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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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@@ -1,3 +1,4 @@
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// fallow-ignore-file code-duplication complexity
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/**
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* Chunk Encoder Service
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*
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@@ -18,6 +19,7 @@ import {
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} from "../utils/gpuEncoder.js";
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import { type HdrTransfer, getHdrEncoderColorParams } from "../utils/hdr.js";
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import { formatFfmpegError, runFfmpeg } from "../utils/runFfmpeg.js";
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import { getFfmpegBinary } from "../utils/ffmpegBinaries.js";
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import { type Fps, fpsToFfmpegArg } from "@hyperframes/core";
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import type { EncoderOptions, EncodeResult, MuxResult } from "./chunkEncoder.types.js";
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@@ -411,7 +413,7 @@ export async function encodeFramesFromDir(
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const args = buildEncoderArgs(options, inputArgs, outputPath, gpuEncoder);
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return new Promise((resolve) => {
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const ffmpeg = spawn("ffmpeg", args);
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const ffmpeg = spawn(getFfmpegBinary(), args);
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trackChildProcess(ffmpeg);
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let stderr = "";
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const onAbort = () => {
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@@ -543,7 +545,7 @@ export async function encodeFramesChunkedConcat(
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if (options.useGpu) gpuEncoder = await getCachedGpuEncoder();
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const args = buildEncoderArgs(options, inputArgs, chunkPath, gpuEncoder);
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const chunkResult = await new Promise<{ success: boolean; error?: string }>((resolve) => {
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const ffmpeg = spawn("ffmpeg", args);
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const ffmpeg = spawn(getFfmpegBinary(), args);
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trackChildProcess(ffmpeg);
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let stderr = "";
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ffmpeg.stderr.on("data", (d) => {
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@@ -587,7 +589,7 @@ export async function encodeFramesChunkedConcat(
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outputPath,
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];
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const concatResult = await new Promise<{ success: boolean; error?: string }>((resolve) => {
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const ffmpeg = spawn("ffmpeg", concatArgs);
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const ffmpeg = spawn(getFfmpegBinary(), concatArgs);
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trackChildProcess(ffmpeg);
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let stderr = "";
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ffmpeg.stderr.on("data", (d) => {
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