@rangojs/router 0.0.0-experimental.19 → 0.0.0-experimental.1db96a9e

package/src/vite/router-discovery.ts

@@ -10,9 +10,12 @@ import type { Plugin } from "vite";
 import { createServer as createViteServer } from "vite";
 import { resolve } from "node:path";
 import { readFileSync } from "node:fs";
+import { createRequire } from "node:module";
+import { pathToFileURL } from "node:url";
 import {
+  formatNestedRouterConflictError,
+  findNestedRouterConflict,
   findRouterFiles,
-  createScanFilter,
 } from "../build/generate-route-types.js";
 import { createVersionPlugin } from "./plugins/version-plugin.js";
 import { createVirtualStubPlugin } from "./plugins/virtual-stub-plugin.js";
@@ -40,6 +43,7 @@ import {
   generatePerRouterModule,
 } from "./discovery/virtual-module-codegen.js";
 import { postprocessBundle } from "./discovery/bundle-postprocess.js";
+import { resetStagedBuildAssets } from "./utils/prerender-utils.js";
 
 export { VIRTUAL_ROUTES_MANIFEST_ID };
 
@@ -92,6 +96,105 @@ async function createTempRscServer(
   });
 }
 
+// ============================================================================
+// Build-Time Env Resolution
+// ============================================================================
+
+import type {
+  BuildEnvOption,
+  BuildEnvFactoryContext,
+  BuildEnvResult,
+} from "./plugin-types.js";
+
+/**
+ * Resolve the buildEnv option into a concrete { env, dispose? } result.
+ * Handles all four input shapes: false, "auto", factory, plain object.
+ */
+async function resolveBuildEnv(
+  option: BuildEnvOption | undefined,
+  factoryCtx: BuildEnvFactoryContext,
+): Promise<BuildEnvResult | null> {
+  if (!option) return null;
+
+  if (option === "auto") {
+    if (factoryCtx.preset !== "cloudflare") {
+      throw new Error(
+        '[rsc-router] buildEnv: "auto" is only supported with preset: "cloudflare". ' +
+          "Use a factory function or plain object for other presets.",
+      );
+    }
+    try {
+      // Resolve wrangler from the user's project root (not the router package)
+      const userRequire = createRequire(
+        resolve(factoryCtx.root, "package.json"),
+      );
+      const wranglerPath = userRequire.resolve("wrangler");
+      const { getPlatformProxy } = (await import(
+        pathToFileURL(wranglerPath).href
+      )) as {
+        getPlatformProxy: (opts?: any) => Promise<any>;
+      };
+      const proxy = await getPlatformProxy();
+      return {
+        env: proxy.env as Record<string, unknown>,
+        dispose: proxy.dispose,
+      };
+    } catch (err: any) {
+      throw new Error(
+        '[rsc-router] buildEnv: "auto" requires wrangler to be installed.\n' +
+          `Install it with: pnpm add -D wrangler\n${err.message}`,
+      );
+    }
+  }
+
+  if (typeof option === "function") {
+    return await option(factoryCtx);
+  }
+
+  // Plain object
+  return { env: option };
+}
+
+/**
+ * Acquire build-time env bindings and store on discovery state.
+ * Returns true if env was acquired, false if buildEnv is disabled.
+ */
+async function acquireBuildEnv(
+  s: DiscoveryState,
+  command: "serve" | "build",
+  mode: string,
+): Promise<boolean> {
+  const option = s.opts?.buildEnv;
+  if (!option) return false;
+
+  const result = await resolveBuildEnv(option, {
+    root: s.projectRoot,
+    mode,
+    command,
+    preset: s.opts?.preset ?? "node",
+  });
+  if (!result) return false;
+
+  s.resolvedBuildEnv = result.env;
+  s.buildEnvDispose = result.dispose ?? null;
+  return true;
+}
+
+/**
+ * Release build-time env resources and clear state.
+ */
+async function releaseBuildEnv(s: DiscoveryState): Promise<void> {
+  if (s.buildEnvDispose) {
+    try {
+      await s.buildEnvDispose();
+    } catch (err: any) {
+      console.warn(`[rsc-router] buildEnv dispose failed: ${err.message}`);
+    }
+    s.buildEnvDispose = null;
+  }
+  s.resolvedBuildEnv = undefined;
+}
+
 /**
  * Plugin that discovers router instances at dev/build time via the RSC environment.
  *
@@ -109,6 +212,8 @@ export function createRouterDiscoveryPlugin(
   opts?: PluginOptions,
 ): Plugin {
   const s = createDiscoveryState(entryPath, opts);
+  let viteCommand: "serve" | "build" = "build";
+  let viteMode = "production";
 
   return {
     name: "@rangojs/router:discovery",
@@ -119,32 +224,20 @@ export function createRouterDiscoveryPlugin(
           __RANGO_DEBUG__: JSON.stringify(!!process.env.INTERNAL_RANGO_DEBUG),
         },
       };
-      if (opts?.enableBuildPrerender) {
-        config.environments = {
-          rsc: {
-            build: {
-              rollupOptions: {
-                output: {
-                  manualChunks(id: string) {
-                    if (s.resolvedPrerenderModules?.has(id)) {
-                      return "__prerender-handlers";
-                    }
-                    if (s.resolvedStaticModules?.has(id)) {
-                      return "__static-handlers";
-                    }
-                  },
-                },
-              },
-            },
-          },
-        };
-      }
+      // Prerender/static handler modules are bundled naturally with the
+      // rest of the RSC entry.  A previous design forced them into dedicated
+      // __prerender-handlers / __static-handlers chunks via manualChunks,
+      // but Rollup hoisted all shared dependencies into those chunks,
+      // inflating them to ~1 MB with active runtime code.  Handler code is
+      // evicted in closeBundle regardless of which chunk it lands in.
       return config;
     },
 
     configResolved(config) {
       s.projectRoot = config.root;
       s.isBuildMode = config.command === "build";
+      viteCommand = config.command as "serve" | "build";
+      viteMode = config.mode;
       // Capture user's resolve aliases for the temp server
       s.userResolveAlias = config.resolve.alias;
       // Node preset: pick up auto-discovered router path from the config() hook.
@@ -165,13 +258,6 @@ export function createRouterDiscoveryPlugin(
           s.resolvedEntryPath = entries[0];
         }
       }
-      // Compile include/exclude patterns into a scan filter
-      if (opts?.include || opts?.exclude) {
-        s.scanFilter = createScanFilter(s.projectRoot, {
-          include: opts.include,
-          exclude: opts.exclude,
-        });
-      }
       // Generate combined named-routes.gen.ts from static source parsing.
       // Runs before the dev server starts so the gen file exists immediately for IDE.
       // In build mode, the runtime discovery in buildStart produces the definitive
@@ -222,12 +308,13 @@ export function createRouterDiscoveryPlugin(
       let prerenderTempServer: any = null;
       let prerenderNodeRegistry: Map<string, any> | null = null;
 
-      // Clean up the temporary server when the dev server shuts down
+      // Clean up the temporary server and build env when the dev server shuts down
       server.httpServer?.on("close", () => {
         if (prerenderTempServer) {
           prerenderTempServer.close().catch(() => {});
           prerenderTempServer = null;
         }
+        releaseBuildEnv(s).catch(() => {});
       });
 
       async function getOrCreateTempServer(): Promise<any | null> {
@@ -267,6 +354,9 @@ export function createRouterDiscoveryPlugin(
           // Create a temp Node.js server to run runtime discovery and generate
           // named route types (static parser can't resolve factory calls).
           try {
+            // Acquire build-time env bindings for dev prerender
+            await acquireBuildEnv(s, viteCommand, viteMode);
+
             const tempRscEnv = await getOrCreateTempServer();
             if (tempRscEnv) {
               await discoverRouters(s, tempRscEnv);
@@ -283,6 +373,9 @@ export function createRouterDiscoveryPlugin(
         }
 
         try {
+          // Acquire build-time env bindings for dev prerender (Node.js path)
+          await acquireBuildEnv(s, viteCommand, viteMode);
+
           // Set the readiness gate BEFORE discovery so early requests
           // block until manifest is populated
           const serverMod = await rscEnv.runner.import(
@@ -387,9 +480,31 @@ export function createRouterDiscoveryPlugin(
           return;
         }
 
-        // Prefer the main server's registry (Node.js preset: module runner available).
-        // Fall back to a temp server for Cloudflare where the main RSC env uses workerd.
-        let registry = mainRegistry;
+        // Import the user's entry module to force re-evaluation of any
+        // HMR-invalidated modules in the chain (entry → router → urls → handlers).
+        // This ensures createRouter() re-runs with updated handler code before
+        // we read RouterRegistry. Without this, edits to prerender handler files
+        // produce stale content because the old router instance remains registered.
+        const rscEnv = (server.environments as any)?.rsc;
+        let registry: Map<string, any> | null = null;
+        if (rscEnv?.runner && s.resolvedEntryPath) {
+          try {
+            await rscEnv.runner.import(s.resolvedEntryPath);
+            const serverMod = await rscEnv.runner.import(
+              "@rangojs/router/server",
+            );
+            registry = serverMod.RouterRegistry ?? null;
+          } catch (err: any) {
+            console.warn(
+              `[rsc-router] Dev prerender module refresh failed: ${err.message}`,
+            );
+            res.statusCode = 500;
+            res.end(`Prerender handler error: ${err.message}`);
+            return;
+          }
+        } else {
+          registry = mainRegistry;
+        }
 
         if (!registry) {
           // No main registry: the RSC env has no module runner (Cloudflare dev).
@@ -418,6 +533,8 @@ export function createRouterDiscoveryPlugin(
               {},
               undefined,
               wantPassthrough,
+              s.resolvedBuildEnv,
+              true, // devMode: check getParams for passthrough routes
             );
             if (!result) continue;
             if (result.passthrough) continue;
@@ -559,6 +676,16 @@ export function createRouterDiscoveryPlugin(
             if (!hasUrls && !hasCreateRouter) return;
             // Invalidate cache when a router file changes (new router added/removed)
             if (hasCreateRouter) {
+              const nestedRouterConflict = findNestedRouterConflict([
+                ...(s.cachedRouterFiles ?? []),
+                resolve(filePath),
+              ]);
+              if (nestedRouterConflict) {
+                server.config.logger.error(
+                  formatNestedRouterConflictError(nestedRouterConflict),
+                );
+                return;
+              }
               s.cachedRouterFiles = undefined;
             }
             scheduleRouteRegeneration();
@@ -592,6 +719,12 @@ export function createRouterDiscoveryPlugin(
       if (!s.isBuildMode) return;
       // Only run once across environment builds
       if (s.mergedRouteManifest !== null) return;
+      resetStagedBuildAssets(s.projectRoot);
+      s.prerenderManifestEntries = null;
+      s.staticManifestEntries = null;
+
+      // Acquire build-time env bindings if configured
+      await acquireBuildEnv(s, viteCommand, viteMode);
 
       let tempServer: any = null;
       // Signal to user-space code (e.g. reverse.ts) that build-time discovery
@@ -651,6 +784,7 @@ export function createRouterDiscoveryPlugin(
         if (tempServer) {
           await tempServer.close();
         }
+        await releaseBuildEnv(s);
       }
     },
 
@@ -711,33 +845,40 @@ export function createRouterDiscoveryPlugin(
       if (!s.resolvedPrerenderModules?.size && !s.resolvedStaticModules?.size)
         return;
 
+      // Clear maps at the start of each RSC generateBundle pass.
+      // Vite 6 multi-environment builds run RSC twice (analysis + production);
+      // clearing prevents stale/duplicate records from the analysis pass.
+      s.handlerChunkInfoMap.clear();
+      s.staticHandlerChunkInfoMap.clear();
+
       for (const [fileName, chunk] of Object.entries(bundle) as [
         string,
         any,
       ][]) {
         if (chunk.type !== "chunk") continue;
 
-        // Prerender handlers chunk
-        if (
-          fileName.includes("__prerender-handlers") &&
-          s.resolvedPrerenderModules?.size
-        ) {
+        // Scan all chunks for handler exports (handlers may land in any chunk)
+        if (s.resolvedPrerenderModules?.size) {
           const handlers = extractHandlerExportsFromChunk(
             chunk.code,
             s.resolvedPrerenderModules,
             "Prerender",
-            true,
+            false,
           );
           if (handlers.length > 0) {
-            s.handlerChunkInfo = { fileName, exports: handlers };
+            const existing = s.handlerChunkInfoMap.get(fileName);
+            if (existing) {
+              existing.exports.push(...handlers);
+            } else {
+              s.handlerChunkInfoMap.set(fileName, {
+                fileName,
+                exports: handlers,
+              });
+            }
           }
         }
 
-        // Static handlers chunk
-        if (
-          fileName.includes("__static-handlers") &&
-          s.resolvedStaticModules?.size
-        ) {
+        if (s.resolvedStaticModules?.size) {
           const handlers = extractHandlerExportsFromChunk(
             chunk.code,
             s.resolvedStaticModules,
@@ -745,7 +886,15 @@ export function createRouterDiscoveryPlugin(
             false,
           );
           if (handlers.length > 0) {
-            s.staticHandlerChunkInfo = { fileName, exports: handlers };
+            const existing = s.staticHandlerChunkInfoMap.get(fileName);
+            if (existing) {
+              existing.exports.push(...handlers);
+            } else {
+              s.staticHandlerChunkInfoMap.set(fileName, {
+                fileName,
+                exports: handlers,
+              });
+            }
           }
         }
       }

package/src/vite/utils/banner.ts

@@ -23,11 +23,11 @@ ${dim} ╱${reset}    ${bold}╔═╗${reset}${dim}      *      ╱
 ${dim}      ${reset}${bold}║ ║${reset} ${bold}╔═╗${reset}${dim}                    *                ✧.   ╱${reset}
 ${dim}   ${reset}${bold}╔╗ ║ ║ ║ ║${reset}${dim}                          *               ╱${reset}
 ${dim}   ${reset}${bold}║║ ║ ║ ║ ║  ╦═╗╔═╗╔╗╔╔═╗╔═╗${reset}${dim}             ✧              ✦${reset}
-${dim}  ${reset}${bold}═╣║ ║ ╠═╝ ║  ╠╦╝╠═╣║║║║ ╦║ ║${reset}${dim}        *           ✧${reset}
+${dim}   ${reset}${bold}║║ ║ ╠═╝ ║  ╠╦╝╠═╣║║║║ ╦║ ║${reset}${dim}        *           ✧${reset}
 ${dim}   ${reset}${bold}║╚═╝ ╔═══╝  ╩╚═╩ ╩╝╚╝╚═╝╚═╝${reset}${dim}            ✦          .      *${reset}
 ${dim}   ${reset}${bold}╚══╗ ║${reset}${dim} *      RSC Wrangler         ✧                ✦${reset}
-${dim}  *   ${reset}${bold}║ ╠═${reset}${dim}                         *            ✧.    ╱${reset}
-${bold}══════╝ ╚═════════╩═══${reset}${dim}                  ✦            *${reset}
+${dim}  *   ${reset}${bold}║ ║${reset}${dim}                          *            ✧.    ╱${reset}
+${dim}   ${reset}${bold}═══╝ ╚════${reset}${dim}                           ✦            *${reset}
 
    v${version} · ${preset} · ${mode}
 `;

package/src/vite/utils/prerender-utils.ts

@@ -1,3 +1,14 @@
+import { createHash } from "node:crypto";
+import {
+  copyFileSync,
+  existsSync,
+  mkdirSync,
+  rmSync,
+  statSync,
+  writeFileSync,
+} from "node:fs";
+import { resolve } from "node:path";
+
 /**
  * Escape special RegExp characters in a string for safe interpolation
  * into new RegExp() patterns.
@@ -20,6 +31,7 @@ export function encodePathParam(value: unknown): string {
 /**
  * Substitute route params into a pattern, stripping constraint and optional
  * syntax (:param(a|b)? -> value). Also handles wildcard params (*key).
+ * Optional params not present in `params` are removed from the output.
  */
 export function substituteRouteParams(
   pattern: string,
@@ -27,6 +39,9 @@ export function substituteRouteParams(
   encode: (value: string) => string = encodeURIComponent,
 ): string {
   let result = pattern;
+  let hadOmittedOptional = false;
+
+  // First pass: substitute provided params
   for (const [key, value] of Object.entries(params)) {
     const escaped = escapeRegExp(key);
     result = result.replace(
@@ -35,6 +50,20 @@ export function substituteRouteParams(
     );
     result = result.replace(`*${key}`, encode(value));
   }
+
+  // Second pass: strip remaining optional param placeholders not in params
+  result = result.replace(/:([a-zA-Z_][a-zA-Z0-9_]*)(\([^)]*\))?\?/g, () => {
+    hadOmittedOptional = true;
+    return "";
+  });
+
+  // Clean up slashes from omitted optional segments
+  if (hadOmittedOptional) {
+    const hadTrailingSlash = pattern.length > 1 && pattern.endsWith("/");
+    result = result.replace(/\/\/+/g, "/").replace(/\/+$/, "") || "/";
+    if (hadTrailingSlash && !result.endsWith("/")) result += "/";
+  }
+
   return result;
 }
 
@@ -127,3 +156,52 @@ export function notifyOnError(
     break; // Only notify the first router with onError
   }
 }
+
+function getStagedAssetDir(projectRoot: string): string {
+  return resolve(projectRoot, "node_modules/.rangojs-router-build/rsc-assets");
+}
+
+export function resetStagedBuildAssets(projectRoot: string): void {
+  rmSync(getStagedAssetDir(projectRoot), { recursive: true, force: true });
+}
+
+export function stageBuildAssetModule(
+  projectRoot: string,
+  prefix: "__pr" | "__st",
+  exportValue: string,
+): string {
+  const stagedDir = getStagedAssetDir(projectRoot);
+  mkdirSync(stagedDir, { recursive: true });
+
+  const contentHash = createHash("sha256")
+    .update(exportValue)
+    .digest("hex")
+    .slice(0, 8);
+  const fileName = `${prefix}-${contentHash}.js`;
+  const filePath = resolve(stagedDir, fileName);
+
+  if (!existsSync(filePath)) {
+    writeFileSync(filePath, `export default ${exportValue};\n`);
+  }
+
+  return fileName;
+}
+
+export function copyStagedBuildAssets(
+  projectRoot: string,
+  fileNames: Iterable<string>,
+): number {
+  const stagedDir = getStagedAssetDir(projectRoot);
+  const distAssetsDir = resolve(projectRoot, "dist/rsc/assets");
+  mkdirSync(distAssetsDir, { recursive: true });
+
+  let totalBytes = 0;
+  for (const fileName of new Set(fileNames)) {
+    const stagedPath = resolve(stagedDir, fileName);
+    const distPath = resolve(distAssetsDir, fileName);
+    copyFileSync(stagedPath, distPath);
+    totalBytes += statSync(stagedPath).size;
+  }
+
+  return totalBytes;
+}

package/src/vite/utils/shared-utils.ts

@@ -1,6 +1,7 @@
 import type { Plugin } from "vite";
 import * as Vite from "vite";
 import { getPublishedPackageName } from "./package-resolution.js";
+import { performanceTracksOptimizeDepsPlugin } from "../plugins/performance-tracks.js";
 import {
   VIRTUAL_ENTRY_BROWSER,
   VIRTUAL_ENTRY_SSR,
@@ -35,9 +36,9 @@ const versionEsbuildPlugin = {
  * Includes the version stub plugin for all environments.
  */
 export const sharedEsbuildOptions: {
-  plugins: (typeof versionEsbuildPlugin)[];
+  plugins: any[];
 } = {
-  plugins: [versionEsbuildPlugin],
+  plugins: [versionEsbuildPlugin, performanceTracksOptimizeDepsPlugin()],
 };
 
 /**