSpy = vi.spyOn(db, 'select');
+      const svc = new FederationClientService(db);
+      const resolveEntry = (
+        svc as unknown as { resolveEntry: (peerId: string) => Promise<unknown> }
+      ).resolveEntry.bind(svc);
+
+      const first = await resolveEntry(PEER_ID);
+      const second = await resolveEntry(PEER_ID);
+
+      expect(first).toBe(second);
+      expect(selectSpy).toHaveBeenCalledTimes(1);
+    });
+
+    it('serializes concurrent resolveEntry calls — only one DB lookup', async () => {
+      const db = makeDb();
+      const selectSpy = vi.spyOn(db, 'select');
+      const svc = new FederationClientService(db);
+      const resolveEntry = (
+        svc as unknown as {
+          resolveEntry: (peerId: string) => Promise<unknown>;
+        }
+      ).resolveEntry.bind(svc);
+
+      const [a, b] = await Promise.all([resolveEntry(PEER_ID), resolveEntry(PEER_ID)]);
+      expect(a).toBe(b);
+      expect(selectSpy).toHaveBeenCalledTimes(1);
+    });
+
+    it('flushPeer destroys the evicted Agent so old TLS connections close', async () => {
+      const db = makeDb();
+      const svc = new FederationClientService(db);
+      const resolveEntry = (
+        svc as unknown as {
+          resolveEntry: (peerId: string) => Promise<{ agent: { destroy: () => Promise<void> } }>;
+        }
+      ).resolveEntry.bind(svc);
+
+      const entry = await resolveEntry(PEER_ID);
+      const destroySpy = vi.spyOn(entry.agent, 'destroy').mockResolvedValue();
+
+      svc.flushPeer(PEER_ID);
+      expect(destroySpy).toHaveBeenCalledTimes(1);
+    });
+
+    it('flushPeer() invalidates cache — next call re-reads DB', async () => {
+      const db = makeDb();
+      const { mockAgent, pool } = makeMockAgent();
+      const svc = makeService(db, pool);
+
+      pool
+        .intercept({ path: '/api/federation/v1/capabilities', method: 'GET' })
+        .reply(200, CAP_BODY, { headers: { 'content-type': 'application/json' } })
+        .times(2);
+
+      // First call — populates cache (via mock resolveEntry)
+      await svc.capabilities(PEER_ID);
+
+      // Flush the cache
+      svc.flushPeer(PEER_ID);
+
+      // The spy on resolveEntry is still active — check it's called again after flush
+      const resolveEntrySpy = vi.spyOn(
+        svc as unknown as { resolveEntry: (peerId: string) => Promise<unknown> },
+        'resolveEntry',
+      );
+
+      // Second call after flush — should call resolveEntry again
+      await svc.capabilities(PEER_ID);
+
+      // resolveEntry should have been called once after we started spying (post-flush)
+      expect(resolveEntrySpy).toHaveBeenCalledTimes(1);
+
+      await mockAgent.close();
+    });
+  });
+
+  // ─── loadStepCaRoot env-var guard ─────────────────────────────────────────
+
+  describe('loadStepCaRoot() env-var guard', () => {
+    it('throws PEER_MISCONFIGURED when STEP_CA_ROOT_CERT_PATH is not set', async () => {
+      delete process.env['STEP_CA_ROOT_CERT_PATH'];
+      const db = makeDb();
+      const svc = new FederationClientService(db);
+      const resolveEntry = (
+        svc as unknown as {
+          resolveEntry: (peerId: string) => Promise<unknown>;
+        }
+      ).resolveEntry.bind(svc);
+
+      await expect(resolveEntry(PEER_ID)).rejects.toMatchObject({
+        code: 'PEER_MISCONFIGURED',
+      });
+    });
+  });
+
+  // ─── FederationClientError class ──────────────────────────────────────────
+
+  describe('FederationClientError', () => {
+    it('is instanceof Error and FederationClientError', () => {
+      const err = new FederationClientError({
+        code: 'PEER_NOT_FOUND',
+        message: 'test',
+        peerId: PEER_ID,
+      });
+      expect(err).toBeInstanceOf(Error);
+      expect(err).toBeInstanceOf(FederationClientError);
+      expect(err.name).toBe('FederationClientError');
+    });
+
+    it('carries status, code, and peerId', () => {
+      const err = new FederationClientError({
+        status: 403,
+        code: 'FORBIDDEN',
+        message: 'forbidden',
+        peerId: PEER_ID,
+      });
+      expect(err.status).toBe(403);
+      expect(err.code).toBe('FORBIDDEN');
+      expect(err.peerId).toBe(PEER_ID);
+    });
+  });
+});

apps/gateway/src/federation/client/federation-client.service.ts

@@ -0,0 +1,500 @@
+/**
+ * FederationClientService — outbound mTLS client for federation requests (FED-M3-08).
+ *
+ * Dials peer gateways over mTLS using the cert+sealed-key stored in `federation_peers`,
+ * invokes federation verbs (list / get / capabilities), and surfaces all failure modes
+ * as typed `FederationClientError` instances.
+ *
+ * ## Error code taxonomy
+ *
+ * | Code               | When                                                          |
+ * | ------------------ | ------------------------------------------------------------- |
+ * | PEER_NOT_FOUND     | No row in federation_peers for the given peerId               |
+ * | PEER_INACTIVE      | Peer row exists but state !== 'active'                        |
+ * | PEER_MISCONFIGURED | Peer row is active but missing endpointUrl or clientKeyPem    |
+ * | NETWORK            | undici threw a connection / TLS / timeout error               |
+ * | HTTP_{status}      | Peer returned a non-2xx response (e.g. HTTP_403, HTTP_404)    |
+ * | FORBIDDEN          | Peer returned 403 (convenience alias alongside HTTP_403)      |
+ * | INVALID_RESPONSE   | Response body failed Zod schema validation                    |
+ *
+ * ## Cache strategy
+ *
+ * Per-peer `undici.Agent` instances are cached in a `Map<peerId, AgentCacheEntry>` for
+ * the lifetime of the service instance.  The cache is keyed on peerId (UUID).
+ *
+ * Cache invalidation:
+ *  - `flushPeer(peerId)` — removes the entry immediately.  M5/M6 MUST call this on
+ *    cert rotation or peer revocation events so the next request re-reads the DB and
+ *    builds a fresh TLS Agent with the new cert material.
+ *  - On cache miss: re-reads the DB, checks state === 'active', rebuilds Agent.
+ *
+ * Cache does NOT auto-expire.  The service is expected to be a singleton scoped to the
+ * NestJS application lifecycle; flushing on revocation/rotation is the only invalidation
+ * path by design (avoids redundant DB round-trips on the hot path).
+ */
+
+import { Injectable, Inject, Logger } from '@nestjs/common';
+import { readFileSync } from 'node:fs';
+import { Agent, fetch as undiciFetch } from 'undici';
+import type { Dispatcher } from 'undici';
+import { z } from 'zod';
+import { type Db, eq, federationPeers } from '@mosaicstack/db';
+import {
+  FederationListResponseSchema,
+  FederationGetResponseSchema,
+  FederationCapabilitiesResponseSchema,
+  FederationErrorEnvelopeSchema,
+  type FederationListResponse,
+  type FederationGetResponse,
+  type FederationCapabilitiesResponse,
+} from '@mosaicstack/types';
+import { DB } from '../../database/database.module.js';
+import { unsealClientKey } from '../peer-key.util.js';
+
+// ---------------------------------------------------------------------------
+// Error taxonomy
+// ---------------------------------------------------------------------------
+
+/**
+ * Client-side error code set.  Distinct from the server-side `FederationErrorCode`
+ * (which lives in `@mosaicstack/types`) because the client has additional failure
+ * modes (PEER_NOT_FOUND, PEER_INACTIVE, PEER_MISCONFIGURED, NETWORK) that the
+ * server never emits.
+ */
+export type FederationClientErrorCode =
+  | 'PEER_NOT_FOUND'
+  | 'PEER_INACTIVE'
+  | 'PEER_MISCONFIGURED'
+  | 'NETWORK'
+  | 'FORBIDDEN'
+  | 'INVALID_RESPONSE'
+  | `HTTP_${number}`;
+
+export interface FederationClientErrorOptions {
+  status?: number;
+  code: FederationClientErrorCode;
+  message: string;
+  peerId: string;
+  cause?: unknown;
+}
+
+/**
+ * Thrown by FederationClientService on every failure path.
+ * Callers can dispatch on `error.code` for programmatic handling.
+ */
+export class FederationClientError extends Error {
+  readonly status?: number;
+  readonly code: FederationClientErrorCode;
+  readonly peerId: string;
+  readonly cause?: unknown;
+
+  constructor(opts: FederationClientErrorOptions) {
+    super(opts.message);
+    this.name = 'FederationClientError';
+    this.status = opts.status;
+    this.code = opts.code;
+    this.peerId = opts.peerId;
+    this.cause = opts.cause;
+  }
+}
+
+// ---------------------------------------------------------------------------
+// Internal cache types
+// ---------------------------------------------------------------------------
+
+interface AgentCacheEntry {
+  agent: Agent;
+  endpointUrl: string;
+  certPem: string;
+  certSerial: string;
+}
+
+// ---------------------------------------------------------------------------
+// Service
+// ---------------------------------------------------------------------------
+
+@Injectable()
+export class FederationClientService {
+  private readonly logger = new Logger(FederationClientService.name);
+
+  /**
+   * Per-peer undici Agent cache.
+   * Key = peerId (UUID string).
+   *
+   * Values are either a resolved `AgentCacheEntry` or an in-flight
+   * `Promise<AgentCacheEntry>` (promise-cache pattern).  Storing the promise
+   * prevents duplicate DB lookups and duplicate key-unseal operations when two
+   * requests for the same peer arrive before the first build completes.
+   *
+   * Flush via `flushPeer(peerId)` on cert rotation / peer revocation (M5/M6).
+   */
+  private readonly cache = new Map<string, AgentCacheEntry | Promise<AgentCacheEntry>>();
+
+  /**
+   * Step-CA root cert PEM, loaded once from `STEP_CA_ROOT_CERT_PATH`.
+   * Used as the trust anchor for peer server certificates so federation TLS is
+   * pinned to our PKI, not the public trust store. Lazily loaded on first use
+   * so unit tests that don't exercise the agent path can run without the env var.
+   */
+  private cachedCaPem: string | null = null;
+
+  constructor(@Inject(DB) private readonly db: Db) {}
+
+  // -------------------------------------------------------------------------
+  // Public verb API
+  // -------------------------------------------------------------------------
+
+  /**
+   * Invoke the `list` verb on a remote peer.
+   *
+   * @param peerId   UUID of the peer row in `federation_peers`.
+   * @param resource Resource path, e.g. "tasks".
+   * @param request  Free-form body sent as JSON in the POST body.
+   * @returns Parsed `FederationListResponse<T>`.
+   */
+  async list<T>(
+    peerId: string,
+    resource: string,
+    request: Record<string, unknown>,
+  ): Promise<FederationListResponse<T>> {
+    const { endpointUrl, agent } = await this.resolveEntry(peerId);
+    const url = `${endpointUrl}/api/federation/v1/list/${encodeURIComponent(resource)}`;
+    const body = await this.doPost(peerId, url, agent, request);
+    return this.parseWith<FederationListResponse<T>>(
+      peerId,
+      body,
+      FederationListResponseSchema(z.unknown()),
+    );
+  }
+
+  /**
+   * Invoke the `get` verb on a remote peer.
+   *
+   * @param peerId   UUID of the peer row in `federation_peers`.
+   * @param resource Resource path, e.g. "tasks".
+   * @param id       Resource identifier.
+   * @param request  Free-form body sent as JSON in the POST body.
+   * @returns Parsed `FederationGetResponse<T>`.
+   */
+  async get<T>(
+    peerId: string,
+    resource: string,
+    id: string,
+    request: Record<string, unknown>,
+  ): Promise<FederationGetResponse<T>> {
+    const { endpointUrl, agent } = await this.resolveEntry(peerId);
+    const url = `${endpointUrl}/api/federation/v1/get/${encodeURIComponent(resource)}/${encodeURIComponent(id)}`;
+    const body = await this.doPost(peerId, url, agent, request);
+    return this.parseWith<FederationGetResponse<T>>(
+      peerId,
+      body,
+      FederationGetResponseSchema(z.unknown()),
+    );
+  }
+
+  /**
+   * Invoke the `capabilities` verb on a remote peer.
+   *
+   * @param peerId UUID of the peer row in `federation_peers`.
+   * @returns Parsed `FederationCapabilitiesResponse`.
+   */
+  async capabilities(peerId: string): Promise<FederationCapabilitiesResponse> {
+    const { endpointUrl, agent } = await this.resolveEntry(peerId);
+    const url = `${endpointUrl}/api/federation/v1/capabilities`;
+    const body = await this.doGet(peerId, url, agent);
+    return this.parseWith<FederationCapabilitiesResponse>(
+      peerId,
+      body,
+      FederationCapabilitiesResponseSchema,
+    );
+  }
+
+  // -------------------------------------------------------------------------
+  // Cache management
+  // -------------------------------------------------------------------------
+
+  /**
+   * Flush the cached Agent for a specific peer.
+   *
+   * M5/M6 MUST call this on:
+   *  - cert rotation events (so new cert material is picked up)
+   *  - peer revocation events (so future requests fail at PEER_INACTIVE)
+   *
+   * After flushing, the next call to `list`, `get`, or `capabilities` for
+   * this peer will re-read the DB and rebuild the Agent.
+   */
+  flushPeer(peerId: string): void {
+    const entry = this.cache.get(peerId);
+    if (entry === undefined) {
+      return;
+    }
+    this.cache.delete(peerId);
+    if (!(entry instanceof Promise)) {
+      // best-effort destroy; promise-cached entries skip destroy because
+      // the in-flight build owns its own Agent which will be GC'd when the
+      // owning request handles the rejection from the cache miss
+      entry.agent.destroy().catch(() => {
+        // intentionally ignored — destroy errors are not actionable
+      });
+    }
+    this.logger.log(`Cache flushed for peer ${peerId}`);
+  }
+
+  // -------------------------------------------------------------------------
+  // Internal helpers
+  // -------------------------------------------------------------------------
+
+  /**
+   * Load and cache the Step-CA root cert PEM from `STEP_CA_ROOT_CERT_PATH`.
+   * Throws `FederationClientError` if the env var is unset or the file cannot
+   * be read — mTLS to a peer without a pinned trust anchor would silently
+   * fall back to the public trust store.
+   */
+  private loadStepCaRoot(): string {
+    if (this.cachedCaPem !== null) {
+      return this.cachedCaPem;
+    }
+    const path = process.env['STEP_CA_ROOT_CERT_PATH'];
+    if (!path) {
+      throw new FederationClientError({
+        code: 'PEER_MISCONFIGURED',
+        message: 'STEP_CA_ROOT_CERT_PATH is not set; refusing to dial peer without pinned CA trust',
+        peerId: '',
+      });
+    }
+    try {
+      const pem = readFileSync(path, 'utf8');
+      this.cachedCaPem = pem;
+      return pem;
+    } catch (err) {
+      throw new FederationClientError({
+        code: 'PEER_MISCONFIGURED',
+        message: `Failed to read STEP_CA_ROOT_CERT_PATH (${path})`,
+        peerId: '',
+        cause: err,
+      });
+    }
+  }
+
+  /**
+   * Resolve the cache entry for a peer, reading DB on miss.
+   *
+   * Uses a promise-cache pattern: concurrent callers for the same uncached
+   * `peerId` all `await` the same in-flight `Promise<AgentCacheEntry>` so
+   * only one DB lookup and one key-unseal ever runs per peer per cache miss.
+   * The promise is replaced with the concrete entry on success, or deleted on
+   * rejection so a transient error does not poison the cache permanently.
+   *
+   * Throws `FederationClientError` with appropriate code if the peer is not
+   * found, is inactive, or is missing required fields.
+   */
+  private async resolveEntry(peerId: string): Promise<AgentCacheEntry> {
+    const cached = this.cache.get(peerId);
+    if (cached) {
+      return cached; // Promise or concrete entry — both are awaitable
+    }
+
+    const inflight = this.buildEntry(peerId).then(
+      (entry) => {
+        this.cache.set(peerId, entry); // replace promise with concrete value
+        return entry;
+      },
+      (err: unknown) => {
+        this.cache.delete(peerId); // don't poison the cache with a rejected promise
+        throw err;
+      },
+    );
+
+    this.cache.set(peerId, inflight);
+    return inflight;
+  }
+
+  /**
+   * Build the `AgentCacheEntry` for a peer by reading the DB, validating the
+   * peer's state, unsealing the private key, and constructing the mTLS Agent.
+   *
+   * Throws `FederationClientError` with appropriate code if the peer is not
+   * found, is inactive, or is missing required fields.
+   */
+  private async buildEntry(peerId: string): Promise<AgentCacheEntry> {
+    // DB lookup
+    const [peer] = await this.db
+      .select()
+      .from(federationPeers)
+      .where(eq(federationPeers.id, peerId))
+      .limit(1);
+
+    if (!peer) {
+      throw new FederationClientError({
+        code: 'PEER_NOT_FOUND',
+        message: `Federation peer ${peerId} not found`,
+        peerId,
+      });
+    }
+
+    if (peer.state !== 'active') {
+      throw new FederationClientError({
+        code: 'PEER_INACTIVE',
+        message: `Federation peer ${peerId} is not active (state: ${peer.state})`,
+        peerId,
+      });
+    }
+
+    if (!peer.endpointUrl || !peer.clientKeyPem) {
+      throw new FederationClientError({
+        code: 'PEER_MISCONFIGURED',
+        message: `Federation peer ${peerId} is missing endpointUrl or clientKeyPem`,
+        peerId,
+      });
+    }
+
+    // Unseal the private key
+    let privateKeyPem: string;
+    try {
+      privateKeyPem = unsealClientKey(peer.clientKeyPem);
+    } catch (err) {
+      throw new FederationClientError({
+        code: 'PEER_MISCONFIGURED',
+        message: `Failed to unseal client key for peer ${peerId}`,
+        peerId,
+        cause: err,
+      });
+    }
+
+    // Build mTLS agent — pin trust to Step-CA root so we never accept
+    // a peer cert signed by a public CA (defense against MITM with a
+    // publicly-trusted DV cert for the peer's hostname).
+    const agent = new Agent({
+      connect: {
+        cert: peer.certPem,
+        key: privateKeyPem,
+        ca: this.loadStepCaRoot(),
+        // rejectUnauthorized: true is the undici default for HTTPS
+      },
+    });
+
+    const entry: AgentCacheEntry = {
+      agent,
+      endpointUrl: peer.endpointUrl,
+      certPem: peer.certPem,
+      certSerial: peer.certSerial,
+    };
+
+    this.logger.log(`Agent cached for peer ${peerId} (serial: ${peer.certSerial})`);
+
+    return entry;
+  }
+
+  /**
+   * Execute a POST request with a JSON body.
+   * Returns the parsed response body as an unknown value.
+   * Throws `FederationClientError` on network errors and non-2xx responses.
+   */
+  private async doPost(
+    peerId: string,
+    url: string,
+    agent: Dispatcher,
+    body: Record<string, unknown>,
+  ): Promise<unknown> {
+    return this.doRequest(peerId, url, agent, {
+      method: 'POST',
+      headers: { 'Content-Type': 'application/json' },
+      body: JSON.stringify(body),
+    });
+  }
+
+  /**
+   * Execute a GET request.
+   * Returns the parsed response body as an unknown value.
+   * Throws `FederationClientError` on network errors and non-2xx responses.
+   */
+  private async doGet(peerId: string, url: string, agent: Dispatcher): Promise<unknown> {
+    return this.doRequest(peerId, url, agent, { method: 'GET' });
+  }
+
+  private async doRequest(
+    peerId: string,
+    url: string,
+    agent: Dispatcher,
+    init: { method: string; headers?: Record<string, string>; body?: string },
+  ): Promise<unknown> {
+    let response: Awaited<ReturnType<typeof undiciFetch>>;
+
+    try {
+      response = await undiciFetch(url, {
+        ...init,
+        dispatcher: agent,
+      });
+    } catch (err) {
+      throw new FederationClientError({
+        code: 'NETWORK',
+        message: `Network error calling peer ${peerId} at ${url}: ${err instanceof Error ? err.message : String(err)}`,
+        peerId,
+        cause: err,
+      });
+    }
+
+    const rawBody = await response.text().catch(() => '');
+
+    if (!response.ok) {
+      const status = response.status;
+
+      // Attempt to parse as federation error envelope
+      let serverMessage = `HTTP ${status}`;
+      try {
+        const json: unknown = JSON.parse(rawBody);
+        const result = FederationErrorEnvelopeSchema.safeParse(json);
+        if (result.success) {
+          serverMessage = result.data.error.message;
+        }
+      } catch {
+        // Not valid JSON or not a federation envelope — use generic message
+      }
+
+      // Specific code for 403 (most actionable for callers); generic HTTP_{n} for others
+      const code: FederationClientErrorCode = status === 403 ? 'FORBIDDEN' : `HTTP_${status}`;
+
+      throw new FederationClientError({
+        status,
+        code,
+        message: `Peer ${peerId} returned ${status}: ${serverMessage}`,
+        peerId,
+      });
+    }
+
+    try {
+      return JSON.parse(rawBody) as unknown;
+    } catch (err) {
+      throw new FederationClientError({
+        code: 'INVALID_RESPONSE',
+        message: `Peer ${peerId} returned non-JSON body`,
+        peerId,
+        cause: err,
+      });
+    }
+  }
+
+  /**
+   * Parse and validate a response body against a Zod schema.
+   *
+   * For list/get, callers pass the result of `FederationListResponseSchema(z.unknown())`
+   * so that the envelope structure is validated without requiring a concrete item schema
+   * at the client level.  The generic `T` provides compile-time typing.
+   *
+   * Throws `FederationClientError({ code: 'INVALID_RESPONSE' })` on parse failure.
+   */
+  private parseWith<T>(peerId: string, body: unknown, schema: z.ZodTypeAny): T {
+    const result = schema.safeParse(body);
+    if (!result.success) {
+      const issues = result.error.issues
+        .map((e: z.ZodIssue) => `[${e.path.join('.') || 'root'}] ${e.message}`)
+        .join('; ');
+      throw new FederationClientError({
+        code: 'INVALID_RESPONSE',
+        message: `Peer ${peerId} returned invalid response shape: ${issues}`,
+        peerId,
+      });
+    }
+    return result.data as T;
+  }
+}

apps/gateway/src/federation/client/index.ts

@@ -0,0 +1,13 @@
+/**
+ * Federation client barrel — re-exports for FederationModule consumers.
+ *
+ * M3-09 (QuerySourceService) and future milestones should import from here,
+ * not directly from the implementation file.
+ */
+
+export {
+  FederationClientService,
+  FederationClientError,
+  type FederationClientErrorCode,
+  type FederationClientErrorOptions,
+} from './federation-client.service.js';

apps/gateway/src/federation/federation.module.ts

@@ -5,10 +5,11 @@ import { EnrollmentController } from './enrollment.controller.js';
 import { EnrollmentService } from './enrollment.service.js';
 import { FederationController } from './federation.controller.js';
 import { GrantsService } from './grants.service.js';
+import { FederationClientService } from './client/index.js';
 
 @Module({
   controllers: [EnrollmentController, FederationController],
-  providers: [AdminGuard, CaService, EnrollmentService, GrantsService],
+  providers: [AdminGuard, CaService, EnrollmentService, GrantsService, FederationClientService],
-  exports: [CaService, EnrollmentService, GrantsService],
+  exports: [CaService, EnrollmentService, GrantsService, FederationClientService],
 })
 export class FederationModule {}

packages/types/package.json

@@ -26,7 +26,8 @@
   },
   "dependencies": {
     "class-transformer": "^0.5.1",
-    "class-validator": "^0.15.1"
+    "class-validator": "^0.15.1",
+    "zod": "^4.3.6"
   },
   "publishConfig": {
     "registry": "https://git.mosaicstack.dev/api/packages/mosaicstack/npm/",

packages/types/src/federation/__tests__/federation.spec.ts

@@ -0,0 +1,435 @@
+/**
+ * Unit tests for federation wire-format DTOs.
+ *
+ * Coverage:
+ *  - FederationRequestSchema  (valid + invalid)
+ *  - FederationListResponseSchema factory
+ *  - FederationGetResponseSchema factory
+ *  - FederationCapabilitiesResponseSchema
+ *  - FederationErrorEnvelopeSchema + error code exhaustiveness
+ *  - FederationError exception hierarchy
+ *  - tagWithSource helper round-trip
+ *  - SourceTagSchema
+ */
+
+import { describe, expect, it } from 'vitest';
+import { z } from 'zod';
+
+import {
+  FEDERATION_ERROR_CODES,
+  FEDERATION_VERBS,
+  FederationCapabilitiesResponseSchema,
+  FederationError,
+  FederationErrorEnvelopeSchema,
+  FederationForbiddenError,
+  FederationInternalError,
+  FederationInvalidRequestError,
+  FederationNotFoundError,
+  FederationRateLimitedError,
+  FederationRequestSchema,
+  FederationScopeViolationError,
+  FederationUnauthorizedError,
+  FederationGetResponseSchema,
+  FederationListResponseSchema,
+  SOURCE_LOCAL,
+  SourceTagSchema,
+  parseFederationErrorEnvelope,
+  tagWithSource,
+} from '../index.js';
+
+// ---------------------------------------------------------------------------
+// Verbs
+// ---------------------------------------------------------------------------
+
+describe('FEDERATION_VERBS', () => {
+  it('contains exactly list, get, capabilities', () => {
+    expect(FEDERATION_VERBS).toEqual(['list', 'get', 'capabilities']);
+  });
+});
+
+// ---------------------------------------------------------------------------
+// FederationRequestSchema
+// ---------------------------------------------------------------------------
+
+describe('FederationRequestSchema', () => {
+  it('accepts a minimal valid list request', () => {
+    const result = FederationRequestSchema.safeParse({ verb: 'list', resource: 'tasks' });
+    expect(result.success).toBe(true);
+  });
+
+  it('accepts a get request with cursor and params', () => {
+    const result = FederationRequestSchema.safeParse({
+      verb: 'get',
+      resource: 'notes',
+      cursor: 'abc123',
+      params: { filter: 'mine' },
+    });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.cursor).toBe('abc123');
+      expect(result.data.params?.['filter']).toBe('mine');
+    }
+  });
+
+  it('accepts a capabilities request', () => {
+    const result = FederationRequestSchema.safeParse({ verb: 'capabilities', resource: 'tasks' });
+    expect(result.success).toBe(true);
+  });
+
+  it('rejects an unknown verb', () => {
+    const result = FederationRequestSchema.safeParse({ verb: 'search', resource: 'tasks' });
+    expect(result.success).toBe(false);
+  });
+
+  it('rejects an empty resource string', () => {
+    const result = FederationRequestSchema.safeParse({ verb: 'list', resource: '' });
+    expect(result.success).toBe(false);
+  });
+
+  it('rejects a missing verb', () => {
+    const result = FederationRequestSchema.safeParse({ resource: 'tasks' });
+    expect(result.success).toBe(false);
+  });
+});
+
+// ---------------------------------------------------------------------------
+// FederationListResponseSchema factory
+// ---------------------------------------------------------------------------
+
+describe('FederationListResponseSchema', () => {
+  const ItemSchema = z.object({ id: z.string(), name: z.string() });
+  const ListSchema = FederationListResponseSchema(ItemSchema);
+
+  it('accepts a valid list envelope', () => {
+    const result = ListSchema.safeParse({
+      items: [{ id: '1', name: 'Task A' }],
+      nextCursor: 'page2',
+      _partial: false,
+      _truncated: false,
+    });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.items).toHaveLength(1);
+      expect(result.data.nextCursor).toBe('page2');
+    }
+  });
+
+  it('accepts a minimal envelope with empty items', () => {
+    const result = ListSchema.safeParse({ items: [] });
+    expect(result.success).toBe(true);
+  });
+
+  it('rejects when items is missing', () => {
+    const result = ListSchema.safeParse({ nextCursor: 'x' });
+    expect(result.success).toBe(false);
+  });
+
+  it('rejects when an item fails validation', () => {
+    const result = ListSchema.safeParse({ items: [{ id: 1, name: 'bad' }] });
+    expect(result.success).toBe(false);
+  });
+});
+
+// ---------------------------------------------------------------------------
+// FederationGetResponseSchema factory
+// ---------------------------------------------------------------------------
+
+describe('FederationGetResponseSchema', () => {
+  const ItemSchema = z.object({ id: z.string() });
+  const GetSchema = FederationGetResponseSchema(ItemSchema);
+
+  it('accepts a found item', () => {
+    const result = GetSchema.safeParse({ item: { id: 'abc' } });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.item).toEqual({ id: 'abc' });
+    }
+  });
+
+  it('accepts null item (not found)', () => {
+    const result = GetSchema.safeParse({ item: null });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.item).toBeNull();
+    }
+  });
+
+  it('rejects when item is missing', () => {
+    const result = GetSchema.safeParse({});
+    expect(result.success).toBe(false);
+  });
+});
+
+// ---------------------------------------------------------------------------
+// FederationCapabilitiesResponseSchema
+// ---------------------------------------------------------------------------
+
+describe('FederationCapabilitiesResponseSchema', () => {
+  it('accepts a valid capabilities response', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks', 'notes'],
+      excluded_resources: ['credentials'],
+      max_rows_per_query: 500,
+      supported_verbs: ['list', 'get', 'capabilities'],
+    });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.max_rows_per_query).toBe(500);
+    }
+  });
+
+  it('accepts a response with filters field', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks', 'notes'],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['list'],
+      filters: {
+        tasks: { include_teams: ['team-a'], include_personal: true },
+        notes: { include_personal: false },
+      },
+    });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.filters?.['tasks']?.include_teams).toEqual(['team-a']);
+    }
+  });
+
+  it('accepts a response with partial filters (only include_teams)', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 50,
+      supported_verbs: ['list'],
+      filters: { tasks: { include_teams: ['eng'] } },
+    });
+    expect(result.success).toBe(true);
+  });
+
+  it('accepts a response with rate_limit (M4 full shape)', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['list'],
+      rate_limit: { limit_per_minute: 60, remaining: 55, reset_at: '2026-04-23T12:00:00Z' },
+    });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.rate_limit?.limit_per_minute).toBe(60);
+      expect(result.data.rate_limit?.remaining).toBe(55);
+    }
+  });
+
+  it('accepts a response with rate_limit (M3 minimal — limit_per_minute only)', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['list'],
+      rate_limit: { limit_per_minute: 120 },
+    });
+    expect(result.success).toBe(true);
+  });
+
+  it('accepts a response without rate_limit (field is optional)', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['list'],
+    });
+    expect(result.success).toBe(true);
+    if (result.success) {
+      expect(result.data.rate_limit).toBeUndefined();
+    }
+  });
+
+  it('rejects rate_limit with non-positive limit_per_minute', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['list'],
+      rate_limit: { limit_per_minute: 0 },
+    });
+    expect(result.success).toBe(false);
+  });
+
+  it('rejects rate_limit with invalid reset_at datetime', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['list'],
+      rate_limit: { limit_per_minute: 60, reset_at: 'not-a-datetime' },
+    });
+    expect(result.success).toBe(false);
+  });
+
+  it('rejects supported_verbs with an invalid verb (MED-3 enum guard)', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['invalid_verb'],
+    });
+    expect(result.success).toBe(false);
+  });
+
+  it('rejects empty resources array', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: [],
+      excluded_resources: [],
+      max_rows_per_query: 100,
+      supported_verbs: ['list'],
+    });
+    expect(result.success).toBe(false);
+  });
+
+  it('rejects non-integer max_rows_per_query', () => {
+    const result = FederationCapabilitiesResponseSchema.safeParse({
+      resources: ['tasks'],
+      excluded_resources: [],
+      max_rows_per_query: 1.5,
+      supported_verbs: ['list'],
+    });
+    expect(result.success).toBe(false);
+  });
+});
+
+// ---------------------------------------------------------------------------
+// FederationErrorEnvelopeSchema + error code exhaustiveness
+// ---------------------------------------------------------------------------
+
+describe('FederationErrorEnvelopeSchema', () => {
+  it('accepts each valid error code', () => {
+    for (const code of FEDERATION_ERROR_CODES) {
+      const result = FederationErrorEnvelopeSchema.safeParse({
+        error: { code, message: 'test' },
+      });
+      expect(result.success, `code ${code} should be valid`).toBe(true);
+    }
+  });
+
+  it('rejects an unknown error code', () => {
+    const result = FederationErrorEnvelopeSchema.safeParse({
+      error: { code: 'unknown_code', message: 'test' },
+    });
+    expect(result.success).toBe(false);
+  });
+
+  it('accepts optional details field', () => {
+    const result = FederationErrorEnvelopeSchema.safeParse({
+      error: { code: 'forbidden', message: 'nope', details: { grantId: 'xyz' } },
+    });
+    expect(result.success).toBe(true);
+  });
+
+  it('rejects when message is missing', () => {
+    const result = FederationErrorEnvelopeSchema.safeParse({ error: { code: 'not_found' } });
+    expect(result.success).toBe(false);
+  });
+});
+
+describe('parseFederationErrorEnvelope', () => {
+  it('returns a typed envelope for valid input', () => {
+    const env = parseFederationErrorEnvelope({ error: { code: 'not_found', message: 'gone' } });
+    expect(env.error.code).toBe('not_found');
+  });
+
+  it('throws for invalid input', () => {
+    expect(() => parseFederationErrorEnvelope({ bad: 'shape' })).toThrow();
+  });
+});
+
+// ---------------------------------------------------------------------------
+// FederationError exception hierarchy
+// ---------------------------------------------------------------------------
+
+describe('FederationError hierarchy', () => {
+  const cases: Array<[string, FederationError]> = [
+    ['unauthorized', new FederationUnauthorizedError()],
+    ['forbidden', new FederationForbiddenError()],
+    ['not_found', new FederationNotFoundError()],
+    ['rate_limited', new FederationRateLimitedError()],
+    ['scope_violation', new FederationScopeViolationError()],
+    ['invalid_request', new FederationInvalidRequestError()],
+    ['internal_error', new FederationInternalError()],
+  ];
+
+  it.each(cases)('code %s is an instance of FederationError', (_code, err) => {
+    expect(err).toBeInstanceOf(FederationError);
+    expect(err).toBeInstanceOf(Error);
+  });
+
+  it.each(cases)('code %s has correct code property', (code, err) => {
+    expect(err.code).toBe(code);
+  });
+
+  it('toEnvelope serialises to wire format', () => {
+    const err = new FederationForbiddenError('Access denied', { grantId: 'g1' });
+    const env = err.toEnvelope();
+    expect(env.error.code).toBe('forbidden');
+    expect(env.error.message).toBe('Access denied');
+    expect(env.error.details).toEqual({ grantId: 'g1' });
+  });
+
+  it('toEnvelope omits details when not provided', () => {
+    const err = new FederationNotFoundError();
+    const env = err.toEnvelope();
+    expect(Object.prototype.hasOwnProperty.call(env.error, 'details')).toBe(false);
+  });
+
+  it('error codes tuple covers all subclasses (exhaustiveness check)', () => {
+    // If a new subclass is added without a code, this test fails at compile time.
+    const allCodes = new Set(FEDERATION_ERROR_CODES);
+    for (const [code] of cases) {
+      expect(allCodes.has(code as (typeof FEDERATION_ERROR_CODES)[number])).toBe(true);
+    }
+    // All codes are covered by at least one case
+    expect(cases).toHaveLength(FEDERATION_ERROR_CODES.length);
+  });
+});
+
+// ---------------------------------------------------------------------------
+// Source tag + tagWithSource
+// ---------------------------------------------------------------------------
+
+describe('SourceTagSchema', () => {
+  it('accepts a non-empty _source string', () => {
+    expect(SourceTagSchema.safeParse({ _source: 'local' }).success).toBe(true);
+    expect(SourceTagSchema.safeParse({ _source: 'mosaic.uscllc.com' }).success).toBe(true);
+  });
+
+  it('rejects empty _source string', () => {
+    expect(SourceTagSchema.safeParse({ _source: '' }).success).toBe(false);
+  });
+});
+
+describe('tagWithSource', () => {
+  it('stamps each item with the given source', () => {
+    const items = [{ id: '1' }, { id: '2' }];
+    const tagged = tagWithSource(items, SOURCE_LOCAL);
+    expect(tagged).toEqual([
+      { id: '1', _source: 'local' },
+      { id: '2', _source: 'local' },
+    ]);
+  });
+
+  it('preserves original item fields', () => {
+    const items = [{ id: 'x', name: 'Task', done: false }];
+    const tagged = tagWithSource(items, 'mosaic.uscllc.com');
+    expect(tagged[0]).toMatchObject({ id: 'x', name: 'Task', done: false });
+    expect(tagged[0]?._source).toBe('mosaic.uscllc.com');
+  });
+
+  it('returns empty array for empty input', () => {
+    expect(tagWithSource([], 'local')).toEqual([]);
+  });
+
+  it('round-trip: tagWithSource output passes SourceTagSchema', () => {
+    const tagged = tagWithSource([{ id: '1' }], 'local');
+    expect(SourceTagSchema.safeParse(tagged[0]).success).toBe(true);
+  });
+});

packages/types/src/federation/error.ts

@@ -0,0 +1,164 @@
+/**
+ * Federation wire-format error envelope and exception hierarchy.
+ *
+ * Source of truth: docs/federation/PRD.md §6, §8.
+ *
+ * DESIGN: Typed error classes rather than discriminated union values
+ * ──────────────────────────────────────────────────────────────────
+ * We expose:
+ *   1. `FEDERATION_ERROR_CODES` — closed string-enum tuple (exhaustiveness-checkable).
+ *   2. `FederationErrorCode` — union type inferred from the tuple.
+ *   3. `FederationErrorEnvelopeSchema` — Zod schema for the wire format.
+ *   4. `FederationError` — base Error subclass with a typed `code` property.
+ *      One concrete subclass per code (e.g. `FederationUnauthorizedError`),
+ *      which enables `instanceof` dispatch in handlers without a switch.
+ *
+ * Rationale: subclasses give gateway handlers and the client a clean dispatch
+ * point (catch + instanceof) without re-parsing or switch tables.  All classes
+ * carry `code` so a generic logger can act on any FederationError uniformly.
+ *
+ * Pure — no NestJS, no DB, no Node-only APIs. Safe for browser/edge.
+ */
+
+import { z } from 'zod';
+
+// ---------------------------------------------------------------------------
+// Error code enum (closed)
+// ---------------------------------------------------------------------------
+
+export const FEDERATION_ERROR_CODES = [
+  'unauthorized',
+  'forbidden',
+  'not_found',
+  'rate_limited',
+  'scope_violation',
+  'invalid_request',
+  'internal_error',
+] as const;
+
+export type FederationErrorCode = (typeof FEDERATION_ERROR_CODES)[number];
+
+// ---------------------------------------------------------------------------
+// Wire-format schema
+// ---------------------------------------------------------------------------
+
+export const FederationErrorEnvelopeSchema = z.object({
+  error: z.object({
+    code: z.enum(FEDERATION_ERROR_CODES),
+    message: z.string(),
+    details: z.unknown().optional(),
+  }),
+});
+
+export type FederationErrorEnvelope = z.infer<typeof FederationErrorEnvelopeSchema>;
+
+// ---------------------------------------------------------------------------
+// Exception class hierarchy
+// ---------------------------------------------------------------------------
+
+/**
+ * Base class for all federation errors.
+ * Carries a typed `code` so handlers can act uniformly on any FederationError.
+ */
+export class FederationError extends Error {
+  readonly code: FederationErrorCode;
+  readonly details?: unknown;
+
+  constructor(code: FederationErrorCode, message: string, details?: unknown) {
+    super(message);
+    this.name = 'FederationError';
+    this.code = code;
+    this.details = details;
+  }
+
+  /** Serialise to the wire-format error envelope. */
+  toEnvelope(): FederationErrorEnvelope {
+    return {
+      error: {
+        code: this.code,
+        message: this.message,
+        ...(this.details !== undefined ? { details: this.details } : {}),
+      },
+    };
+  }
+}
+
+/** Client cert is missing, invalid, or signed by an untrusted CA. */
+export class FederationUnauthorizedError extends FederationError {
+  constructor(message = 'Unauthorized', details?: unknown) {
+    super('unauthorized', message, details);
+    this.name = 'FederationUnauthorizedError';
+  }
+}
+
+/** Grant is inactive, revoked, or the subject user lacks access to the resource. */
+export class FederationForbiddenError extends FederationError {
+  constructor(message = 'Forbidden', details?: unknown) {
+    super('forbidden', message, details);
+    this.name = 'FederationForbiddenError';
+  }
+}
+
+/** Requested resource does not exist. */
+export class FederationNotFoundError extends FederationError {
+  constructor(message = 'Not found', details?: unknown) {
+    super('not_found', message, details);
+    this.name = 'FederationNotFoundError';
+  }
+}
+
+/** Grant has exceeded its rate limit; Retry-After should accompany this. */
+export class FederationRateLimitedError extends FederationError {
+  constructor(message = 'Rate limit exceeded', details?: unknown) {
+    super('rate_limited', message, details);
+    this.name = 'FederationRateLimitedError';
+  }
+}
+
+/**
+ * The request targets a resource or performs an action that the grant's
+ * scope explicitly disallows (distinct from generic 403 — scope_violation
+ * means the scope configuration itself blocked the request).
+ */
+export class FederationScopeViolationError extends FederationError {
+  constructor(message = 'Scope violation', details?: unknown) {
+    super('scope_violation', message, details);
+    this.name = 'FederationScopeViolationError';
+  }
+}
+
+/** Malformed request — missing fields, invalid cursor, unknown verb, etc. */
+export class FederationInvalidRequestError extends FederationError {
+  constructor(message = 'Invalid request', details?: unknown) {
+    super('invalid_request', message, details);
+    this.name = 'FederationInvalidRequestError';
+  }
+}
+
+/** Unexpected server-side failure. */
+export class FederationInternalError extends FederationError {
+  constructor(message = 'Internal error', details?: unknown) {
+    super('internal_error', message, details);
+    this.name = 'FederationInternalError';
+  }
+}
+
+// ---------------------------------------------------------------------------
+// Typed parser
+// ---------------------------------------------------------------------------
+
+/**
+ * Parse an unknown value as a FederationErrorEnvelope.
+ * Throws a plain Error (not FederationError) when parsing fails — this means
+ * the payload wasn't even a valid error envelope.
+ */
+export function parseFederationErrorEnvelope(input: unknown): FederationErrorEnvelope {
+  const result = FederationErrorEnvelopeSchema.safeParse(input);
+  if (!result.success) {
+    const issues = result.error.issues
+      .map((e) => `  - [${e.path.join('.') || 'root'}] ${e.message}`)
+      .join('\n');
+    throw new Error(`Invalid federation error envelope:\n${issues}`);
+  }
+  return result.data;
+}

packages/types/src/federation/index.ts

@@ -0,0 +1,16 @@
+/**
+ * Federation wire-format DTOs — public barrel.
+ *
+ * Exports everything downstream M3 tasks need:
+ *   verbs.ts      — FEDERATION_VERBS constant + FederationVerb type
+ *   request.ts    — FederationRequestSchema + FederationRequest
+ *   response.ts   — list/get/capabilities schema factories + types
+ *   source-tag.ts — SourceTagSchema, tagWithSource helper
+ *   error.ts      — error envelope schema + typed exception hierarchy
+ */
+
+export * from './verbs.js';
+export * from './request.js';
+export * from './response.js';
+export * from './source-tag.js';
+export * from './error.js';

packages/types/src/federation/request.ts

@@ -0,0 +1,47 @@
+/**
+ * Federation wire-format request schema.
+ *
+ * Source of truth: docs/federation/PRD.md §9 (query model).
+ *
+ * Pure — no NestJS, no DB, no Node-only APIs. Safe for browser/edge.
+ */
+
+import { z } from 'zod';
+import { FEDERATION_VERBS } from './verbs.js';
+
+// ---------------------------------------------------------------------------
+// Query params — free-form key/value pairs passed alongside the request
+// ---------------------------------------------------------------------------
+
+const QueryParamsSchema = z.record(z.string(), z.string()).optional();
+
+// ---------------------------------------------------------------------------
+// Top-level request schema
+// ---------------------------------------------------------------------------
+
+export const FederationRequestSchema = z.object({
+  /**
+   * Verb being invoked. One of the M3 federation verbs.
+   */
+  verb: z.enum(FEDERATION_VERBS),
+
+  /**
+   * Resource path being queried, e.g. "tasks", "notes", "memory".
+   * Forward-slash-separated for sub-resources (e.g. "teams/abc/tasks").
+   */
+  resource: z.string().min(1, { message: 'resource must not be empty' }),
+
+  /**
+   * Optional free-form query params (filters, sort, etc.).
+   * Values are always strings; consumers parse as needed.
+   */
+  params: QueryParamsSchema,
+
+  /**
+   * Opaque pagination cursor returned by a previous list response.
+   * Absent on first page.
+   */
+  cursor: z.string().optional(),
+});
+
+export type FederationRequest = z.infer<typeof FederationRequestSchema>;

packages/types/src/federation/response.ts

@@ -0,0 +1,162 @@
+/**
+ * Federation wire-format response schemas.
+ *
+ * Source of truth: docs/federation/PRD.md §9 and MILESTONES.md §M3.
+ *
+ * DESIGN: Generic factory functions rather than z.lazy
+ * ─────────────────────────────────────────────────────
+ * Zod generic schemas cannot be expressed as a single re-usable `z.ZodType`
+ * value because TypeScript's type system erases the generic at the call site.
+ * The idiomatic Zod v4 pattern is factory functions that take an item schema
+ * and return a fully-typed schema.
+ *
+ *   const MyListSchema = FederationListResponseSchema(z.string());
+ *   type MyList = z.infer<typeof MyListSchema>;
+ *   // => { items: string[]; nextCursor?: string; _partial?: boolean; _truncated?: boolean }
+ *
+ * Downstream consumers (M3-03..M3-07, M3-08, M3-09) should call these
+ * factories once per resource type and cache the result.
+ *
+ * Pure — no NestJS, no DB, no Node-only APIs. Safe for browser/edge.
+ */
+
+import { z } from 'zod';
+
+import { FEDERATION_VERBS } from './verbs.js';
+
+// ---------------------------------------------------------------------------
+// Shared envelope flags
+// ---------------------------------------------------------------------------
+
+/**
+ * `_partial`: true when the response is a subset of available data (e.g. due
+ * to scope intersection reducing the result set).
+ */
+const PartialFlag = z.boolean().optional();
+
+/**
+ * `_truncated`: true when the response was capped by max_rows_per_query and
+ * additional pages exist beyond the current cursor.
+ */
+const TruncatedFlag = z.boolean().optional();
+
+// ---------------------------------------------------------------------------
+// FederationListResponseSchema<T> factory
+// ---------------------------------------------------------------------------
+
+/**
+ * Returns a Zod schema for a paginated federation list envelope.
+ *
+ * @param itemSchema - Zod schema for a single item in the list.
+ *
+ * @example
+ * ```ts
+ * const TaskListSchema = FederationListResponseSchema(TaskSchema);
+ * type TaskList = z.infer<typeof TaskListSchema>;
+ * ```
+ */
+export function FederationListResponseSchema<T extends z.ZodTypeAny>(itemSchema: T) {
+  return z.object({
+    items: z.array(itemSchema),
+    nextCursor: z.string().optional(),
+    _partial: PartialFlag,
+    _truncated: TruncatedFlag,
+  });
+}
+
+export type FederationListResponse<T> = {
+  items: T[];
+  nextCursor?: string;
+  _partial?: boolean;
+  _truncated?: boolean;
+};
+
+// ---------------------------------------------------------------------------
+// FederationGetResponseSchema<T> factory
+// ---------------------------------------------------------------------------
+
+/**
+ * Returns a Zod schema for a single-item federation get envelope.
+ *
+ * `item` is null when the resource was not found (404 equivalent on the wire).
+ *
+ * @param itemSchema - Zod schema for the item (nullable is applied internally).
+ *
+ * @example
+ * ```ts
+ * const TaskGetSchema = FederationGetResponseSchema(TaskSchema);
+ * type TaskGet = z.infer<typeof TaskGetSchema>;
+ * ```
+ */
+export function FederationGetResponseSchema<T extends z.ZodTypeAny>(itemSchema: T) {
+  return z.object({
+    item: itemSchema.nullable(),
+    _partial: PartialFlag,
+  });
+}
+
+export type FederationGetResponse<T> = {
+  item: T | null;
+  _partial?: boolean;
+};
+
+// ---------------------------------------------------------------------------
+// FederationCapabilitiesResponseSchema (fixed shape)
+// ---------------------------------------------------------------------------
+
+/**
+ * Shape mirrors FederationScope (apps/gateway/src/federation/scope-schema.ts)
+ * but is kept separate to avoid coupling packages/types to the gateway module.
+ * The serving side populates this from the resolved grant scope at request time.
+ */
+export const FederationCapabilitiesResponseSchema = z.object({
+  /**
+   * Resources this grant is allowed to query.
+   */
+  resources: z.array(z.string()).nonempty(),
+
+  /**
+   * Resources explicitly blocked for this grant even if they exist.
+   */
+  excluded_resources: z.array(z.string()),
+
+  /**
+   * Per-resource filters (mirrors FederationScope.filters from PRD §8.1).
+   * Keys are resource names; values control team/personal visibility.
+   */
+  filters: z
+    .record(
+      z.string(),
+      z.object({
+        include_teams: z.array(z.string()).optional(),
+        include_personal: z.boolean().optional(),
+      }),
+    )
+    .optional(),
+
+  /**
+   * Hard cap on rows returned per query for this grant.
+   */
+  max_rows_per_query: z.number().int().positive(),
+
+  /**
+   * Verbs currently available. Will expand in M4+ (search).
+   * Closed enum — only values from FEDERATION_VERBS are accepted.
+   */
+  supported_verbs: z.array(z.enum(FEDERATION_VERBS)).nonempty(),
+
+  /**
+   * Rate-limit state for this grant (PRD §9.1).
+   * M4 populates `remaining` and `reset_at`; M3 servers may return only
+   * `limit_per_minute` or omit the field entirely.
+   */
+  rate_limit: z
+    .object({
+      limit_per_minute: z.number().int().positive(),
+      remaining: z.number().int().nonnegative().optional(),
+      reset_at: z.string().datetime().optional(),
+    })
+    .optional(),
+});
+
+export type FederationCapabilitiesResponse = z.infer<typeof FederationCapabilitiesResponseSchema>;

packages/types/src/federation/source-tag.ts

@@ -0,0 +1,61 @@
+/**
+ * _source tag for federation fan-out results.
+ *
+ * Source of truth: docs/federation/PRD.md §9.3 and MILESTONES.md §M3 acceptance test #8.
+ *
+ * When source: "all" is requested, the gateway fans out to local + all active
+ * federated peers, merges results, and tags each item with _source so the
+ * caller knows the provenance.
+ *
+ * Pure — no NestJS, no DB, no Node-only APIs. Safe for browser/edge.
+ */
+
+import { z } from 'zod';
+
+// ---------------------------------------------------------------------------
+// Source tag schema
+// ---------------------------------------------------------------------------
+
+/**
+ * `_source` is either:
+ * - `"local"` — the item came from this gateway's own storage.
+ * - a peer common name (e.g. `"mosaic.uscllc.com"`) — the item came from
+ *   that federated peer.
+ */
+export const SourceTagSchema = z.object({
+  _source: z.string().min(1, { message: '_source must not be empty' }),
+});
+
+export type SourceTag = z.infer<typeof SourceTagSchema>;
+
+/**
+ * Literal union for the well-known local source value.
+ * Peers are identified by hostname strings, so there is no closed enum.
+ */
+export const SOURCE_LOCAL = 'local' as const;
+
+// ---------------------------------------------------------------------------
+// Helper: tagWithSource
+// ---------------------------------------------------------------------------
+
+/**
+ * Stamps each item in `items` with `{ _source: source }`.
+ *
+ * The return type merges the item type with SourceTag so callers get full
+ * type-safety on both the original fields and `_source`.
+ *
+ * @param items  - Array of items to tag.
+ * @param source - Either `"local"` or a peer hostname (common name from the
+ *                 client cert's CN or O field).
+ *
+ * @example
+ * ```ts
+ * const local = tagWithSource([{ id: '1', title: 'Task' }], 'local');
+ * // => [{ id: '1', title: 'Task', _source: 'local' }]
+ *
+ * const remote = tagWithSource(peerItems, 'mosaic.uscllc.com');
+ * ```
+ */
+export function tagWithSource<T extends object>(items: T[], source: string): Array<T & SourceTag> {
+  return items.map((item) => ({ ...item, _source: source }));
+}

packages/types/src/federation/verbs.ts

@@ -0,0 +1,11 @@
+/**
+ * Federation verb constants and types.
+ *
+ * Source of truth: docs/federation/PRD.md §9.1
+ *
+ * M3 ships list, get, capabilities. search lives in M4.
+ */
+
+export const FEDERATION_VERBS = ['list', 'get', 'capabilities'] as const;
+
+export type FederationVerb = (typeof FEDERATION_VERBS)[number];

packages/types/src/index.ts

@@ -5,3 +5,4 @@ export * from './agent/index.js';
 export * from './provider/index.js';
 export * from './routing/index.js';
 export * from './commands/index.js';
+export * from './federation/index.js';

pnpm-lock.yaml

@@ -179,6 +179,9 @@ importers:
       socket.io:
         specifier: ^4.8.0
         version: 4.8.3
+      undici:
+        specifier: ^7.24.6
+        version: 7.24.6
       uuid:
         specifier: ^11.0.0
         version: 11.1.0
@@ -679,6 +682,9 @@ importers:
       class-validator:
         specifier: ^0.15.1
         version: 0.15.1
+      zod:
+        specifier: ^4.3.6
+        version: 4.3.6
     devDependencies:
       typescript:
         specifier: ^5.8.0
@@ -6990,10 +6996,6 @@ packages:
     resolution: {integrity: sha512-gBLkYIlEnSp8pFbT64yFgGE6UIB9tAkhukC23PmMDCe5Nd+cRqKxSjw5y54MK2AZMgZfJWMaNE4nYUHgi1XEOw==}
     engines: {node: '>=18.17'}
 
-  undici@7.24.3:
-    resolution: {integrity: sha512-eJdUmK/Wrx2d+mnWWmwwLRyA7OQCkLap60sk3dOK4ViZR7DKwwptwuIvFBg2HaiP9ESaEdhtpSymQPvytpmkCA==}
-    engines: {node: '>=20.18.1'}
-
   undici@7.24.6:
     resolution: {integrity: sha512-Xi4agocCbRzt0yYMZGMA6ApD7gvtUFaxm4ZmeacWI4cZxaF6C+8I8QfofC20NAePiB/IcvZmzkJ7XPa471AEtA==}
     engines: {node: '>=20.18.1'}
@@ -8728,7 +8730,7 @@ snapshots:
       openai: 6.26.0(ws@8.20.0)(zod@4.3.6)
       partial-json: 0.1.7
       proxy-agent: 6.5.0
-      undici: 7.24.3
+      undici: 7.24.6
       zod-to-json-schema: 3.25.1(zod@4.3.6)
     transitivePeerDependencies:
       - '@modelcontextprotocol/sdk'
@@ -12587,7 +12589,7 @@ snapshots:
       saxes: 6.0.0
       symbol-tree: 3.2.4
       tough-cookie: 6.0.1
-      undici: 7.24.3
+      undici: 7.24.6
       w3c-xmlserializer: 5.0.0
       webidl-conversions: 8.0.1
       whatwg-mimetype: 5.0.0
@@ -14438,8 +14440,6 @@ snapshots:
 
   undici@6.21.3: {}
 
-  undici@7.24.3: {}
-
   undici@7.24.6: {}
 
   unhomoglyph@1.0.6: {}