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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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/**
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* Shared FFmpeg process runner.
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*
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@@ -6,6 +7,7 @@
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*/
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import { spawn } from "child_process";
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import { getFfmpegBinary } from "./ffmpegBinaries.js";
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import { trackChildProcess } from "./processTracker.js";
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export interface RunFfmpegOptions {
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@@ -25,6 +27,23 @@ const DEFAULT_TIMEOUT = 300_000;
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const DEFAULT_STDERR_TAIL_LINES = 15;
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function formatWindowsFfmpegExit(exitCode: number | null): string | undefined {
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if (process.platform !== "win32" || exitCode === null) return undefined;
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if (exitCode === 3221225595 || exitCode === -1073741701) {
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return (
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"[FFmpeg] Windows could not start ffmpeg.exe (STATUS_INVALID_IMAGE_FORMAT). " +
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"The binary may be corrupted or the wrong architecture. Reinstall a 64-bit Windows FFmpeg build."
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);
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}
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if (exitCode === 3221225794 || exitCode === -1073741502) {
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return (
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"[FFmpeg] Windows failed while initializing ffmpeg.exe. " +
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"The binary may be corrupted, blocked, or missing runtime DLLs. Reinstall a 64-bit Windows FFmpeg build."
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);
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}
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return undefined;
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}
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/**
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* Build a user-facing error message for a failed ffmpeg invocation.
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*
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@@ -48,6 +67,10 @@ export function formatFfmpegError(
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if (exitCode === null) {
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return tail ? `[FFmpeg] ${tail}` : "[FFmpeg] process error";
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}
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const windowsMessage = formatWindowsFfmpegExit(exitCode);
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if (windowsMessage) {
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return tail ? `${windowsMessage}\nffmpeg stderr (tail):\n${tail}` : windowsMessage;
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}
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return tail
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? `FFmpeg exited with code ${exitCode}\nffmpeg stderr (tail):\n${tail}`
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: `FFmpeg exited with code ${exitCode}`;
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@@ -60,7 +83,7 @@ export async function runFfmpeg(args: string[], opts?: RunFfmpegOptions): Promis
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const onStderr = opts?.onStderr;
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return new Promise<RunFfmpegResult>((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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