@hyperframes/engine 0.6.55 → 0.6.57

package/dist/services/audioMixer.d.ts.map

@@ -1 +1 @@
-{"version":3,"file":"audioMixer.d.ts","sourceRoot":"","sources":["../../src/services/audioMixer.ts"],"names":[],"mappings":"AAAA;;;;GAIG;AAOH,OAAO,EAAkB,KAAK,YAAY,EAAE,MAAM,cAAc,CAAC;AAIjE,OAAO,KAAK,EAAE,YAAY,EAAc,SAAS,EAAE,MAAM,uBAAuB,CAAC;AAEjF,YAAY,EAAE,YAAY,EAAE,SAAS,EAAE,MAAM,uBAAuB,CAAC;AAqErE,wBAAgB,kBAAkB,CAAC,IAAI,EAAE,MAAM,GAAG,YAAY,EAAE,CAuD/D;AAgOD,wBAAsB,uBAAuB,CAC3C,QAAQ,EAAE,YAAY,EAAE,EACxB,OAAO,EAAE,MAAM,EACf,OAAO,EAAE,MAAM,EACf,UAAU,EAAE,MAAM,EAClB,aAAa,EAAE,MAAM,EACrB,MAAM,CAAC,EAAE,WAAW,EACpB,MAAM,CAAC,EAAE,OAAO,CAAC,IAAI,CAAC,YAAY,EAAE,sBAAsB,GAAG,WAAW,CAAC,CAAC,EAC1E,WAAW,CAAC,EAAE,MAAM,GACnB,OAAO,CAAC,SAAS,CAAC,CA6GpB"}
+{"version":3,"file":"audioMixer.d.ts","sourceRoot":"","sources":["../../src/services/audioMixer.ts"],"names":[],"mappings":"AAAA;;;;GAIG;AAOH,OAAO,EAAkB,KAAK,YAAY,EAAE,MAAM,cAAc,CAAC;AAIjE,OAAO,KAAK,EAAE,YAAY,EAAc,SAAS,EAAE,MAAM,uBAAuB,CAAC;AAGjF,YAAY,EAAE,YAAY,EAAE,SAAS,EAAE,MAAM,uBAAuB,CAAC;AAyJrE,wBAAgB,kBAAkB,CAAC,IAAI,EAAE,MAAM,GAAG,YAAY,EAAE,CAuD/D;AAmPD,wBAAsB,uBAAuB,CAC3C,QAAQ,EAAE,YAAY,EAAE,EACxB,OAAO,EAAE,MAAM,EACf,OAAO,EAAE,MAAM,EACf,UAAU,EAAE,MAAM,EAClB,aAAa,EAAE,MAAM,EACrB,MAAM,CAAC,EAAE,WAAW,EACpB,MAAM,CAAC,EAAE,OAAO,CAAC,IAAI,CAAC,YAAY,EAAE,sBAAsB,GAAG,WAAW,CAAC,CAAC,EAC1E,WAAW,CAAC,EAAE,MAAM,GACnB,OAAO,CAAC,SAAS,CAAC,CA2HpB"}

package/dist/services/audioMixer.js

@@ -12,6 +12,7 @@ import { DEFAULT_CONFIG } from "../config.js";
 import { runFfmpeg } from "../utils/runFfmpeg.js";
 import { unwrapTemplate } from "../utils/htmlTemplate.js";
 import { resolveProjectRelativeSrc } from "./videoFrameExtractor.js";
+import { applyVolumeEnvelopeToWav } from "./audioVolumeEnvelope.js";
 function clampVolume(volume) {
     if (!Number.isFinite(volume))
         return 1;
@@ -23,10 +24,83 @@ function formatFilterNumber(value) {
 function escapeExpressionCommas(expression) {
     return expression.replace(/\\/g, "\\\\").replace(/,/g, "\\,");
 }
-function buildVolumeExpression(track) {
+/**
+ * Upper bound on volume-automation keyframes folded into the FFmpeg `volume`
+ * expression. The expression nests one `if(lt(...))` per keyframe, and
+ * FFmpeg's expression evaluator has a finite nesting depth: past ~95 levels
+ * (build-dependent — lower on some Linux ffmpeg builds) `volume=...:eval=frame`
+ * fails filter-graph init, which fails the whole mix and drops the audio track
+ * entirely. The 60 Hz timeline probe routinely emits 100–300 keyframes for a
+ * multi-second fade (GH #1066 follow-up: a 171-keyframe GSAP fade rendered with
+ * no audio). 32 segments keeps a wide safety margin and is far more resolution
+ * than a piecewise-linear volume envelope needs.
+ */
+const MAX_VOLUME_SEGMENTS = 32;
+/**
+ * Volume delta below which a keyframe is collinear enough to drop. Kept tight
+ * (0.5% linear) so the rendered piecewise-linear envelope tracks the GSAP curve
+ * the browser plays in preview to within ~0.2 dB across the audible range — well
+ * under the ~1 dB loudness JND, so render stays WYSIWYG with preview. A full
+ * ease-in/ease-out fade still reduces to ~25 segments, inside MAX_VOLUME_SEGMENTS.
+ */
+const VOLUME_SIMPLIFY_EPSILON = 0.005;
+/**
+ * Reduce a sorted keyframe list to a perceptually-equivalent piecewise-linear
+ * envelope with a bounded segment count.
+ *
+ * Ramer–Douglas–Peucker drops control points lying within
+ * `VOLUME_SIMPLIFY_EPSILON` of the line through their neighbours (a linear fade
+ * collapses to its two endpoints; an eased fade to a handful). A uniform
+ * downsample backstop then bounds pathological inputs (e.g. audio-rate volume
+ * oscillation) to `MAX_VOLUME_SEGMENTS`. Endpoints are always preserved so the
+ * envelope still spans the full clip.
+ */
+function simplifyVolumeKeyframes(keyframes) {
+    if (keyframes.length < 3)
+        return keyframes;
+    const keep = new Array(keyframes.length).fill(false);
+    keep[0] = true;
+    keep[keyframes.length - 1] = true;
+    const stack = [[0, keyframes.length - 1]];
+    while (stack.length > 0) {
+        const [startIndex, endIndex] = stack.pop();
+        const start = keyframes[startIndex];
+        const end = keyframes[endIndex];
+        const span = end.time - start.time;
+        let maxDistance = VOLUME_SIMPLIFY_EPSILON;
+        let splitIndex = -1;
+        for (let i = startIndex + 1; i < endIndex; i += 1) {
+            const point = keyframes[i];
+            const interpolated = span === 0
+                ? start.volume
+                : start.volume + ((end.volume - start.volume) * (point.time - start.time)) / span;
+            const distance = Math.abs(point.volume - interpolated);
+            if (distance > maxDistance) {
+                maxDistance = distance;
+                splitIndex = i;
+            }
+        }
+        if (splitIndex !== -1) {
+            keep[splitIndex] = true;
+            stack.push([startIndex, splitIndex], [splitIndex, endIndex]);
+        }
+    }
+    const simplified = keyframes.filter((_, i) => keep[i]);
+    if (simplified.length <= MAX_VOLUME_SEGMENTS)
+        return simplified;
+    const step = (simplified.length - 1) / (MAX_VOLUME_SEGMENTS - 1);
+    const sampled = [];
+    for (let i = 0; i < MAX_VOLUME_SEGMENTS; i += 1) {
+        const point = simplified[Math.round(i * step)];
+        if (sampled.length === 0 || point.time > sampled.at(-1).time)
+            sampled.push(point);
+    }
+    return sampled;
+}
+function buildVolumeExpression(track, ignoreKeyframes = false) {
     const trimDuration = track.end - track.start;
     const staticVolume = clampVolume(track.volume);
-    const keyframes = (track.volumeKeyframes ?? [])
+    const keyframes = (ignoreKeyframes ? [] : (track.volumeKeyframes ?? []))
         .filter((keyframe) => Number.isFinite(keyframe.time) && Number.isFinite(keyframe.volume))
         .map((keyframe) => ({
         time: Math.max(0, Math.min(trimDuration, keyframe.time - track.start)),
@@ -48,13 +122,17 @@ function buildVolumeExpression(track) {
             deduped.push(keyframe);
         }
     }
-    if (deduped.length === 1) {
-        return `volume=${formatFilterNumber(deduped[0].volume)}`;
+    // Collapse the densely-sampled probe output to a bounded piecewise-linear
+    // envelope. Without this, the nested-if expression below grows one level per
+    // keyframe and overflows FFmpeg's expression evaluator (see MAX_VOLUME_SEGMENTS).
+    const simplified = simplifyVolumeKeyframes(deduped);
+    if (simplified.length === 1) {
+        return `volume=${formatFilterNumber(simplified[0].volume)}`;
     }
-    let expression = formatFilterNumber(deduped.at(-1).volume);
-    for (let i = deduped.length - 2; i >= 0; i -= 1) {
-        const current = deduped[i];
-        const next = deduped[i + 1];
+    let expression = formatFilterNumber(simplified.at(-1).volume);
+    for (let i = simplified.length - 2; i >= 0; i -= 1) {
+        const current = simplified[i];
+        const next = simplified[i + 1];
         const currentTime = formatFilterNumber(current.time);
         const nextTime = formatFilterNumber(next.time);
         const currentVolume = formatFilterNumber(current.volume);
@@ -240,36 +318,52 @@ async function mixAudioTracks(tracks, outputPath, totalDuration, signal, config)
     const outputDir = dirname(outputPath);
     if (!existsSync(outputDir))
         mkdirSync(outputDir, { recursive: true });
-    const inputs = [];
-    const filterParts = [];
-    tracks.forEach((track, i) => {
-        inputs.push("-i", track.srcPath);
-        const delayMs = Math.round(track.start * 1000);
-        const trimDuration = track.end - track.start;
-        const volumeFilter = buildVolumeExpression(track);
-        filterParts.push(`[${i}:a]atrim=0:${trimDuration},${volumeFilter},adelay=${delayMs}|${delayMs},apad=whole_dur=${totalDuration}[a${i}]`);
-    });
-    const mixInputs = tracks.map((_, i) => `[a${i}]`).join("");
-    const weights = tracks.map(() => "1").join(" ");
-    const mixFilter = `${mixInputs}amix=inputs=${tracks.length}:duration=longest:dropout_transition=0:normalize=0:weights='${weights}'[mixed]`;
-    const postMixGainFilter = `[mixed]volume=${masterOutputGain}[out]`;
-    const fullFilter = [...filterParts, mixFilter, postMixGainFilter].join(";");
-    const args = [
-        ...inputs,
-        "-filter_complex",
-        fullFilter,
-        "-map",
-        "[out]",
-        "-acodec",
-        "aac",
-        "-b:a",
-        "192k",
-        "-t",
-        String(totalDuration),
-        "-y",
-        outputPath,
-    ];
-    const result = await runFfmpeg(args, { signal, timeout: ffmpegProcessTimeout });
+    const buildArgs = (ignoreAutomation) => {
+        const inputs = [];
+        const filterParts = [];
+        tracks.forEach((track, i) => {
+            inputs.push("-i", track.srcPath);
+            const delayMs = Math.round(track.start * 1000);
+            const trimDuration = track.end - track.start;
+            const volumeFilter = buildVolumeExpression(track, ignoreAutomation);
+            filterParts.push(`[${i}:a]atrim=0:${trimDuration},${volumeFilter},adelay=${delayMs}|${delayMs},apad=whole_dur=${totalDuration}[a${i}]`);
+        });
+        const mixInputs = tracks.map((_, i) => `[a${i}]`).join("");
+        const weights = tracks.map(() => "1").join(" ");
+        const mixFilter = `${mixInputs}amix=inputs=${tracks.length}:duration=longest:dropout_transition=0:normalize=0:weights='${weights}'[mixed]`;
+        const postMixGainFilter = `[mixed]volume=${masterOutputGain}[out]`;
+        const fullFilter = [...filterParts, mixFilter, postMixGainFilter].join(";");
+        return [
+            ...inputs,
+            "-filter_complex",
+            fullFilter,
+            "-map",
+            "[out]",
+            "-acodec",
+            "aac",
+            "-b:a",
+            "192k",
+            "-t",
+            String(totalDuration),
+            "-y",
+            outputPath,
+        ];
+    };
+    let result = await runFfmpeg(buildArgs(false), { signal, timeout: ffmpegProcessTimeout });
+    // Defense in depth: volume automation is folded into an FFmpeg `volume`
+    // expression whose evaluator limits are build-dependent (see
+    // MAX_VOLUME_SEGMENTS). If that ever fails the mix, retry once without the
+    // automation so the track renders at its base volume rather than being
+    // dropped from the output entirely — a missing fade beats missing audio.
+    let degradedAutomation = false;
+    const hasAutomation = tracks.some((track) => (track.volumeKeyframes?.length ?? 0) > 0);
+    if (!result.success && !signal?.aborted && hasAutomation) {
+        const retry = await runFfmpeg(buildArgs(true), { signal, timeout: ffmpegProcessTimeout });
+        if (retry.success) {
+            result = retry;
+            degradedAutomation = true;
+        }
+    }
     if (signal?.aborted) {
         return {
             success: false,
@@ -293,6 +387,9 @@ async function mixAudioTracks(tracks, outputPath, totalDuration, signal, config)
         outputPath,
         durationMs: result.durationMs,
         tracksProcessed: tracks.length,
+        error: degradedAutomation
+            ? "Volume automation exceeded this ffmpeg build's expression limits; rendered at base volume"
+            : undefined,
     };
 }
 export async function processCompositionAudio(elements, baseDir, workDir, outputPath, totalDuration, signal, config, compiledDir) {
@@ -355,6 +452,14 @@ export async function processCompositionAudio(elements, baseDir, workDir, output
                 }
                 audioSrcPath = trimmedPath;
             }
+            // Primary volume-automation path: bake the envelope into the PCM samples
+            // (sample-accurate, no keyframe ceiling). If the WAV isn't the expected
+            // 16-bit PCM, fall back to the ffmpeg expression path by leaving the
+            // keyframes on the track for buildVolumeExpression to handle.
+            let bakedEnvelope = false;
+            if (element.volumeKeyframes && element.volumeKeyframes.length > 0) {
+                bakedEnvelope = applyVolumeEnvelopeToWav(audioSrcPath, element.volumeKeyframes, element.start, element.volume ?? 1.0);
+            }
             tracks.push({
                 id: element.id,
                 srcPath: audioSrcPath,
@@ -362,8 +467,9 @@ export async function processCompositionAudio(elements, baseDir, workDir, output
                 end: element.end,
                 mediaStart: element.mediaStart,
                 duration: element.end - element.start,
-                volume: element.volume ?? 1.0,
-                volumeKeyframes: element.volumeKeyframes,
+                // Gain is already in the samples when baked, so mix at unity.
+                volume: bakedEnvelope ? 1.0 : (element.volume ?? 1.0),
+                volumeKeyframes: bakedEnvelope ? undefined : element.volumeKeyframes,
             });
         }
         catch (err) {

package/dist/services/audioMixer.js.map

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package/dist/services/audioVolumeEnvelope.d.ts

@@ -0,0 +1,25 @@
+/**
+ * Sample-accurate volume automation.
+ *
+ * The audio mixer's primary path for time-varying volume bakes the envelope
+ * directly into the prepared PCM rather than encoding it as an FFmpeg `volume`
+ * expression. The expression approach nests one `if(lt(t,...))` per keyframe and
+ * overflows FFmpeg's expression evaluator past ~95 levels (a dense GSAP fade
+ * emits hundreds of keyframes), which fails the whole mix and drops the audio
+ * track. Multiplying the samples in-house has no such ceiling, is exact at every
+ * sample, and keeps the downstream ffmpeg `amix`/AAC encode untouched — so the
+ * output (and the golden baselines) only change where a fade is actually applied.
+ *
+ * The prepared tracks are always `pcm_s16le`, 48 kHz, stereo (see
+ * `prepareAudioTrack` / `extractAudioFromVideo`). Anything else is rejected so
+ * the caller can fall back to the expression path rather than corrupting audio.
+ */
+import type { AudioVolumeKeyframe } from "./audioMixer.types.js";
+/**
+ * Multiply a prepared WAV's samples by a time-varying gain envelope in place.
+ *
+ * @returns `true` if the envelope was applied; `false` if the file isn't the
+ *   expected 16-bit PCM (caller should fall back to the expression path).
+ */
+export declare function applyVolumeEnvelopeToWav(wavPath: string, keyframes: AudioVolumeKeyframe[], trackStart: number, baseVolume: number): boolean;
+//# sourceMappingURL=audioVolumeEnvelope.d.ts.map

package/dist/services/audioVolumeEnvelope.d.ts.map

@@ -0,0 +1 @@
+{"version":3,"file":"audioVolumeEnvelope.d.ts","sourceRoot":"","sources":["../../src/services/audioVolumeEnvelope.ts"],"names":[],"mappings":"AAAA;;;;;;;;;;;;;;;GAeG;AAIH,OAAO,KAAK,EAAE,mBAAmB,EAAE,MAAM,uBAAuB,CAAC;AAyDjE;;;;;GAKG;AACH,wBAAgB,wBAAwB,CACtC,OAAO,EAAE,MAAM,EACf,SAAS,EAAE,mBAAmB,EAAE,EAChC,UAAU,EAAE,MAAM,EAClB,UAAU,EAAE,MAAM,GACjB,OAAO,CAkDT"}

package/dist/services/audioVolumeEnvelope.js

@@ -0,0 +1,123 @@
+/**
+ * Sample-accurate volume automation.
+ *
+ * The audio mixer's primary path for time-varying volume bakes the envelope
+ * directly into the prepared PCM rather than encoding it as an FFmpeg `volume`
+ * expression. The expression approach nests one `if(lt(t,...))` per keyframe and
+ * overflows FFmpeg's expression evaluator past ~95 levels (a dense GSAP fade
+ * emits hundreds of keyframes), which fails the whole mix and drops the audio
+ * track. Multiplying the samples in-house has no such ceiling, is exact at every
+ * sample, and keeps the downstream ffmpeg `amix`/AAC encode untouched — so the
+ * output (and the golden baselines) only change where a fade is actually applied.
+ *
+ * The prepared tracks are always `pcm_s16le`, 48 kHz, stereo (see
+ * `prepareAudioTrack` / `extractAudioFromVideo`). Anything else is rejected so
+ * the caller can fall back to the expression path rather than corrupting audio.
+ */
+import { readFileSync, renameSync, writeFileSync } from "fs";
+import { randomBytes } from "crypto";
+import { normaliseEnvelope } from "@hyperframes/core/media-volume-envelope";
+const PCM_FORMAT = 1; // WAVE_FORMAT_PCM
+const SUPPORTED_BITS = 16;
+/**
+ * Locate the `fmt ` and `data` chunks and validate the format we know how to edit.
+ *
+ * Scans every chunk rather than assuming an ordering: the loop always advances
+ * past a chunk's body (using its declared size), so `data` may precede `fmt `
+ * and trailing chunks (LIST/fact/etc.) are skipped harmlessly. Returns null on
+ * anything unexpected so the caller falls back to the expression path.
+ */
+function parseWavLayout(buffer) {
+    if (buffer.length < 12 || buffer.toString("ascii", 0, 4) !== "RIFF")
+        return null;
+    if (buffer.toString("ascii", 8, 12) !== "WAVE")
+        return null;
+    let offset = 12;
+    let fmt = null;
+    let data = null;
+    while (offset + 8 <= buffer.length) {
+        const chunkId = buffer.toString("ascii", offset, offset + 4);
+        const chunkSize = buffer.readUInt32LE(offset + 4);
+        const body = offset + 8;
+        if (chunkId === "fmt " && body + 16 <= buffer.length) {
+            if (buffer.readUInt16LE(body) !== PCM_FORMAT)
+                return null;
+            fmt = {
+                numChannels: buffer.readUInt16LE(body + 2),
+                sampleRate: buffer.readUInt32LE(body + 4),
+                bitsPerSample: buffer.readUInt16LE(body + 14),
+            };
+        }
+        else if (chunkId === "data") {
+            data = { offset: body, size: Math.min(chunkSize, buffer.length - body) };
+        }
+        // Chunks are word-aligned: an odd size carries a trailing pad byte.
+        offset = body + chunkSize + (chunkSize % 2);
+    }
+    if (!fmt || !data)
+        return null;
+    if (fmt.bitsPerSample !== SUPPORTED_BITS || fmt.numChannels < 1)
+        return null;
+    return {
+        numChannels: fmt.numChannels,
+        sampleRate: fmt.sampleRate,
+        dataOffset: data.offset,
+        dataSize: data.size,
+    };
+}
+/**
+ * Multiply a prepared WAV's samples by a time-varying gain envelope in place.
+ *
+ * @returns `true` if the envelope was applied; `false` if the file isn't the
+ *   expected 16-bit PCM (caller should fall back to the expression path).
+ */
+export function applyVolumeEnvelopeToWav(wavPath, keyframes, trackStart, baseVolume) {
+    const envelope = normaliseEnvelope(keyframes, trackStart, baseVolume);
+    if (envelope.length === 0)
+        return false;
+    try {
+        const buffer = readFileSync(wavPath);
+        const layout = parseWavLayout(buffer);
+        if (!layout)
+            return false;
+        const { numChannels, sampleRate, dataOffset, dataSize } = layout;
+        const bytesPerSample = SUPPORTED_BITS / 8;
+        const frameBytes = numChannels * bytesPerSample;
+        const frameCount = Math.floor(dataSize / frameBytes);
+        // Maintain an incremental segment cursor so the per-frame envelope lookup
+        // is O(N+M) overall, not O(N×M). interpolateVolumeGain restarts from 0 on
+        // each call — fine for the preview path (one call per RAF tick) but not for
+        // the PCM path (one call per sample, 48k×duration frames total).
+        let segment = 0;
+        for (let frame = 0; frame < frameCount; frame += 1) {
+            const time = frame / sampleRate;
+            while (segment < envelope.length - 2 && time >= envelope[segment + 1].time)
+                segment += 1;
+            const a = envelope[segment];
+            const b = envelope[segment + 1] ?? a;
+            const span = b.time - a.time;
+            const progress = span <= 0 ? 0 : Math.min(1, Math.max(0, (time - a.time) / span));
+            const gain = a.volume + (b.volume - a.volume) * progress;
+            const base = dataOffset + frame * frameBytes;
+            for (let channel = 0; channel < numChannels; channel += 1) {
+                const at = base + channel * bytesPerSample;
+                const scaled = Math.round(buffer.readInt16LE(at) * gain);
+                buffer.writeInt16LE(scaled < -32768 ? -32768 : scaled > 32767 ? 32767 : scaled, at);
+            }
+        }
+        // Write to a uniquely-named sibling then atomically rename over the
+        // original. The random name avoids following a pre-planted symlink at a
+        // predictable path, and the rename means a crash mid-write can't leave a
+        // truncated WAV for the downstream mix.
+        const tempPath = `${wavPath}.${randomBytes(6).toString("hex")}.tmp`;
+        writeFileSync(tempPath, buffer);
+        renameSync(tempPath, wavPath);
+        return true;
+    }
+    catch {
+        // Any read/parse/write failure → leave the file untouched and let the
+        // caller fall back to the ffmpeg expression path rather than losing audio.
+        return false;
+    }
+}
+//# sourceMappingURL=audioVolumeEnvelope.js.map

package/dist/services/audioVolumeEnvelope.js.map

@@ -0,0 +1 @@
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package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "@hyperframes/engine",
-  "version": "0.6.55",
+  "version": "0.6.57",
   "description": "Seekable web page to video rendering engine (Puppeteer + FFmpeg)",
   "repository": {
     "type": "git",
@@ -21,7 +21,7 @@
     "linkedom": "^0.18.12",
     "puppeteer": "^24.0.0",
     "puppeteer-core": "^24.39.1",
-    "@hyperframes/core": "^0.6.55"
+    "@hyperframes/core": "^0.6.57"
   },
   "devDependencies": {
     "@types/node": "^25.0.10",

package/src/services/audioMixer.test.ts

@@ -108,6 +108,121 @@ describe("processCompositionAudio", () => {
     expect(filter).toContain("adelay=2000|2000");
   });
 
+  it("bounds expression nesting for dense keyframe automation without dropping the envelope", async () => {
+    const baseDir = mkdtempSync(join(tmpdir(), "hf-audio-base-"));
+    const workDir = mkdtempSync(join(tmpdir(), "hf-audio-work-"));
+    tempDirs.push(baseDir, workDir);
+
+    writeFileSync(join(baseDir, "bgm.wav"), "stub");
+
+    // Mirrors the 60 Hz timeline probe: a 10s eased fade emits hundreds of
+    // keyframes. The nested-if volume expression must not grow one level per
+    // keyframe — past ~95 levels FFmpeg fails filter-graph init and the audio
+    // track is dropped entirely (GH #1066 follow-up).
+    const keyframes = Array.from({ length: 300 }, (_, i) => {
+      const time = (i / 299) * 10;
+      const volume =
+        time < 3 ? 0.8 * (time / 3) ** 2 : time < 7 ? 0.8 : 0.8 * (1 - (time - 7) / 3) ** 2;
+      return { time, volume };
+    });
+
+    const result = await processCompositionAudio(
+      [
+        {
+          id: "bgm",
+          src: "bgm.wav",
+          start: 0,
+          end: 10,
+          mediaStart: 0,
+          layer: 0,
+          volume: 0,
+          volumeKeyframes: keyframes,
+          type: "audio",
+        },
+      ],
+      baseDir,
+      workDir,
+      join(baseDir, "out.m4a"),
+      10,
+    );
+
+    expect(result.success).toBe(true);
+
+    const mixArgs = runFfmpegMock.mock.calls[1]?.[0];
+    const filterIndex = mixArgs.indexOf("-filter_complex");
+    const filter = mixArgs[filterIndex + 1];
+
+    // One nested `if(lt(...))` is emitted per segment; cap it well under the
+    // FFmpeg evaluator's nesting limit (MAX_VOLUME_SEGMENTS = 32).
+    const nestingDepth = (filter.match(/if\(lt\(t/g) ?? []).length;
+    expect(nestingDepth).toBeGreaterThan(1);
+    expect(nestingDepth).toBeLessThan(32);
+
+    // The simplified envelope still spans the clip: silent start, audible peak.
+    expect(filter).toContain(":eval=frame");
+    expect(filter).toMatch(/volume=if\(lt\(t\\,[0-9.]+\)\\,0\+/);
+  });
+
+  it("falls back to a static-volume mix instead of dropping audio when the automated mix fails", async () => {
+    const baseDir = mkdtempSync(join(tmpdir(), "hf-audio-base-"));
+    const workDir = mkdtempSync(join(tmpdir(), "hf-audio-work-"));
+    tempDirs.push(baseDir, workDir);
+
+    writeFileSync(join(baseDir, "bgm.wav"), "stub");
+
+    // Simulate an ffmpeg build that rejects the automation expression: the
+    // first mix attempt fails, the static-volume retry succeeds. (prepare =
+    // call 0, automated mix = call 1, fallback mix = call 2.)
+    runFfmpegMock
+      .mockImplementationOnce(async () => ({
+        success: true,
+        durationMs: 1,
+        stderr: "",
+        exitCode: 0,
+      }))
+      .mockImplementationOnce(async () => ({
+        success: false,
+        durationMs: 1,
+        stderr: "Error initializing filters",
+        exitCode: 234,
+      }));
+
+    const result = await processCompositionAudio(
+      [
+        {
+          id: "bgm",
+          src: "bgm.wav",
+          start: 0,
+          end: 5,
+          mediaStart: 0,
+          layer: 0,
+          volume: 0.8,
+          volumeKeyframes: [
+            { time: 0, volume: 0.8 },
+            { time: 5, volume: 0 },
+          ],
+          type: "audio",
+        },
+      ],
+      baseDir,
+      workDir,
+      join(baseDir, "out.m4a"),
+      5,
+    );
+
+    expect(result.success).toBe(true);
+    expect(result.tracksProcessed).toBe(1);
+    expect(runFfmpegMock).toHaveBeenCalledTimes(3);
+    // Degradation is surfaced, not silent — the track rendered at base volume.
+    expect(result.error).toMatch(/base volume/i);
+
+    // The fallback mix omits the automation expression (base volume only).
+    const fallbackArgs = runFfmpegMock.mock.calls[2]?.[0];
+    const fallbackFilter = fallbackArgs[fallbackArgs.indexOf("-filter_complex") + 1];
+    expect(fallbackFilter).not.toContain(":eval=frame");
+    expect(fallbackFilter).toContain("volume=0.8");
+  });
+
   it("prepares percent-encoded non-Latin audio srcs from decoded filesystem paths", async () => {
     const baseDir = mkdtempSync(join(tmpdir(), "hf-audio-base-"));
     const workDir = mkdtempSync(join(tmpdir(), "hf-audio-work-"));

package/src/services/audioMixer.ts

@@ -14,6 +14,7 @@ import { runFfmpeg } from "../utils/runFfmpeg.js";
 import { unwrapTemplate } from "../utils/htmlTemplate.js";
 import { resolveProjectRelativeSrc } from "./videoFrameExtractor.js";
 import type { AudioElement, AudioTrack, MixResult } from "./audioMixer.types.js";
+import { applyVolumeEnvelopeToWav } from "./audioVolumeEnvelope.js";
 
 export type { AudioElement, MixResult } from "./audioMixer.types.js";
 
@@ -30,10 +31,89 @@ function escapeExpressionCommas(expression: string): string {
   return expression.replace(/\\/g, "\\\\").replace(/,/g, "\\,");
 }
 
-function buildVolumeExpression(track: AudioTrack): string {
+/**
+ * Upper bound on volume-automation keyframes folded into the FFmpeg `volume`
+ * expression. The expression nests one `if(lt(...))` per keyframe, and
+ * FFmpeg's expression evaluator has a finite nesting depth: past ~95 levels
+ * (build-dependent — lower on some Linux ffmpeg builds) `volume=...:eval=frame`
+ * fails filter-graph init, which fails the whole mix and drops the audio track
+ * entirely. The 60 Hz timeline probe routinely emits 100–300 keyframes for a
+ * multi-second fade (GH #1066 follow-up: a 171-keyframe GSAP fade rendered with
+ * no audio). 32 segments keeps a wide safety margin and is far more resolution
+ * than a piecewise-linear volume envelope needs.
+ */
+const MAX_VOLUME_SEGMENTS = 32;
+
+/**
+ * Volume delta below which a keyframe is collinear enough to drop. Kept tight
+ * (0.5% linear) so the rendered piecewise-linear envelope tracks the GSAP curve
+ * the browser plays in preview to within ~0.2 dB across the audible range — well
+ * under the ~1 dB loudness JND, so render stays WYSIWYG with preview. A full
+ * ease-in/ease-out fade still reduces to ~25 segments, inside MAX_VOLUME_SEGMENTS.
+ */
+const VOLUME_SIMPLIFY_EPSILON = 0.005;
+
+/**
+ * Reduce a sorted keyframe list to a perceptually-equivalent piecewise-linear
+ * envelope with a bounded segment count.
+ *
+ * Ramer–Douglas–Peucker drops control points lying within
+ * `VOLUME_SIMPLIFY_EPSILON` of the line through their neighbours (a linear fade
+ * collapses to its two endpoints; an eased fade to a handful). A uniform
+ * downsample backstop then bounds pathological inputs (e.g. audio-rate volume
+ * oscillation) to `MAX_VOLUME_SEGMENTS`. Endpoints are always preserved so the
+ * envelope still spans the full clip.
+ */
+function simplifyVolumeKeyframes(
+  keyframes: { time: number; volume: number }[],
+): { time: number; volume: number }[] {
+  if (keyframes.length < 3) return keyframes;
+
+  const keep = new Array<boolean>(keyframes.length).fill(false);
+  keep[0] = true;
+  keep[keyframes.length - 1] = true;
+  const stack: [number, number][] = [[0, keyframes.length - 1]];
+  while (stack.length > 0) {
+    const [startIndex, endIndex] = stack.pop()!;
+    const start = keyframes[startIndex]!;
+    const end = keyframes[endIndex]!;
+    const span = end.time - start.time;
+    let maxDistance = VOLUME_SIMPLIFY_EPSILON;
+    let splitIndex = -1;
+    for (let i = startIndex + 1; i < endIndex; i += 1) {
+      const point = keyframes[i]!;
+      const interpolated =
+        span === 0
+          ? start.volume
+          : start.volume + ((end.volume - start.volume) * (point.time - start.time)) / span;
+      const distance = Math.abs(point.volume - interpolated);
+      if (distance > maxDistance) {
+        maxDistance = distance;
+        splitIndex = i;
+      }
+    }
+    if (splitIndex !== -1) {
+      keep[splitIndex] = true;
+      stack.push([startIndex, splitIndex], [splitIndex, endIndex]);
+    }
+  }
+
+  const simplified = keyframes.filter((_, i) => keep[i]);
+  if (simplified.length <= MAX_VOLUME_SEGMENTS) return simplified;
+
+  const step = (simplified.length - 1) / (MAX_VOLUME_SEGMENTS - 1);
+  const sampled: { time: number; volume: number }[] = [];
+  for (let i = 0; i < MAX_VOLUME_SEGMENTS; i += 1) {
+    const point = simplified[Math.round(i * step)]!;
+    if (sampled.length === 0 || point.time > sampled.at(-1)!.time) sampled.push(point);
+  }
+  return sampled;
+}
+
+function buildVolumeExpression(track: AudioTrack, ignoreKeyframes = false): string {
   const trimDuration = track.end - track.start;
   const staticVolume = clampVolume(track.volume);
-  const keyframes = (track.volumeKeyframes ?? [])
+  const keyframes = (ignoreKeyframes ? [] : (track.volumeKeyframes ?? []))
     .filter((keyframe) => Number.isFinite(keyframe.time) && Number.isFinite(keyframe.volume))
     .map((keyframe) => ({
       time: Math.max(0, Math.min(trimDuration, keyframe.time - track.start)),
@@ -57,14 +137,19 @@ function buildVolumeExpression(track: AudioTrack): string {
     }
   }
 
-  if (deduped.length === 1) {
-    return `volume=${formatFilterNumber(deduped[0]!.volume)}`;
+  // Collapse the densely-sampled probe output to a bounded piecewise-linear
+  // envelope. Without this, the nested-if expression below grows one level per
+  // keyframe and overflows FFmpeg's expression evaluator (see MAX_VOLUME_SEGMENTS).
+  const simplified = simplifyVolumeKeyframes(deduped);
+
+  if (simplified.length === 1) {
+    return `volume=${formatFilterNumber(simplified[0]!.volume)}`;
   }
 
-  let expression = formatFilterNumber(deduped.at(-1)!.volume);
-  for (let i = deduped.length - 2; i >= 0; i -= 1) {
-    const current = deduped[i]!;
-    const next = deduped[i + 1]!;
+  let expression = formatFilterNumber(simplified.at(-1)!.volume);
+  for (let i = simplified.length - 2; i >= 0; i -= 1) {
+    const current = simplified[i]!;
+    const next = simplified[i + 1]!;
     const currentTime = formatFilterNumber(current.time);
     const nextTime = formatFilterNumber(next.time);
     const currentVolume = formatFilterNumber(current.volume);
@@ -299,42 +384,58 @@ async function mixAudioTracks(
   const outputDir = dirname(outputPath);
   if (!existsSync(outputDir)) mkdirSync(outputDir, { recursive: true });
 
-  const inputs: string[] = [];
-  const filterParts: string[] = [];
-
-  tracks.forEach((track, i) => {
-    inputs.push("-i", track.srcPath);
-    const delayMs = Math.round(track.start * 1000);
-    const trimDuration = track.end - track.start;
-    const volumeFilter = buildVolumeExpression(track);
-    filterParts.push(
-      `[${i}:a]atrim=0:${trimDuration},${volumeFilter},adelay=${delayMs}|${delayMs},apad=whole_dur=${totalDuration}[a${i}]`,
-    );
-  });
-
-  const mixInputs = tracks.map((_, i) => `[a${i}]`).join("");
-  const weights = tracks.map(() => "1").join(" ");
-  const mixFilter = `${mixInputs}amix=inputs=${tracks.length}:duration=longest:dropout_transition=0:normalize=0:weights='${weights}'[mixed]`;
-  const postMixGainFilter = `[mixed]volume=${masterOutputGain}[out]`;
-  const fullFilter = [...filterParts, mixFilter, postMixGainFilter].join(";");
+  const buildArgs = (ignoreAutomation: boolean): string[] => {
+    const inputs: string[] = [];
+    const filterParts: string[] = [];
+    tracks.forEach((track, i) => {
+      inputs.push("-i", track.srcPath);
+      const delayMs = Math.round(track.start * 1000);
+      const trimDuration = track.end - track.start;
+      const volumeFilter = buildVolumeExpression(track, ignoreAutomation);
+      filterParts.push(
+        `[${i}:a]atrim=0:${trimDuration},${volumeFilter},adelay=${delayMs}|${delayMs},apad=whole_dur=${totalDuration}[a${i}]`,
+      );
+    });
 
-  const args = [
-    ...inputs,
-    "-filter_complex",
-    fullFilter,
-    "-map",
-    "[out]",
-    "-acodec",
-    "aac",
-    "-b:a",
-    "192k",
-    "-t",
-    String(totalDuration),
-    "-y",
-    outputPath,
-  ];
+    const mixInputs = tracks.map((_, i) => `[a${i}]`).join("");
+    const weights = tracks.map(() => "1").join(" ");
+    const mixFilter = `${mixInputs}amix=inputs=${tracks.length}:duration=longest:dropout_transition=0:normalize=0:weights='${weights}'[mixed]`;
+    const postMixGainFilter = `[mixed]volume=${masterOutputGain}[out]`;
+    const fullFilter = [...filterParts, mixFilter, postMixGainFilter].join(";");
+
+    return [
+      ...inputs,
+      "-filter_complex",
+      fullFilter,
+      "-map",
+      "[out]",
+      "-acodec",
+      "aac",
+      "-b:a",
+      "192k",
+      "-t",
+      String(totalDuration),
+      "-y",
+      outputPath,
+    ];
+  };
 
-  const result = await runFfmpeg(args, { signal, timeout: ffmpegProcessTimeout });
+  let result = await runFfmpeg(buildArgs(false), { signal, timeout: ffmpegProcessTimeout });
+
+  // Defense in depth: volume automation is folded into an FFmpeg `volume`
+  // expression whose evaluator limits are build-dependent (see
+  // MAX_VOLUME_SEGMENTS). If that ever fails the mix, retry once without the
+  // automation so the track renders at its base volume rather than being
+  // dropped from the output entirely — a missing fade beats missing audio.
+  let degradedAutomation = false;
+  const hasAutomation = tracks.some((track) => (track.volumeKeyframes?.length ?? 0) > 0);
+  if (!result.success && !signal?.aborted && hasAutomation) {
+    const retry = await runFfmpeg(buildArgs(true), { signal, timeout: ffmpegProcessTimeout });
+    if (retry.success) {
+      result = retry;
+      degradedAutomation = true;
+    }
+  }
 
   if (signal?.aborted) {
     return {
@@ -360,6 +461,9 @@ async function mixAudioTracks(
     outputPath,
     durationMs: result.durationMs,
     tracksProcessed: tracks.length,
+    error: degradedAutomation
+      ? "Volume automation exceeded this ffmpeg build's expression limits; rendered at base volume"
+      : undefined,
   };
 }
 
@@ -452,6 +556,19 @@ export async function processCompositionAudio(
           audioSrcPath = trimmedPath;
         }
 
+        // Primary volume-automation path: bake the envelope into the PCM samples
+        // (sample-accurate, no keyframe ceiling). If the WAV isn't the expected
+        // 16-bit PCM, fall back to the ffmpeg expression path by leaving the
+        // keyframes on the track for buildVolumeExpression to handle.
+        let bakedEnvelope = false;
+        if (element.volumeKeyframes && element.volumeKeyframes.length > 0) {
+          bakedEnvelope = applyVolumeEnvelopeToWav(
+            audioSrcPath,
+            element.volumeKeyframes,
+            element.start,
+            element.volume ?? 1.0,
+          );
+        }
         tracks.push({
           id: element.id,
           srcPath: audioSrcPath,
@@ -459,8 +576,9 @@ export async function processCompositionAudio(
           end: element.end,
           mediaStart: element.mediaStart,
           duration: element.end - element.start,
-          volume: element.volume ?? 1.0,
-          volumeKeyframes: element.volumeKeyframes,
+          // Gain is already in the samples when baked, so mix at unity.
+          volume: bakedEnvelope ? 1.0 : (element.volume ?? 1.0),
+          volumeKeyframes: bakedEnvelope ? undefined : element.volumeKeyframes,
         });
       } catch (err: unknown) {
         errors.push(`Error: ${element.id} — ${err instanceof Error ? err.message : String(err)}`);

package/src/services/audioVolumeEnvelope.test.ts

@@ -0,0 +1,176 @@
+import { afterEach, describe, expect, it } from "vitest";
+import { mkdtempSync, readFileSync, rmSync, writeFileSync } from "node:fs";
+import { join } from "node:path";
+import { tmpdir } from "node:os";
+import { applyVolumeEnvelopeToWav } from "./audioVolumeEnvelope.js";
+
+const SAMPLE_RATE = 48000;
+const CHANNELS = 2;
+
+/** Build a PCM s16le stereo WAV whose every sample equals `value`. */
+function writeConstantWav(path: string, frames: number, value: number): void {
+  const bytesPerSample = 2;
+  const dataSize = frames * CHANNELS * bytesPerSample;
+  const buffer = Buffer.alloc(44 + dataSize);
+  buffer.write("RIFF", 0, "ascii");
+  buffer.writeUInt32LE(36 + dataSize, 4);
+  buffer.write("WAVE", 8, "ascii");
+  buffer.write("fmt ", 12, "ascii");
+  buffer.writeUInt32LE(16, 16);
+  buffer.writeUInt16LE(1, 20); // PCM
+  buffer.writeUInt16LE(CHANNELS, 22);
+  buffer.writeUInt32LE(SAMPLE_RATE, 24);
+  buffer.writeUInt32LE(SAMPLE_RATE * CHANNELS * bytesPerSample, 28);
+  buffer.writeUInt16LE(CHANNELS * bytesPerSample, 32);
+  buffer.writeUInt16LE(16, 34);
+  buffer.write("data", 36, "ascii");
+  buffer.writeUInt32LE(dataSize, 40);
+  for (let i = 0; i < frames * CHANNELS; i += 1) buffer.writeInt16LE(value, 44 + i * 2);
+  writeFileSync(path, buffer);
+}
+
+function sampleAt(path: string, frame: number, channel = 0): number {
+  const buffer = readFileSync(path);
+  return buffer.readInt16LE(44 + (frame * CHANNELS + channel) * 2);
+}
+
+describe("applyVolumeEnvelopeToWav", () => {
+  const dirs: string[] = [];
+  const tmp = () => {
+    const d = mkdtempSync(join(tmpdir(), "hf-env-"));
+    dirs.push(d);
+    return d;
+  };
+  afterEach(() => {
+    for (const d of dirs.splice(0)) rmSync(d, { recursive: true, force: true });
+  });
+
+  it("applies a linear fade sample-accurately", () => {
+    const path = join(tmp(), "a.wav");
+    const frames = SAMPLE_RATE; // 1 second
+    writeConstantWav(path, frames, 10000);
+
+    // Fade 0 -> 1 over the full second.
+    const applied = applyVolumeEnvelopeToWav(
+      path,
+      [
+        { time: 0, volume: 0 },
+        { time: 1, volume: 1 },
+      ],
+      0,
+      0,
+    );
+    expect(applied).toBe(true);
+
+    expect(sampleAt(path, 0)).toBe(0); // gain 0
+    expect(sampleAt(path, frames / 2)).toBeCloseTo(5000, -2); // gain ~0.5
+    expect(sampleAt(path, frames - 1)).toBeGreaterThan(9900); // gain ~1
+  });
+
+  it("offsets keyframes by the track start (composition time -> track-relative)", () => {
+    const path = join(tmp(), "b.wav");
+    const frames = SAMPLE_RATE;
+    writeConstantWav(path, frames, 10000);
+
+    // Track starts at 5s; the fade runs from comp-time 5s..6s -> wav 0s..1s.
+    applyVolumeEnvelopeToWav(
+      path,
+      [
+        { time: 5, volume: 0 },
+        { time: 6, volume: 1 },
+      ],
+      5,
+      0,
+    );
+
+    expect(sampleAt(path, 0)).toBe(0);
+    expect(sampleAt(path, frames / 2)).toBeCloseTo(5000, -2);
+  });
+
+  it("holds base volume before the first keyframe and the last value after", () => {
+    const path = join(tmp(), "c.wav");
+    const frames = SAMPLE_RATE * 3; // 3 seconds
+    writeConstantWav(path, frames, 10000);
+
+    // Base 0.8 held until a fade-out begins at 2s.
+    applyVolumeEnvelopeToWav(
+      path,
+      [
+        { time: 2, volume: 0.8 },
+        { time: 3, volume: 0 },
+      ],
+      0,
+      0.8,
+    );
+
+    expect(sampleAt(path, SAMPLE_RATE)).toBeCloseTo(8000, -2); // 1s: base 0.8
+    expect(sampleAt(path, frames - 1)).toBeLessThan(200); // 3s: faded to ~0
+  });
+
+  it("handles thousands of keyframes without failing (no expression ceiling)", () => {
+    const path = join(tmp(), "d.wav");
+    const frames = SAMPLE_RATE * 2;
+    writeConstantWav(path, frames, 10000);
+
+    const keyframes = Array.from({ length: 5000 }, (_, i) => ({
+      time: (i / 4999) * 2,
+      volume: Math.abs(Math.sin(i / 50)),
+    }));
+    expect(applyVolumeEnvelopeToWav(path, keyframes, 0, 0)).toBe(true);
+  });
+
+  it("parses chunks in any order (data before fmt)", () => {
+    const path = join(tmp(), "order.wav");
+    const frames = 4;
+    const dataSize = frames * CHANNELS * 2;
+    // Lay the data chunk before fmt to exercise order-independent scanning.
+    const buffer = Buffer.alloc(12 + (8 + dataSize) + (8 + 16));
+    buffer.write("RIFF", 0, "ascii");
+    buffer.writeUInt32LE(buffer.length - 8, 4);
+    buffer.write("WAVE", 8, "ascii");
+    let o = 12;
+    buffer.write("data", o, "ascii");
+    buffer.writeUInt32LE(dataSize, o + 4);
+    for (let i = 0; i < frames * CHANNELS; i += 1) buffer.writeInt16LE(10000, o + 8 + i * 2);
+    o += 8 + dataSize;
+    buffer.write("fmt ", o, "ascii");
+    buffer.writeUInt32LE(16, o + 4);
+    buffer.writeUInt16LE(1, o + 8);
+    buffer.writeUInt16LE(CHANNELS, o + 10);
+    buffer.writeUInt32LE(SAMPLE_RATE, o + 12);
+    buffer.writeUInt16LE(16, o + 22);
+    writeFileSync(path, buffer);
+
+    expect(applyVolumeEnvelopeToWav(path, [{ time: 0, volume: 0 }], 0, 0)).toBe(true);
+    expect(readFileSync(path).readInt16LE(12 + 8)).toBe(0); // first sample muted
+  });
+
+  it("rejects non-16-bit PCM so the caller can fall back", () => {
+    const path = join(tmp(), "e.wav");
+    // 24-bit PCM header (bitsPerSample = 24); body contents are irrelevant.
+    const buffer = Buffer.alloc(44);
+    buffer.write("RIFF", 0, "ascii");
+    buffer.write("WAVE", 8, "ascii");
+    buffer.write("fmt ", 12, "ascii");
+    buffer.writeUInt32LE(16, 16);
+    buffer.writeUInt16LE(1, 20);
+    buffer.writeUInt16LE(CHANNELS, 22);
+    buffer.writeUInt32LE(SAMPLE_RATE, 24);
+    buffer.writeUInt16LE(24, 34);
+    buffer.write("data", 36, "ascii");
+    buffer.writeUInt32LE(0, 40);
+    writeFileSync(path, buffer);
+
+    expect(
+      applyVolumeEnvelopeToWav(
+        path,
+        [
+          { time: 0, volume: 0 },
+          { time: 1, volume: 1 },
+        ],
+        0,
+        0,
+      ),
+    ).toBe(false);
+  });
+});

package/src/services/audioVolumeEnvelope.ts

@@ -0,0 +1,138 @@
+/**
+ * Sample-accurate volume automation.
+ *
+ * The audio mixer's primary path for time-varying volume bakes the envelope
+ * directly into the prepared PCM rather than encoding it as an FFmpeg `volume`
+ * expression. The expression approach nests one `if(lt(t,...))` per keyframe and
+ * overflows FFmpeg's expression evaluator past ~95 levels (a dense GSAP fade
+ * emits hundreds of keyframes), which fails the whole mix and drops the audio
+ * track. Multiplying the samples in-house has no such ceiling, is exact at every
+ * sample, and keeps the downstream ffmpeg `amix`/AAC encode untouched — so the
+ * output (and the golden baselines) only change where a fade is actually applied.
+ *
+ * The prepared tracks are always `pcm_s16le`, 48 kHz, stereo (see
+ * `prepareAudioTrack` / `extractAudioFromVideo`). Anything else is rejected so
+ * the caller can fall back to the expression path rather than corrupting audio.
+ */
+
+import { readFileSync, renameSync, writeFileSync } from "fs";
+import { randomBytes } from "crypto";
+import type { AudioVolumeKeyframe } from "./audioMixer.types.js";
+import { normaliseEnvelope } from "@hyperframes/core/media-volume-envelope";
+
+const PCM_FORMAT = 1; // WAVE_FORMAT_PCM
+const SUPPORTED_BITS = 16;
+
+interface WavLayout {
+  numChannels: number;
+  sampleRate: number;
+  dataOffset: number;
+  dataSize: number;
+}
+
+/**
+ * Locate the `fmt ` and `data` chunks and validate the format we know how to edit.
+ *
+ * Scans every chunk rather than assuming an ordering: the loop always advances
+ * past a chunk's body (using its declared size), so `data` may precede `fmt `
+ * and trailing chunks (LIST/fact/etc.) are skipped harmlessly. Returns null on
+ * anything unexpected so the caller falls back to the expression path.
+ */
+function parseWavLayout(buffer: Buffer): WavLayout | null {
+  if (buffer.length < 12 || buffer.toString("ascii", 0, 4) !== "RIFF") return null;
+  if (buffer.toString("ascii", 8, 12) !== "WAVE") return null;
+
+  let offset = 12;
+  let fmt: { numChannels: number; sampleRate: number; bitsPerSample: number } | null = null;
+  let data: { offset: number; size: number } | null = null;
+
+  while (offset + 8 <= buffer.length) {
+    const chunkId = buffer.toString("ascii", offset, offset + 4);
+    const chunkSize = buffer.readUInt32LE(offset + 4);
+    const body = offset + 8;
+    if (chunkId === "fmt " && body + 16 <= buffer.length) {
+      if (buffer.readUInt16LE(body) !== PCM_FORMAT) return null;
+      fmt = {
+        numChannels: buffer.readUInt16LE(body + 2),
+        sampleRate: buffer.readUInt32LE(body + 4),
+        bitsPerSample: buffer.readUInt16LE(body + 14),
+      };
+    } else if (chunkId === "data") {
+      data = { offset: body, size: Math.min(chunkSize, buffer.length - body) };
+    }
+    // Chunks are word-aligned: an odd size carries a trailing pad byte.
+    offset = body + chunkSize + (chunkSize % 2);
+  }
+
+  if (!fmt || !data) return null;
+  if (fmt.bitsPerSample !== SUPPORTED_BITS || fmt.numChannels < 1) return null;
+  return {
+    numChannels: fmt.numChannels,
+    sampleRate: fmt.sampleRate,
+    dataOffset: data.offset,
+    dataSize: data.size,
+  };
+}
+
+/**
+ * Multiply a prepared WAV's samples by a time-varying gain envelope in place.
+ *
+ * @returns `true` if the envelope was applied; `false` if the file isn't the
+ *   expected 16-bit PCM (caller should fall back to the expression path).
+ */
+export function applyVolumeEnvelopeToWav(
+  wavPath: string,
+  keyframes: AudioVolumeKeyframe[],
+  trackStart: number,
+  baseVolume: number,
+): boolean {
+  const envelope = normaliseEnvelope(keyframes, trackStart, baseVolume);
+  if (envelope.length === 0) return false;
+
+  try {
+    const buffer = readFileSync(wavPath);
+    const layout = parseWavLayout(buffer);
+    if (!layout) return false;
+
+    const { numChannels, sampleRate, dataOffset, dataSize } = layout;
+    const bytesPerSample = SUPPORTED_BITS / 8;
+    const frameBytes = numChannels * bytesPerSample;
+    const frameCount = Math.floor(dataSize / frameBytes);
+
+    // Maintain an incremental segment cursor so the per-frame envelope lookup
+    // is O(N+M) overall, not O(N×M). interpolateVolumeGain restarts from 0 on
+    // each call — fine for the preview path (one call per RAF tick) but not for
+    // the PCM path (one call per sample, 48k×duration frames total).
+    let segment = 0;
+    for (let frame = 0; frame < frameCount; frame += 1) {
+      const time = frame / sampleRate;
+      while (segment < envelope.length - 2 && time >= envelope[segment + 1]!.time) segment += 1;
+
+      const a = envelope[segment]!;
+      const b = envelope[segment + 1] ?? a;
+      const span = b.time - a.time;
+      const progress = span <= 0 ? 0 : Math.min(1, Math.max(0, (time - a.time) / span));
+      const gain = a.volume + (b.volume - a.volume) * progress;
+
+      const base = dataOffset + frame * frameBytes;
+      for (let channel = 0; channel < numChannels; channel += 1) {
+        const at = base + channel * bytesPerSample;
+        const scaled = Math.round(buffer.readInt16LE(at) * gain);
+        buffer.writeInt16LE(scaled < -32768 ? -32768 : scaled > 32767 ? 32767 : scaled, at);
+      }
+    }
+
+    // Write to a uniquely-named sibling then atomically rename over the
+    // original. The random name avoids following a pre-planted symlink at a
+    // predictable path, and the rename means a crash mid-write can't leave a
+    // truncated WAV for the downstream mix.
+    const tempPath = `${wavPath}.${randomBytes(6).toString("hex")}.tmp`;
+    writeFileSync(tempPath, buffer);
+    renameSync(tempPath, wavPath);
+    return true;
+  } catch {
+    // Any read/parse/write failure → leave the file untouched and let the
+    // caller fall back to the ffmpeg expression path rather than losing audio.
+    return false;
+  }
+}