diff --git a/.claude/settings.local.json b/.claude/settings.local.json
deleted file mode 100644
index 877d932ef..000000000
--- a/.claude/settings.local.json
+++ /dev/null
@@ -1,22 +0,0 @@
-{
-  "permissions": {
-    "allow": [
-      "Bash(chmod:*)",
-      "Bash(mkdir:*)",
-      "Bash(./gradlew:*)",
-      "Bash(grep:*)",
-      "Bash(cat:*)",
-      "Bash(find:*)",
-      "Bash(npm test)",
-      "Bash(npm test:*)",
-      "Bash(ls:*)",
-      "Bash(npx tsc:*)",
-      "Bash(node:*)",
-      "Bash(npm run dev:*)",
-      "Bash(sed:*)",
-      "Bash(npm run typecheck:*)"
-    ],
-    "deny": [],
-    "defaultMode": "acceptEdits"
-  }
-}
\ No newline at end of file
diff --git a/CLAUDE.md b/CLAUDE.md
index a806d0098..bc6af38c9 100644
--- a/CLAUDE.md
+++ b/CLAUDE.md
@@ -39,7 +39,7 @@ Frontend designed for **stateful document processing**:
 #### FileContext - Central State Management
 **Location**: `src/contexts/FileContext.tsx`
 - **Active files**: Currently loaded PDFs and their variants
-- **Tool navigation**: Current mode (viewer/pageEditor/fileEditor/toolName)  
+- **Tool navigation**: Current mode (viewer/pageEditor/fileEditor/toolName)
 - **Memory management**: PDF document cleanup, blob URL lifecycle, Web Worker management
 - **IndexedDB persistence**: File storage with thumbnail caching
 - **Preview system**: Tools can preview results (e.g., Split → Viewer → back to Split) without context pollution
@@ -89,7 +89,6 @@ return useToolOperation({
   endpoint: '/api/v1/misc/compress-pdf',
   buildFormData: (params, file: File) => { /* single file */ },
   multiFileEndpoint: false,
-  filePrefix: 'compressed_'
 });
 ```
 
@@ -103,7 +102,7 @@ return useToolOperation({
   endpoint: '/api/v1/general/split-pages',
   buildFormData: (params, files: File[]) => { /* all files */ },
   multiFileEndpoint: true,
-  filePrefix: 'split_'
+  filePrefix: 'split_',
 });
 ```
 
@@ -115,13 +114,12 @@ return useToolOperation({
 return useToolOperation({
   operationType: 'convert',
   customProcessor: async (params, files) => { /* custom logic */ },
-  filePrefix: 'converted_'
 });
 ```
 
 **Benefits**:
 - **No Timeouts**: Operations run until completion (supports 100GB+ files)
-- **Consistent**: All tools follow same pattern and interface  
+- **Consistent**: All tools follow same pattern and interface
 - **Maintainable**: Single responsibility hooks, easy to test and modify
 - **i18n Ready**: Built-in internationalization support
 - **Type Safe**: Full TypeScript support with generic interfaces
@@ -185,7 +183,7 @@ return useToolOperation({
 ## Frontend Architecture Status
 
 - **Core Status**: React SPA architecture complete with multi-tool workflow support
-- **State Management**: FileContext handles all file operations and tool navigation  
+- **State Management**: FileContext handles all file operations and tool navigation
 - **File Processing**: Production-ready with memory management for large PDF workflows (up to 100GB+)
 - **Tool Integration**: Modular hook architecture with `useToolOperation` orchestrator
   - Individual hooks: `useToolState`, `useToolApiCalls`, `useToolResources`
diff --git a/frontend/src/components/fileEditor/FileEditor.tsx b/frontend/src/components/fileEditor/FileEditor.tsx
index 93cb4e6a0..f03404eac 100644
--- a/frontend/src/components/fileEditor/FileEditor.tsx
+++ b/frontend/src/components/fileEditor/FileEditor.tsx
@@ -11,6 +11,8 @@ import FileEditorThumbnail from './FileEditorThumbnail';
 import FilePickerModal from '../shared/FilePickerModal';
 import SkeletonLoader from '../shared/SkeletonLoader';
 import { FileId, StirlingFile } from '../../types/fileContext';
+import { downloadBlob } from '../../utils/downloadUtils';
+
 
 interface FileEditorProps {
   onOpenPageEditor?: () => void;
@@ -278,7 +280,6 @@ const FileEditor = ({
   const handleDeleteFile = useCallback((fileId: FileId) => {
     const record = activeStirlingFileStubs.find(r => r.id === fileId);
     const file = record ? selectors.getFile(record.id) : null;
-
     if (record && file) {
       // Remove file from context but keep in storage (close, don't delete)
       const contextFileId = record.id;
@@ -290,6 +291,14 @@ const FileEditor = ({
     }
   }, [activeStirlingFileStubs, selectors, removeFiles, setSelectedFiles, selectedFileIds]);
 
+  const handleDownloadFile = useCallback((fileId: FileId) => {
+    const record = activeStirlingFileStubs.find(r => r.id === fileId);
+    const file = record ? selectors.getFile(record.id) : null;
+    if (record && file) {
+       downloadBlob(file, file.name);
+    }
+  }, [activeStirlingFileStubs, selectors, setStatus]);
+
   const handleViewFile = useCallback((fileId: FileId) => {
     const record = activeStirlingFileStubs.find(r => r.id === fileId);
     if (record) {
@@ -401,6 +410,7 @@ const FileEditor = ({
                   onViewFile={handleViewFile}
                   onSetStatus={setStatus}
                   onReorderFiles={handleReorderFiles}
+                  onDownloadFile={handleDownloadFile}
                   toolMode={toolMode}
                   isSupported={isFileSupported(record.name)}
                 />
diff --git a/frontend/src/components/fileEditor/FileEditorThumbnail.tsx b/frontend/src/components/fileEditor/FileEditorThumbnail.tsx
index 2a927d012..f28713c73 100644
--- a/frontend/src/components/fileEditor/FileEditorThumbnail.tsx
+++ b/frontend/src/components/fileEditor/FileEditorThumbnail.tsx
@@ -13,6 +13,7 @@ import { StirlingFileStub } from '../../types/fileContext';
 import styles from './FileEditor.module.css';
 import { useFileContext } from '../../contexts/FileContext';
 import { FileId } from '../../types/file';
+import { formatFileSize } from '../../utils/fileUtils';
 import ToolChain from '../shared/ToolChain';
 
 
@@ -28,7 +29,7 @@ interface FileEditorThumbnailProps {
   onViewFile: (fileId: FileId) => void;
   onSetStatus: (status: string) => void;
   onReorderFiles?: (sourceFileId: FileId, targetFileId: FileId, selectedFileIds: FileId[]) => void;
-  onDownloadFile?: (fileId: FileId) => void;
+  onDownloadFile: (fileId: FileId) => void;
   toolMode?: boolean;
   isSupported?: boolean;
 }
@@ -61,29 +62,6 @@ const FileEditorThumbnail = ({
 
   const pageCount = file.processedFile?.totalPages || 0;
 
-  const downloadSelectedFile = useCallback(() => {
-    // Prefer parent-provided handler if available
-    if (typeof onDownloadFile === 'function') {
-      onDownloadFile(file.id);
-      return;
-    }
-
-    // Fallback: attempt to download using the File object if provided
-    const maybeFile = (file as unknown as { file?: File }).file;
-    if (maybeFile instanceof File) {
-      const link = document.createElement('a');
-      link.href = URL.createObjectURL(maybeFile);
-      link.download = maybeFile.name || file.name || 'download';
-      document.body.appendChild(link);
-      link.click();
-      document.body.removeChild(link);
-      URL.revokeObjectURL(link.href);
-      return;
-    }
-
-    // If we can't find a way to download, surface a status message
-    onSetStatus?.(typeof t === 'function' ? t('downloadUnavailable', 'Download unavailable for this item') : 'Download unavailable for this item');
-  }, [file, onDownloadFile, onSetStatus, t]);
   const handleRef = useRef<HTMLSpanElement | null>(null);
 
   // ---- Selection ----
@@ -91,12 +69,7 @@ const FileEditorThumbnail = ({
 
   // ---- Meta formatting ----
   const prettySize = useMemo(() => {
-    const bytes = file.size ?? 0;
-    if (bytes === 0) return '0 B';
-    const k = 1024;
-    const sizes = ['B', 'KB', 'MB', 'GB', 'TB'];
-    const i = Math.floor(Math.log(bytes) / Math.log(k));
-    return `${parseFloat((bytes / Math.pow(k, i)).toFixed(1))} ${sizes[i]}`;
+    return formatFileSize(file.size);
   }, [file.size]);
 
   const extUpper = useMemo(() => {
@@ -305,7 +278,7 @@ const FileEditorThumbnail = ({
 
           <button
             className={styles.actionRow}
-            onClick={() => { downloadSelectedFile(); setShowActions(false); }}
+            onClick={() => { onDownloadFile(file.id); setShowActions(false); }}
           >
             <DownloadOutlinedIcon fontSize="small" />
             <span>{t('download', 'Download')}</span>
diff --git a/frontend/src/constants/app.ts b/frontend/src/constants/app.ts
index 0abebc54b..3b8b765df 100644
--- a/frontend/src/constants/app.ts
+++ b/frontend/src/constants/app.ts
@@ -3,5 +3,5 @@ import { useAppConfig } from '../hooks/useAppConfig';
 // Get base URL from app config with fallback
 export const getBaseUrl = (): string => {
   const { config } = useAppConfig();
-  return config?.baseUrl || 'https://demo.stirlingpdf.com';
-};
\ No newline at end of file
+  return config?.baseUrl || 'https://stirling.com';
+};
diff --git a/frontend/src/hooks/tools/merge/useMergeOperation.test.ts b/frontend/src/hooks/tools/merge/useMergeOperation.test.ts
index f811febcf..4d41c5162 100644
--- a/frontend/src/hooks/tools/merge/useMergeOperation.test.ts
+++ b/frontend/src/hooks/tools/merge/useMergeOperation.test.ts
@@ -81,24 +81,6 @@ describe('useMergeOperation', () => {
     expect(formData.get('generateToc')).toBe('false');
   });
 
-  test('should handle response correctly', () => {
-    renderHook(() => useMergeOperation());
-
-    const config = getToolConfig();
-    const mockBlob = new Blob(['merged content'], { type: 'application/pdf' });
-    const mockFiles = [
-      new File(['content1'], 'file1.pdf', { type: 'application/pdf' }),
-      new File(['content2'], 'file2.pdf', { type: 'application/pdf' })
-    ];
-
-    const result = config.responseHandler!(mockBlob, mockFiles) as File[];
-
-    expect(result).toHaveLength(1);
-    expect(result[0].name).toBe('merged_file1.pdf');
-    expect(result[0].type).toBe('application/pdf');
-    expect(result[0].size).toBe(mockBlob.size);
-  });
-
   test('should return the hook result from useToolOperation', () => {
     const { result } = renderHook(() => useMergeOperation());
 
diff --git a/frontend/src/hooks/tools/merge/useMergeOperation.ts b/frontend/src/hooks/tools/merge/useMergeOperation.ts
index a356be443..ea630ea0d 100644
--- a/frontend/src/hooks/tools/merge/useMergeOperation.ts
+++ b/frontend/src/hooks/tools/merge/useMergeOperation.ts
@@ -1,5 +1,5 @@
 import { useTranslation } from 'react-i18next';
-import { useToolOperation, ResponseHandler, ToolOperationConfig, ToolType } from '../shared/useToolOperation';
+import { useToolOperation, ToolOperationConfig, ToolType } from '../shared/useToolOperation';
 import { createStandardErrorHandler } from '../../../utils/toolErrorHandler';
 import { MergeParameters } from './useMergeParameters';
 
@@ -16,11 +16,6 @@ const buildFormData = (parameters: MergeParameters, files: File[]): FormData =>
   return formData;
 };
 
-const mergeResponseHandler: ResponseHandler = (blob: Blob, originalFiles: File[]): File[] => {
-  const filename = `merged_${originalFiles[0].name}`
-  return [new File([blob], filename, { type: 'application/pdf' })];
-};
-
 // Operation configuration for automation
 export const mergeOperationConfig: ToolOperationConfig<MergeParameters> = {
   toolType: ToolType.multiFile,
@@ -28,7 +23,6 @@ export const mergeOperationConfig: ToolOperationConfig<MergeParameters> = {
   operationType: 'merge',
   endpoint: '/api/v1/general/merge-pdfs',
   filePrefix: 'merged_',
-  responseHandler: mergeResponseHandler,
 };
 
 export const useMergeOperation = () => {
diff --git a/frontend/src/hooks/tools/shared/useToolOperation.ts b/frontend/src/hooks/tools/shared/useToolOperation.ts
index b50d1c175..0b7ba75b6 100644
--- a/frontend/src/hooks/tools/shared/useToolOperation.ts
+++ b/frontend/src/hooks/tools/shared/useToolOperation.ts
@@ -31,7 +31,10 @@ interface BaseToolOperationConfig<TParams> {
   /** Operation identifier for tracking and logging */
   operationType: string;
 
-  /** Prefix added to processed filenames (e.g., 'compressed_', 'split_') */
+  /**
+   * Prefix added to processed filenames (e.g., 'compressed_', 'split_').
+   * Only generally useful for multiFile interfaces.
+   */
   filePrefix?: string;
 
   /**
@@ -68,6 +71,9 @@ export interface MultiFileToolOperationConfig<TParams> extends BaseToolOperation
   /** This tool processes multiple files at once. */
   toolType: ToolType.multiFile;
 
+  /** Prefix added to processed filename (e.g., 'merged_', 'split_') */
+  filePrefix: string;
+
   /** Builds FormData for API request. */
   buildFormData: ((params: TParams, files: File[]) => FormData);
 
@@ -214,9 +220,9 @@ export const useToolOperation = <TParams>(
             processedFiles = await config.responseHandler(response.data, filesForAPI);
           } else if (response.data.type === 'application/pdf' ||
                     (response.headers && response.headers['content-type'] === 'application/pdf')) {
-            // Single PDF response (e.g. split with merge option) - use original filename
-            const originalFileName = filesForAPI[0]?.name || 'document.pdf';
-            const singleFile = new File([response.data], originalFileName, { type: 'application/pdf' });
+            // Single PDF response (e.g. split with merge option) - add prefix to first original filename
+            const filename = `${config.filePrefix}${filesForAPI[0]?.name || 'document.pdf'}`;
+            const singleFile = new File([response.data], filename, { type: 'application/pdf' });
             processedFiles = [singleFile];
           } else {
             // Default: assume ZIP response for multi-file endpoints