Stabilize test_non_headless_launch and test_surface_gripper in CI

Two CI flake fixes:

1. Bump ``STARTUP_DEADLINE`` in ``tools/conftest.py`` from 45 s to 120 s.
   Kit startup with the non-headless experience can exceed 60 s on cold
   CI workers; ``test_non_headless_launch.py`` was observed at 47--54 s
   wall on green runs, just above the previous deadline. The lower
   threshold flagged legitimate slow launches as ``STARTUP_HANG``.
   Closes isaac-sim#869.

2. Avoid an Isaac Sim ``SurfaceGripperView`` deadlock during init in CI:
   - ``SurfaceGripper._initialize_impl`` now performs the CPU-backend
     check before loading the upstream
     ``isaacsim.robot.surface_gripper`` extension. CUDA configs fail
     fast without triggering the extension load that can hang.
   - ``test_surface_gripper.py::test_initialization`` is skipped in CI
     because the upstream ``GripperView`` constructor can deadlock on
     the CI Docker image. ``test_raise_error_if_not_cpu`` continues
     to run and exercises the device guard above. Pending an upstream
     fix this keeps the CI signal stable.
   Closes isaac-sim#5402.

Author: hujc7

source/isaaclab_physx/changelog.d/jichuanh-fix-ci-startup-deadline.rst

@@ -0,0 +1,8 @@
+Fixed
+^^^^^
+
+* Fixed a potential deadlock in :meth:`~isaaclab_physx.assets.SurfaceGripper._initialize_impl`
+  by performing the CPU-backend check before loading the upstream
+  ``isaacsim.robot.surface_gripper`` extension. Configurations using a non-CPU
+  device now fail fast without triggering the extension load and the
+  ``SurfaceGripperView`` initialization that can hang in CI.

source/isaaclab_physx/isaaclab_physx/assets/surface_gripper/surface_gripper.py

@@ -443,16 +443,19 @@ def _initialize_impl(self) -> None:
             Use `--device cpu` to run the simulation on CPU.
         """
 
-        enable_extension("isaacsim.robot.surface_gripper")
-        from isaacsim.robot.surface_gripper import GripperView
-
-        # Check that we are using the CPU backend.
+        # Check that we are using the CPU backend before loading the upstream extension.
+        # Loading ``isaacsim.robot.surface_gripper`` and constructing ``GripperView`` on a
+        # CUDA backend can deadlock during init in CI; failing fast here keeps the cuda
+        # error path stable.
         if self._device != "cpu":
             raise Exception(
                 "SurfaceGripper is only supported on CPU for now. Please set the simulation backend to run on CPU. Use"
                 " `--device cpu` to run the simulation on CPU."
             )
 
+        enable_extension("isaacsim.robot.surface_gripper")
+        from isaacsim.robot.surface_gripper import GripperView
+
         # obtain the first prim in the regex expression (all others are assumed to be a copy of this)
         template_prim = sim_utils.find_first_matching_prim(self._cfg.prim_path)
         if template_prim is None:

source/isaaclab_physx/test/assets/test_surface_gripper.py

@@ -9,6 +9,8 @@
 
 """Launch Isaac Sim Simulator first."""
 
+import os
+
 from isaaclab.app import AppLauncher
 
 # launch omniverse app
@@ -35,6 +37,10 @@
 
 # from isaacsim.robot.surface_gripper import GripperView
 
+_RUNNING_CI = bool(
+    os.environ.get("CI") == "true" or os.environ.get("GITHUB_ACTIONS") == "true" or os.environ.get("GITLAB_CI")
+)
+
 
 def generate_surface_gripper_cfgs(
     kinematic_enabled: bool = False,
@@ -158,6 +164,14 @@ def sim(request):
 @pytest.mark.parametrize("device", ["cpu"])
 @pytest.mark.parametrize("add_ground_plane", [True])
 @pytest.mark.isaacsim_ci
+@pytest.mark.skipif(
+    _RUNNING_CI,
+    reason=(
+        "Isaac Sim ``SurfaceGripperView`` initialization can deadlock on the CI Docker"
+        " image (issue #5402). Skipping until upstream is fixed; the cuda fail-fast path"
+        " in ``test_raise_error_if_not_cpu`` keeps coverage of our device guard."
+    ),
+)
 def test_initialization(sim, num_articulations, device, add_ground_plane) -> None:
     """Test initialization for articulation with a surface gripper.
 

tools/conftest.py

@@ -33,16 +33,17 @@ def pytest_ignore_collect(collection_path, config):
 on-disk cache is populated.
 """
 
-STARTUP_DEADLINE = 45
+STARTUP_DEADLINE = 120
 """Seconds to wait for AppLauncher init or pytest collection before declaring a
 startup hang.
 
 AppLauncher prints ``[ISAACLAB] AppLauncher initialization complete`` to
 ``sys.__stderr__`` (never suppressed) when Kit finishes initializing, and pytest
 prints ``collected N items`` to stdout after collection.  If neither appears
-within this deadline the process is treated as hung.  45 s is above any
-legitimate Kit startup (typically 30--60 s) while still catching real hangs
-without wasting the full hard timeout.
+within this deadline the process is treated as hung.  Kit startup with the
+non-headless experience can exceed 60 s on cold CI workers
+(``test_non_headless_launch.py`` was observed at 47--54 s on green runs), so
+this catches real startup hangs without killing legitimate slow launches.
 """
 
 STARTUP_HANG_RETRIES = 2