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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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// fallow-ignore-file code-duplication
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import { resolve } from "node:path";
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import { afterEach, describe, expect, it } from "vitest";
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import {
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assertConfiguredFfmpegBinariesExist,
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getFfmpegBinary,
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getFfprobeBinary,
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} from "./ffmpegBinaries.js";
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describe("ffmpeg binary env resolution", () => {
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const originalFfmpegPath = process.env.HYPERFRAMES_FFMPEG_PATH;
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const originalFfprobePath = process.env.HYPERFRAMES_FFPROBE_PATH;
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afterEach(() => {
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if (originalFfmpegPath === undefined) delete process.env.HYPERFRAMES_FFMPEG_PATH;
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else process.env.HYPERFRAMES_FFMPEG_PATH = originalFfmpegPath;
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if (originalFfprobePath === undefined) delete process.env.HYPERFRAMES_FFPROBE_PATH;
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else process.env.HYPERFRAMES_FFPROBE_PATH = originalFfprobePath;
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});
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it("uses configured absolute paths when env vars are set", () => {
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process.env.HYPERFRAMES_FFMPEG_PATH = "/tools/ffmpeg.exe";
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process.env.HYPERFRAMES_FFPROBE_PATH = "/tools/ffprobe.exe";
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expect(getFfmpegBinary()).toBe(resolve("/tools/ffmpeg.exe"));
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expect(getFfprobeBinary()).toBe(resolve("/tools/ffprobe.exe"));
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});
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it("throws a clear error when a configured FFmpeg path is missing", () => {
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process.env.HYPERFRAMES_FFMPEG_PATH = "/missing/ffmpeg.exe";
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expect(() => assertConfiguredFfmpegBinariesExist()).toThrow(
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/FFmpeg binary not found at HYPERFRAMES_FFMPEG_PATH/,
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);
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});
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it("accepts existing configured paths", () => {
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process.env.HYPERFRAMES_FFMPEG_PATH = process.execPath;
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process.env.HYPERFRAMES_FFPROBE_PATH = process.execPath;
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expect(() => assertConfiguredFfmpegBinariesExist()).not.toThrow();
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});
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});
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