fix(hyperframes-media): npx spawn without shell:true fails silently on Windows (#1845)

* fix(hyperframes-media): npx spawn without shell:true fails silently on Windows

Two independent user reports of Kokoro TTS silently failing on Windows,
both naming the same site: lib/tts.mjs synthesizeOne() spawns "npx" via
plain spawn(cmd, args). On Windows npx resolves to npx.cmd, which Node's
spawn() cannot exec without shell:true — it fails ENOENT, and spawnP's
"error" listener turns that into a plain ok:false ("TTS failed") with no
indication of the real cause.

Scope the fix to the npx call specifically (python3/ffmpeg are real
binaries and don't need it), with the platform/spawn function injectable
so the win32 branch is testable without mocking node:child_process (its
ESM exports are non-configurable, so mock.method can't patch it) or the
real process.platform.

* fix(hyperframes-media): avoid shell true for windows npx

skills-manifest.json

@@ -38,8 +38,8 @@
       "files": 3
     },
     "hyperframes-media": {
-      "hash": "cefef0080fc780df",
+      "hash": "eb72d0765185b36d",
-      "files": 43
+      "files": 44
     },
     "hyperframes-registry": {
       "hash": "e3b389526834109d",

skills/hyperframes-media/scripts/lib/tts.mjs

@@ -25,7 +25,9 @@ export function heygenAvailable() {
 }
 export function elevenlabsAvailable() {
   if (!process.env.ELEVENLABS_API_KEY) return false;
-  const r = spawnSync("python3", ["-c", "import elevenlabs"], { stdio: "ignore" });
+  const r = spawnSync("python3", ["-c", "import elevenlabs"], {
+    stdio: "ignore",
+  });
   return r.status === 0;
 }
 
@@ -72,7 +74,12 @@ export async function resolveVoiceId({ provider, userVoice, lang = "en" }) {
 
 // ── helpers ─────────────────────────────────────────────────────────────────
 export function withWordIds(words) {
-  return (words ?? []).map((w, i) => ({ id: `w${i}`, text: w.text, start: w.start, end: w.end }));
+  return (words ?? []).map((w, i) => ({
+    id: `w${i}`,
+    text: w.text,
+    start: w.start,
+    end: w.end,
+  }));
 }
 
 // `ffmpeg -i <file>` prints a `Duration: HH:MM:SS.ms` line to stderr even
@@ -108,9 +115,57 @@ export function ffprobeDuration(absPath) {
   return parseFloat(String(r.stdout).trim());
 }
 
-function spawnP(cmd, args, opts) {
+export function resolveNpxCliFromNpmExecPath(
+  npmExecPath = process.env.npm_execpath,
+  pathExists = existsSync,
+) {
+  if (!npmExecPath) return null;
+  const fileName = npmExecPath.replace(/\\/g, "/").split("/").pop()?.toLowerCase();
+  const npxCliPath =
+    fileName === "npx-cli.js" ? npmExecPath : join(dirname(npmExecPath), "npx-cli.js");
+  return pathExists(npxCliPath) ? npxCliPath : null;
+}
+
+export function resolveSpawnCommand(
+  cmd,
+  args,
+  opts = {},
+  platform = process.platform,
+  env = process.env,
+  pathExists = existsSync,
+) {
+  if (cmd !== "npx" || platform !== "win32") {
+    return { cmd, args, opts: { stdio: "ignore", ...opts } };
+  }
+
+  // On Windows, npx resolves to npx.cmd, which Node cannot execute directly.
+  // Avoid `shell:true` and the .cmd shim entirely by invoking npm's JS CLI with
+  // node, preserving request-provided values as argv data instead of shell text.
+  const npxCliPath = resolveNpxCliFromNpmExecPath(env.npm_execpath, pathExists);
+  if (!npxCliPath) return null;
+  return {
+    cmd: env.npm_node_execpath || process.execPath,
+    args: [npxCliPath, ...args.map((arg) => String(arg))],
+    opts: { stdio: "ignore", windowsHide: true, ...opts },
+  };
+}
+
+// `platform`/`spawnFn` params (default process.platform / the real spawn)
+// exist so tests can exercise the win32 branch without mocking node:child_process
+// (its ESM exports are non-configurable, so mock.method can't patch it).
+export function spawnP(
+  cmd,
+  args,
+  opts = {},
+  platform = process.platform,
+  spawnFn = spawn,
+  env = process.env,
+  pathExists = existsSync,
+) {
+  const resolved = resolveSpawnCommand(cmd, args, opts, platform, env, pathExists);
+  if (!resolved) return Promise.resolve({ status: -1 });
   return new Promise((resolve) => {
-    const p = spawn(cmd, args, { stdio: "ignore", ...opts });
+    const p = spawnFn(resolved.cmd, resolved.args, resolved.opts);
     p.on("exit", (code) => resolve({ status: code ?? -1 }));
     p.on("error", () => resolve({ status: -1 }));
   });

skills/hyperframes-media/scripts/lib/tts.spawn.test.mjs

@@ -0,0 +1,97 @@
+import { test } from "node:test";
+import assert from "node:assert/strict";
+import { EventEmitter } from "node:events";
+import { resolveNpxCliFromNpmExecPath, resolveSpawnCommand, spawnP } from "./tts.mjs";
+
+// Regression: on Windows, npx resolves to npx.cmd, which spawn() cannot exec
+// without shell:true — it fails ENOENT, silently swallowed as ok:false by the
+// caller. spawnP takes injectable platform/spawnFn params so this doesn't
+// need to touch the real process.platform or mock node:child_process (whose
+// ESM exports are non-configurable).
+function fakeSpawn(captured) {
+  return (cmd, args, opts) => {
+    captured.push({ cmd, args, opts });
+    const p = new EventEmitter();
+    setImmediate(() => p.emit("exit", 0));
+    return p;
+  };
+}
+
+const envWithNpxCli = {
+  npm_execpath: "/opt/node/lib/node_modules/npm/bin/npm-cli.js",
+  npm_node_execpath: "/opt/node/bin/node",
+};
+const npxCliPath = "/opt/node/lib/node_modules/npm/bin/npx-cli.js";
+const pathExists = (path) => path === npxCliPath;
+
+test("resolveNpxCliFromNpmExecPath finds npx-cli next to npm-cli", () => {
+  assert.equal(resolveNpxCliFromNpmExecPath(envWithNpxCli.npm_execpath, pathExists), npxCliPath);
+});
+
+test("resolveSpawnCommand routes npx through node+npx-cli on win32 without shell:true", () => {
+  const resolved = resolveSpawnCommand(
+    "npx",
+    ["hyperframes", "tts", "C:\\Users\\Test User\\line.txt", "--voice", "am_michael"],
+    {},
+    "win32",
+    envWithNpxCli,
+    pathExists,
+  );
+  assert.ok(resolved);
+  assert.equal(resolved.cmd, envWithNpxCli.npm_node_execpath);
+  assert.deepEqual(resolved.args, [
+    npxCliPath,
+    "hyperframes",
+    "tts",
+    "C:\\Users\\Test User\\line.txt",
+    "--voice",
+    "am_michael",
+  ]);
+  assert.equal(resolved.opts.shell, undefined);
+});
+
+test("resolveSpawnCommand preserves Windows npx shell metacharacters as argv data", () => {
+  const resolved = resolveSpawnCommand(
+    "npx",
+    ["hyperframes", "tts", "hello & calc"],
+    {},
+    "win32",
+    envWithNpxCli,
+    pathExists,
+  );
+  assert.ok(resolved);
+  assert.deepEqual(resolved.args, [npxCliPath, "hyperframes", "tts", "hello & calc"]);
+});
+
+test("spawnP uses the resolved node+npx-cli command for npx on win32", async () => {
+  const captured = [];
+  await spawnP(
+    "npx",
+    ["hyperframes", "tts"],
+    {},
+    "win32",
+    fakeSpawn(captured),
+    envWithNpxCli,
+    pathExists,
+  );
+  assert.equal(captured.length, 1);
+  assert.equal(captured[0].cmd, envWithNpxCli.npm_node_execpath);
+  assert.deepEqual(captured[0].args, [npxCliPath, "hyperframes", "tts"]);
+  assert.equal(captured[0].opts.shell, undefined);
+});
+
+test("spawnP does not enable shell for npx on darwin/linux", async () => {
+  const captured = [];
+  await spawnP("npx", ["hyperframes", "tts"], {}, "darwin", fakeSpawn(captured));
+  assert.equal(captured[0].cmd, "npx");
+  assert.deepEqual(captured[0].args, ["hyperframes", "tts"]);
+  assert.equal(captured[0].opts.shell, undefined);
+});
+
+test("spawnP does not enable shell for non-npx commands even on win32", async () => {
+  const captured = [];
+  await spawnP("python3", ["-c", "pass"], {}, "win32", fakeSpawn(captured));
+  assert.equal(captured[0].cmd, "python3");
+  assert.deepEqual(captured[0].args, ["-c", "pass"]);
+  assert.equal(captured[0].opts.shell, undefined);
+});