Pro-tip: don't have a name that is similar to one on the watch-list. I haven't been able to use e-passport gates in the past 8 years or so, they always "malfunction" and someone in uniform with firearms shows up for a manual check. And the "random" carry-on checks at the gate pick me 9 times out of 10. And when travelling to the US the TSA is always kind enough to repack and refold everything in the checked luggage and leave a handy flyer that can be used as a bookmark.[..]What does stand out: I never got picked out while travelling with the wife, and get picked out rather often while traveling solo while carrying a lot of gear (large camera bag+laptop bag).
But I haven't had a customs inspection since 2008, so maybe they use a different watch-list
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