fix(cli): prevent esbuild runtime error in global/npx installs (#452)

* fix(cli): resolve runtime fallback for globally-installed hyperframes

When hyperframes is installed globally via npm, the `loadRuntimeSourceFallback()`
path that dynamically imports @hyperframes/core and runs esbuild fails because
@hyperframes/core is inlined into cli.js and import.meta.url resolves to the
wrong location for the entry.ts source file.

Add a disk-based fallback that searches for the pre-built IIFE runtime artifact
in multiple locations:
- Alongside the bundled CLI (dist/hyperframe-runtime.js, dist/hyperframe.runtime.iife.js)
- Walking up from __dirname through node_modules

The esbuild path is tried first to preserve live-rebuild behavior in dev,
with the pre-built artifact search as a safety net for the bundled context.

Also adds the IIFE artifact name variant to resolveRuntimePath() in the
studio server so it checks both naming conventions.

* fix(cli): gate esbuild fallback on source availability

The previous fix still triggered esbuild's stderr output before the
catch could suppress it. Now check whether the runtime entry.ts source
file actually exists before attempting the on-the-fly build, avoiding
the noisy error in global installs entirely.

* fix(cli): remove noisy console.warn from runtime fallback

The caller already handles a null return — no need to warn about
something the user can't act on. If both paths fail, the /api/runtime.js
route returns a 404 which the studio handles gracefully.

* style(engine): fix oxfmt trailing blank line in chunkEncoder test

* fix(cli): guard against null/undefined from loadHyperframeRuntimeSource

Fall through to the pre-built artifact if the function returns a
falsy value without throwing.

* refactor(cli): consolidate runtime source resolution into single module

Replace the scattered path-probing logic with a single loadRuntimeSource()
that encodes the full priority chain: esbuild from source (dev only,
gated on entry.ts existence) → pre-built artifact alongside cli.js →
core/dist artifact → node_modules walk.

Rename loadRuntimeSourceFallback → loadRuntimeSource since it's now
the primary resolution function, not a fallback.

Author: miguel-heygen

packages/cli/src/server/runtimeSource.ts

@@ -1,11 +1,77 @@
-export async function loadRuntimeSourceFallback(): Promise<string | null> {
+import { existsSync, readFileSync } from "node:fs";
+import { resolve, dirname } from "node:path";
+
+const ARTIFACT_NAMES = ["hyperframe-runtime.js", "hyperframe.runtime.iife.js"];
+
+/**
+ * Resolve the runtime JS source for the studio preview server.
+ *
+ * Two contexts exist:
+ *
+ *   Dev (monorepo workspace) — `entry.ts` exists next to `@hyperframes/core`
+ *   source. We build from source via esbuild so edits to the runtime are
+ *   reflected without a manual `bun run build`.
+ *
+ *   Installed (npm global / npx) — only `dist/` ships. We read the pre-built
+ *   IIFE artifact that `build:runtime` copies alongside `cli.js`.
+ *
+ * The priority chain:
+ *   1. esbuild from source  (dev only — gated on entry.ts existence)
+ *   2. pre-built artifact    (alongside cli.js in dist/)
+ *   3. core/dist artifact    (dev fallback if build:runtime already ran)
+ *   4. node_modules walk     (nested install edge cases)
+ */
+export async function loadRuntimeSource(): Promise<string | null> {
+  return (await buildFromSource()) ?? readPrebuiltArtifact();
+}
+
+// ── Strategy 1: live build from source (dev only) ──────────────────────────
+
+const ENTRY_TS = resolve(__dirname, "..", "..", "..", "core", "src", "runtime", "entry.ts");
+
+async function buildFromSource(): Promise<string | null> {
+  if (!existsSync(ENTRY_TS)) return null;
   try {
     const mod = await import("@hyperframes/core");
     if (typeof mod.loadHyperframeRuntimeSource === "function") {
-      return mod.loadHyperframeRuntimeSource();
+      const source = mod.loadHyperframeRuntimeSource();
+      if (source) return source;
+    }
+  } catch {
+    // esbuild failed — fall through to artifact
+  }
+  return null;
+}
+
+// ── Strategy 2-4: pre-built IIFE artifact ──────────────────────────────────
+
+function readPrebuiltArtifact(): string | null {
+  return readFromDir(__dirname) ?? readFromCoreDistDir() ?? readFromNodeModules();
+}
+
+function readFromDir(dir: string): string | null {
+  for (const name of ARTIFACT_NAMES) {
+    const path = resolve(dir, name);
+    if (existsSync(path)) return readFileSync(path, "utf-8");
+  }
+  return null;
+}
+
+function readFromCoreDistDir(): string | null {
+  return readFromDir(resolve(__dirname, "..", "..", "..", "core", "dist"));
+}
+
+function readFromNodeModules(): string | null {
+  const subPaths = ["node_modules/hyperframes/dist", "node_modules/@hyperframes/core/dist"];
+  let dir = __dirname;
+  for (;;) {
+    for (const sub of subPaths) {
+      const result = readFromDir(resolve(dir, sub));
+      if (result) return result;
     }
-  } catch (err) {
-    console.warn("[studio] Failed to load runtime source fallback:", err);
+    const parent = dirname(dir);
+    if (parent === dir) break;
+    dir = parent;
   }
   return null;
 }

packages/cli/src/server/studioServer.test.ts

@@ -1,9 +1,9 @@
 import { describe, expect, it } from "vitest";
 import { loadHyperframeRuntimeSource } from "@hyperframes/core";
-import { loadRuntimeSourceFallback } from "./runtimeSource.js";
+import { loadRuntimeSource } from "./runtimeSource.js";
 
-describe("loadRuntimeSourceFallback", () => {
+describe("loadRuntimeSource", () => {
   it("loads runtime source from the published core entrypoint", async () => {
-    await expect(loadRuntimeSourceFallback()).resolves.toBe(loadHyperframeRuntimeSource());
+    await expect(loadRuntimeSource()).resolves.toBe(loadHyperframeRuntimeSource());
   });
 });

packages/cli/src/server/studioServer.ts

@@ -10,7 +10,7 @@ import { streamSSE } from "hono/streaming";
 import { existsSync, readFileSync, writeFileSync, statSync } from "node:fs";
 import { resolve, join, basename } from "node:path";
 import { createProjectWatcher, type ProjectWatcher } from "./fileWatcher.js";
-import { loadRuntimeSourceFallback } from "./runtimeSource.js";
+import { loadRuntimeSource } from "./runtimeSource.js";
 import { VERSION as version } from "../version.js";
 import {
   createStudioApi,
@@ -33,6 +33,8 @@ function resolveDistDir(): string {
 function resolveRuntimePath(): string {
   const builtPath = resolve(__dirname, "hyperframe-runtime.js");
   if (existsSync(builtPath)) return builtPath;
+  const iifePath = resolve(__dirname, "hyperframe.runtime.iife.js");
+  if (existsSync(iifePath)) return iifePath;
   const devPath = resolve(
     __dirname,
     "..",
@@ -282,12 +284,8 @@ export function createStudioServer(options: StudioServerOptions): StudioServer {
   // CLI-specific routes (before shared API)
   app.get("/api/runtime.js", (c) => {
     const serve = async () => {
-      // Prefer the runtime generated from the current core source over a
-      // potentially stale copied artifact. This keeps local studio/preview
-      // sessions aligned with source edits without requiring a manual
-      // rebuild of the CLI runtime bundle first.
       const runtimeSource =
-        (await loadRuntimeSourceFallback()) ??
+        (await loadRuntimeSource()) ??
         (existsSync(runtimePath) ? readFileSync(runtimePath, "utf-8") : null);
       if (!runtimeSource) return c.text("runtime not available", 404);
       return c.body(runtimeSource, 200, {

packages/engine/src/services/chunkEncoder.test.ts

@@ -460,7 +460,6 @@ describe("buildEncoderArgs HDR color space", () => {
       expect.stringContaining("HDR is not supported with codec=h264"),
     );
     warnSpy.mockRestore();
-
   });
 
   it("uses range conversion for HDR CPU encoding", () => {