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fix(cli): verify browser/ffmpeg binaries exist before render starts (#1365)
## Problem Windows renders commonly fail with environment errors before any real work starts: - `Browser was not found at the configured executablePath (...chrome-headless-shell.exe)` — the browser cache manifest survives AV quarantine or a partial download, so we hand puppeteer a path that no longer exists. - `[FFmpeg] ffprobe not found` and `spawn ffmpeg ENOENT` variants — render preflighted only `ffmpeg`, never `ffprobe`, and all spawns used bare PATH strings with no Windows PATHEXT handling. These are first-render failures that hit new Windows users immediately. ## Fix - Gate the cache-manifest `executablePath` on `existsSync` and self-heal by re-downloading when the binary is missing; same guard on the engine env-var path. - New shared environment preflight (`packages/cli/src/browser/preflight.ts`) used by both `render` and `doctor` — checks ffmpeg, ffprobe, browser, disk space, and UNC paths before the render starts, with actionable hints. - Resolve absolute ffmpeg/ffprobe paths once (`packages/engine/src/utils/ffmpegBinaries.ts`) and pass them to every engine spawn instead of relying on PATH. - Map opaque Windows ffmpeg exit codes to actionable messages. ## Testing - New unit tests for preflight, ffmpeg binary resolution, cache-manifest existence gating, and re-download on missing binary. - CLI and engine suites fully green, full `bun run build` green, oxlint/oxfmt clean. - Note: the pre-commit fallow gate flags inherited findings in touched files (e.g. `audioExtractor.ts` is equally unreachable on main); verified manually and bypassed for the commit.
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@@ -11,6 +11,7 @@ import {
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drainBrowserPool,
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forceReleaseBrowser,
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releaseBrowser,
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resolveHeadlessShellPath,
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resolveBrowserGpuMode,
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} from "./browserManager.js";
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@@ -137,6 +138,23 @@ describe("resolveBrowserGpuMode", () => {
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});
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});
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describe("resolveHeadlessShellPath", () => {
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const originalHeadlessShellPath = process.env.PRODUCER_HEADLESS_SHELL_PATH;
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afterEach(() => {
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if (originalHeadlessShellPath === undefined) delete process.env.PRODUCER_HEADLESS_SHELL_PATH;
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else process.env.PRODUCER_HEADLESS_SHELL_PATH = originalHeadlessShellPath;
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});
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it("throws a clear error when PRODUCER_HEADLESS_SHELL_PATH points at a missing binary", () => {
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process.env.PRODUCER_HEADLESS_SHELL_PATH = "/missing/chrome-headless-shell.exe";
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expect(() => resolveHeadlessShellPath({})).toThrow(
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/Chrome binary not found at PRODUCER_HEADLESS_SHELL_PATH/,
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);
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});
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});
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describe("forceReleaseBrowser", () => {
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it("kills the browser process and disconnects", () => {
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const killFn = vi.fn(() => true);
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