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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
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import { EventEmitter } from "events";
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import { readFileSync } from "fs";
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import { resolve } from "path";
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@@ -164,9 +165,35 @@ function createSpawnSpy(outcomes: SpawnOutcome[]): {
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}
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describe("ffprobe missing-binary fallback", () => {
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const originalFfprobePath = process.env.HYPERFRAMES_FFPROBE_PATH;
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afterEach(() => {
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vi.resetModules();
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vi.doUnmock("child_process");
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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("spawns the configured absolute FFprobe path when HYPERFRAMES_FFPROBE_PATH is set", async () => {
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process.env.HYPERFRAMES_FFPROBE_PATH = "/tools/ffprobe.exe";
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const { spawn, calls } = createSpawnSpy([
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{
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kind: "exit",
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code: 0,
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stdout: JSON.stringify({
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streams: [{ codec_type: "audio", codec_name: "aac", sample_rate: "48000", channels: 2 }],
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format: { duration: "1.25", bit_rate: "128000" },
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}),
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},
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]);
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vi.resetModules();
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vi.doMock("child_process", () => ({ spawn }));
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const { extractAudioMetadata } = await import("./ffprobe.js");
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const meta = await extractAudioMetadata("/tmp/uses-configured-ffprobe.wav");
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expect(meta.durationSeconds).toBe(1.25);
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expect(calls[0]?.command).toBe(resolve("/tools/ffprobe.exe"));
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});
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it("extractMediaMetadata falls back to PNG cICP metadata when ffprobe is missing", async () => {
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