@rangojs/router 0.0.0-experimental.d20dd405 → 0.0.0-experimental.d5d3070a

package/src/vite/discovery/prerender-collection.ts

@@ -6,13 +6,14 @@
  * generation.
  */
 
-import { contextSet } from "../../context-var.js";
+import { contextSet, hasContextVars } from "../../context-var.js";
 import {
   encodePathParam,
   substituteRouteParams,
   runWithConcurrency,
   groupByConcurrency,
   notifyOnError,
+  resolvePrerenderError,
   stageBuildAssetModule,
 } from "../utils/prerender-utils.js";
 import type { DiscoveryState } from "./state.js";
@@ -81,7 +82,7 @@ export async function expandPrerenderRoutes(
       ? setInterval(() => {
           const elapsed = ((performance.now() - paramsStart) / 1000).toFixed(1);
           console.log(
-            `[rsc-router] Resolving prerender params... ${resolvedRoutes}/${totalDynamic} routes (${elapsed}s)`,
+            `[rango] Resolving prerender params... ${resolvedRoutes}/${totalDynamic} routes (${elapsed}s)`,
           );
         }, 5000)
       : undefined;
@@ -122,7 +123,7 @@ export async function expandPrerenderRoutes(
                 get env() {
                   if (buildEnv !== undefined) return buildEnv;
                   throw new Error(
-                    "[rsc-router] ctx.env is not available during build-time getParams(). " +
+                    "[rango] ctx.env is not available during build-time getParams(). " +
                       "Configure buildEnv in your rango() plugin options to enable build-time env access.",
                   );
                 },
@@ -135,9 +136,7 @@ export async function expandPrerenderRoutes(
                 (performance.now() - getParamsStart).toFixed(1),
               );
               const concurrency = def.options?.concurrency ?? 1;
-              const hasBuildVars =
-                Object.keys(buildVars).length > 0 ||
-                Object.getOwnPropertySymbols(buildVars).length > 0;
+              const hasBuildVars = hasContextVars(buildVars);
               for (const params of paramsList) {
                 let url = substituteRouteParams(
                   pattern,
@@ -170,7 +169,7 @@ export async function expandPrerenderRoutes(
               // Skip in getParams() skips the entire route
               if (err.name === "Skip") {
                 console.log(
-                  `[rsc-router]   SKIP route "${routeName}" - ${err.message}`,
+                  `[rango]   SKIP route "${routeName}" - ${err.message}`,
                 );
                 notifyOnError(
                   registry,
@@ -184,14 +183,14 @@ export async function expandPrerenderRoutes(
               }
               // Regular error: fail the build
               console.error(
-                `[rsc-router] Failed to get params for prerender route "${routeName}": ${err.message}`,
+                `[rango] Failed to get params for prerender route "${routeName}": ${err.message}`,
               );
               notifyOnError(registry, err, "prerender", routeName);
               throw err;
             }
           } else {
             console.warn(
-              `[rsc-router] Dynamic prerender route "${routeName}" has no getParams(), skipping`,
+              `[rango] Dynamic prerender route "${routeName}" has no getParams(), skipping`,
             );
           }
         }
@@ -202,7 +201,7 @@ export async function expandPrerenderRoutes(
       clearInterval(progressInterval);
       const elapsed = ((performance.now() - paramsStart) / 1000).toFixed(1);
       console.log(
-        `[rsc-router] Resolved prerender params: ${resolvedRoutes}/${totalDynamic} routes (${elapsed}s)`,
+        `[rango] Resolved prerender params: ${resolvedRoutes}/${totalDynamic} routes (${elapsed}s)`,
       );
     }
   }
@@ -220,7 +219,7 @@ export async function expandPrerenderRoutes(
   const concurrencyNote =
     maxConcurrency > 1 ? ` (concurrency: ${maxConcurrency})` : "";
   console.log(
-    `[rsc-router] Pre-rendering ${entries.length} URL(s)${concurrencyNote}...`,
+    `[rango] Pre-rendering ${entries.length} URL(s)${concurrencyNote}...`,
   );
   debug?.(
     "prerender loop: %d entries, max concurrency %d",
@@ -233,6 +232,10 @@ export async function expandPrerenderRoutes(
   const manifestEntries: Record<string, string> = {};
   let doneCount = 0;
   let skipCount = 0;
+  // #587: a render error reaches here (matchForPrerender now re-throws it rather
+  // than baking the error boundary). Default "fail" fails the build; "warn" logs
+  // and skips baking the URL.
+  const prerenderOnError = state.opts?.prerenderOnError ?? "fail";
   const startTotal = performance.now();
 
   // Group entries by concurrency for batched rendering.
@@ -261,7 +264,7 @@ export async function expandPrerenderRoutes(
             if (result.passthrough) {
               const elapsed = (performance.now() - startUrl).toFixed(0);
               console.log(
-                `[rsc-router]   PASS ${entry.urlPath.padEnd(40)} (${elapsed}ms) - live fallback`,
+                `[rango]   PASS ${entry.urlPath.padEnd(40)} (${elapsed}ms) - live fallback`,
               );
               doneCount++;
               break;
@@ -282,10 +285,9 @@ export async function expandPrerenderRoutes(
               const interceptKey = `${result.routeName}/${paramHash}/i`;
               const interceptValue = JSON.stringify({
                 segments: [...result.segments, ...result.interceptSegments],
-                handles: {
-                  ...result.handles,
-                  ...(result.interceptHandles || {}),
-                },
+                // interceptHandles is the pre-encoded MERGED (main + intercept)
+                // handle string (the producer merged before encoding).
+                handles: result.interceptHandles ?? "",
               });
               manifestEntries[interceptKey] = stageBuildAssetModule(
                 state.projectRoot,
@@ -295,40 +297,27 @@ export async function expandPrerenderRoutes(
             }
             const elapsed = (performance.now() - startUrl).toFixed(0);
             console.log(
-              `[rsc-router]   OK   ${entry.urlPath.padEnd(40)} (${elapsed}ms)`,
+              `[rango]   OK   ${entry.urlPath.padEnd(40)} (${elapsed}ms)`,
             );
             doneCount++;
             break;
           } catch (err: any) {
-            if (err.name === "Skip") {
-              const elapsed = (performance.now() - startUrl).toFixed(0);
-              console.log(
-                `[rsc-router]   SKIP ${entry.urlPath.padEnd(40)} (${elapsed}ms) - ${err.message}`,
-              );
-              skipCount++;
-              notifyOnError(
-                registry,
-                err,
-                "prerender",
-                entry.routeName,
-                entry.urlPath,
-                true,
-              );
-              break;
-            }
-            // Regular error: log, notify, and fail the build
+            // Skip, or a render error under prerender.onError "warn": skip the
+            // URL (never bake the error page, #587). A render error under the
+            // default "fail" re-throws below to fail the build.
             const elapsed = (performance.now() - startUrl).toFixed(0);
-            console.error(
-              `[rsc-router]   FAIL ${entry.urlPath.padEnd(40)} (${elapsed}ms) - ${err.message}`,
-            );
-            notifyOnError(
+            resolvePrerenderError(
               registry,
               err,
+              prerenderOnError,
+              entry.urlPath.padEnd(40),
+              elapsed,
               "prerender",
               entry.routeName,
               entry.urlPath,
             );
-            throw err;
+            skipCount++;
+            break;
           }
         }
       },
@@ -342,7 +331,7 @@ export async function expandPrerenderRoutes(
   const parts = [`${doneCount} done`];
   if (skipCount > 0) parts.push(`${skipCount} skipped`);
   console.log(
-    `[rsc-router] Pre-render complete: ${parts.join(", ")} (${totalElapsed}ms total)`,
+    `[rango] Pre-render complete: ${parts.join(", ")} (${totalElapsed}ms total)`,
   );
   debug?.(
     "expandPrerenderRoutes done: %d done, %d skipped, %sms (overall %sms)",
@@ -381,15 +370,14 @@ export async function renderStaticHandlers(
   let staticDone = 0;
   let staticSkip = 0;
   let totalStaticCount = 0;
+  const prerenderOnError = state.opts?.prerenderOnError ?? "fail";
 
   // Count handlers for the log header
   for (const [, exportNames] of state.resolvedStaticModules) {
     totalStaticCount += exportNames.length;
   }
   const startStatic = performance.now();
-  console.log(
-    `[rsc-router] Rendering ${totalStaticCount} static handler(s)...`,
-  );
+  console.log(`[rango] Rendering ${totalStaticCount} static handler(s)...`);
 
   for (const [moduleId, exportNames] of state.resolvedStaticModules) {
     let mod: any;
@@ -397,7 +385,7 @@ export async function renderStaticHandlers(
       mod = await rscEnv!.runner.import(moduleId);
     } catch (err: any) {
       console.error(
-        `[rsc-router] Failed to import static module ${moduleId}: ${err.message}`,
+        `[rango] Failed to import static module ${moduleId}: ${err.message}`,
       );
       notifyOnError(registry, err, "static");
       throw err;
@@ -422,7 +410,8 @@ export async function renderStaticHandlers(
             !state.isBuildMode,
           );
           if (result) {
-            const hasHandles = Object.keys(result.handles).length > 0;
+            // result.handles is the pre-encoded handle string ("" when none).
+            const hasHandles = result.handles !== "";
             const exportValue = hasHandles
               ? JSON.stringify(result)
               : JSON.stringify(result.encoded);
@@ -432,37 +421,29 @@ export async function renderStaticHandlers(
               exportValue,
             );
             const elapsed = (performance.now() - startHandler).toFixed(0);
-            console.log(
-              `[rsc-router]   OK   ${name.padEnd(40)} (${elapsed}ms)`,
-            );
+            console.log(`[rango]   OK   ${name.padEnd(40)} (${elapsed}ms)`);
             staticDone++;
             handled = true;
             break;
           }
         } catch (err: any) {
-          if (err.name === "Skip") {
-            const elapsed = (performance.now() - startHandler).toFixed(0);
-            console.log(
-              `[rsc-router]   SKIP ${name.padEnd(40)} (${elapsed}ms) - ${err.message}`,
-            );
-            staticSkip++;
-            notifyOnError(registry, err, "static", undefined, undefined, true);
-            handled = true;
-            break;
-          }
-          // Regular error: log, notify, and fail the build
+          // Same Skip/warn/fail policy as the prerender loop (shared helper).
           const elapsed = (performance.now() - startHandler).toFixed(0);
-          console.error(
-            `[rsc-router]   FAIL ${name.padEnd(40)} (${elapsed}ms) - ${err.message}`,
+          resolvePrerenderError(
+            registry,
+            err,
+            prerenderOnError,
+            name.padEnd(40),
+            elapsed,
+            "static",
           );
-          notifyOnError(registry, err, "static");
-          throw err;
+          staticSkip++;
+          handled = true;
+          break;
         }
       }
       if (!handled) {
-        console.warn(
-          `[rsc-router] No router could render static handler "${name}"`,
-        );
+        console.warn(`[rango] No router could render static handler "${name}"`);
       }
     }
   }
@@ -474,7 +455,7 @@ export async function renderStaticHandlers(
   const staticParts = [`${staticDone} done`];
   if (staticSkip > 0) staticParts.push(`${staticSkip} skipped`);
   console.log(
-    `[rsc-router] Static render complete: ${staticParts.join(", ")} (${totalStaticElapsed}ms total)`,
+    `[rango] Static render complete: ${staticParts.join(", ")} (${totalStaticElapsed}ms total)`,
   );
   debug?.(
     "renderStaticHandlers done: %d done, %d skipped, %sms (overall %sms)",

package/src/vite/discovery/route-types-writer.ts

@@ -5,13 +5,15 @@
  * from discovered router manifests and static source parsing.
  */
 
-import { dirname, basename, join, resolve } from "node:path";
+import { dirname, join, resolve } from "node:path";
 import { readFileSync, writeFileSync, existsSync, unlinkSync } from "node:fs";
 import {
   generateRouteTypesSource,
   writeCombinedRouteTypes,
   findRouterFiles,
   buildCombinedRouteMapForRouterFile,
+  genFileTsPath,
+  resolveSearchSchemas,
 } from "../../build/generate-route-types.js";
 import type { DiscoveryState } from "./state.js";
 import { markSelfGenWrite } from "./self-gen-tracking.js";
@@ -35,6 +37,22 @@ function filterUserNamedRoutes(
   return filtered;
 }
 
+// Write a gen file only when content changed, marking the write as
+// self-generated BEFORE writeFileSync so the watcher distinguishes it from a
+// manual edit (the HMR self-gen-loop guard).
+function writeGenFileIfChanged(
+  state: DiscoveryState,
+  outPath: string,
+  source: string,
+  opts?: { log?: boolean },
+): void {
+  const existing = existsSync(outPath) ? readFileSync(outPath, "utf-8") : null;
+  if (existing === source) return;
+  markSelfGenWrite(state, outPath, source);
+  writeFileSync(outPath, source);
+  if (opts?.log) console.log(`[rango] Generated route types -> ${outPath}`);
+}
+
 /**
  * Write combined route types for all router files.
  * Only writes when content has changed to avoid triggering HMR loops.
@@ -48,45 +66,16 @@ export function writeCombinedRouteTypesWithTracking(
     findRouterFiles(state.projectRoot, state.scanFilter);
   state.cachedRouterFiles = routerFiles;
 
-  // Snapshot pre-write content to detect which files actually change.
-  const preContent = new Map<string, string>();
-  for (const routerFilePath of routerFiles) {
-    const routerDir = dirname(routerFilePath);
-    const routerBasename = basename(routerFilePath).replace(
-      /\.(tsx?|jsx?)$/,
-      "",
-    );
-    const outPath = join(routerDir, `${routerBasename}.named-routes.gen.ts`);
-    try {
-      preContent.set(outPath, readFileSync(outPath, "utf-8"));
-    } catch {
-      // File doesn't exist yet — any write is a real change.
-    }
-  }
-
-  writeCombinedRouteTypes(state.projectRoot, routerFiles, opts);
-
-  // Mark only files that were actually written so the watcher can
-  // distinguish self-triggered change events from manual edits.
-  // Marking unchanged files creates stale entries that interfere with
-  // multi-server setups (e.g. shared webServer + isolated HMR server).
-  for (const routerFilePath of routerFiles) {
-    const routerDir = dirname(routerFilePath);
-    const routerBasename = basename(routerFilePath).replace(
-      /\.(tsx?|jsx?)$/,
-      "",
-    );
-    const outPath = join(routerDir, `${routerBasename}.named-routes.gen.ts`);
-    if (!existsSync(outPath)) continue;
-    try {
-      const content = readFileSync(outPath, "utf-8");
-      if (content !== preContent.get(outPath)) {
-        markSelfGenWrite(state, outPath, content);
-      }
-    } catch {
-      // Ignore transient fs errors while files are being rewritten.
-    }
-  }
+  // Mark each gen file as self-generated BEFORE it is written, via the onWrite
+  // callback fired at every writeFileSync site, so the watcher distinguishes
+  // self-triggered change events from manual edits. The callback fires only
+  // for files actually written, so unchanged files are never marked (stale
+  // entries interfere with multi-server setups such as a shared webServer plus
+  // an isolated HMR server).
+  writeCombinedRouteTypes(state.projectRoot, routerFiles, {
+    ...opts,
+    onWrite: (outPath, content) => markSelfGenWrite(state, outPath, content),
+  });
 }
 
 /**
@@ -104,7 +93,7 @@ export function writeRouteTypesFiles(state: DiscoveryState): void {
     if (existsSync(oldCombinedPath)) {
       unlinkSync(oldCombinedPath);
       console.log(
-        `[rsc-router] Removed stale combined route types: ${oldCombinedPath}`,
+        `[rango] Removed stale combined route types: ${oldCombinedPath}`,
       );
     }
   } catch {}
@@ -122,40 +111,22 @@ export function writeRouteTypesFiles(state: DiscoveryState): void {
     // the wrong location, causing non-deterministic type resolution.
     if (sourceFile.includes("node_modules")) {
       throw new Error(
-        `[rsc-router] Router "${id}" has sourceFile inside node_modules: ${sourceFile}\n` +
+        `[rango] Router "${id}" has sourceFile inside node_modules: ${sourceFile}\n` +
           `This means createRouter() stack trace parsing matched a Vite internal frame.\n` +
           `Set an explicit \`id\` on createRouter() or check the call site.`,
       );
     }
 
-    const routerDir = dirname(sourceFile);
-    const routerBasename = basename(sourceFile).replace(/\.(tsx?|jsx?)$/, "");
-    const outPath = join(routerDir, `${routerBasename}.named-routes.gen.ts`);
+    const outPath = genFileTsPath(sourceFile);
 
     // Filter out auto-generated route names (e.g. "$path____debug_reverse-test")
     // to match the static parser's output and prevent HMR oscillation.
     const userRoutes = filterUserNamedRoutes(routeManifest);
-    let effectiveSearchSchemas = routeSearchSchemas;
-
-    // Runtime manifest may omit search schema metadata in some module-runner
-    // flows. Fall back to static source parsing from the router file.
-    if (
-      (!effectiveSearchSchemas ||
-        Object.keys(effectiveSearchSchemas).length === 0) &&
-      sourceFile
-    ) {
-      const staticParsed = buildCombinedRouteMapForRouterFile(sourceFile);
-      if (Object.keys(staticParsed.searchSchemas).length > 0) {
-        const filtered: Record<string, Record<string, string>> = {};
-        for (const name of Object.keys(userRoutes)) {
-          const schema = staticParsed.searchSchemas[name];
-          if (schema) filtered[name] = schema;
-        }
-        if (Object.keys(filtered).length > 0) {
-          effectiveSearchSchemas = filtered;
-        }
-      }
-    }
+    const effectiveSearchSchemas = resolveSearchSchemas(
+      Object.keys(userRoutes),
+      routeSearchSchemas,
+      sourceFile,
+    );
 
     const source = generateRouteTypesSource(
       userRoutes,
@@ -163,14 +134,7 @@ export function writeRouteTypesFiles(state: DiscoveryState): void {
         ? effectiveSearchSchemas
         : undefined,
     );
-    const existing = existsSync(outPath)
-      ? readFileSync(outPath, "utf-8")
-      : null;
-    if (existing !== source) {
-      markSelfGenWrite(state, outPath, source);
-      writeFileSync(outPath, source);
-      console.log(`[rsc-router] Generated route types -> ${outPath}`);
-    }
+    writeGenFileIfChanged(state, outPath, source, { log: true });
   }
 }
 
@@ -236,22 +200,14 @@ export function supplementGenFilesWithRuntimeRoutes(
       }
     }
 
-    const routerDir = dirname(sourceFile);
-    const routerBasename = basename(sourceFile).replace(/\.(tsx?|jsx?)$/, "");
-    const outPath = join(routerDir, `${routerBasename}.named-routes.gen.ts`);
+    const outPath = genFileTsPath(sourceFile);
     const source = generateRouteTypesSource(
       mergedRoutes,
       Object.keys(mergedSearchSchemas).length > 0
         ? mergedSearchSchemas
         : undefined,
     );
-    const existing = existsSync(outPath)
-      ? readFileSync(outPath, "utf-8")
-      : null;
-    if (existing !== source) {
-      markSelfGenWrite(state, outPath, source);
-      writeFileSync(outPath, source);
-    }
+    writeGenFileIfChanged(state, outPath, source);
   }
   // No manual manifest update needed: the virtual module imports the gen
   // file, so Vite's HMR automatically re-evaluates it with fresh data.

package/src/vite/discovery/state.ts

@@ -20,6 +20,24 @@ export interface PluginOptions {
   buildEnv?: import("../plugin-types.js").BuildEnvOption;
   /** Deployment preset (needed for buildEnv "auto" resolution). */
   preset?: "node" | "cloudflare";
+  /**
+   * Route-discovery scan filter (glob include/exclude) from rango() config.
+   * Compiled into `DiscoveryState.scanFilter` once `projectRoot` is known.
+   */
+  discovery?: { include?: string[]; exclude?: string[] };
+  /**
+   * What to do when a Prerender/Static render throws at build time, from
+   * rango({ prerender: { onError } }). "fail" (default) fails the build; "warn"
+   * logs and skips baking the URL. See {@link import("../plugin-types.js").RangoOptions}.
+   */
+  prerenderOnError?: "fail" | "warn";
+  /**
+   * Shared context the built-in clientChunks strategy reads. Discovery populates
+   * it (registered fallback hashes + single-router name) before the client build
+   * invokes the strategy. Present only when the built-in strategy is active
+   * (`clientChunks: true`/default); undefined for `false` or a custom function.
+   */
+  clientChunkCtx?: import("../utils/client-chunks.js").ClientChunkContext;
 }
 
 export interface PrecomputedEntry {
@@ -45,6 +63,21 @@ export interface DiscoveryState {
   projectRoot: string;
   isBuildMode: boolean;
   userResolveAlias: any;
+  /**
+   * Data-only slice of the user's resolved config (resolve.* incl. native
+   * tsconfigPaths, define, oxc) mirrored into the discovery temp server so it
+   * resolves and transforms modules the same way the real environment does.
+   * See `utils/forward-user-plugins.ts`.
+   */
+  userRunnerConfig:
+    | import("../utils/forward-user-plugins.js").ForwardedRunnerConfig
+    | undefined;
+  /**
+   * User resolution plugins (resolveId/load), stripped to their resolution
+   * surface, forwarded into the discovery temp server. Lets third-party
+   * resolvers such as vite-tsconfig-paths participate in discovery.
+   */
+  userResolvePlugins: import("vite").Plugin[];
   scanFilter: ScanFilter | undefined;
   cachedRouterFiles: string[] | undefined;
   opts: PluginOptions | undefined;
@@ -76,6 +109,14 @@ export interface DiscoveryState {
   resolvedBuildEnv?: Record<string, unknown>;
   /** Cleanup function for build-time env resources (e.g., miniflare). */
   buildEnvDispose?: (() => Promise<void> | void) | null;
+
+  /**
+   * Set when the most recent HMR re-discovery threw. Cleared on the next
+   * successful discovery. Surfaced via debug logs so we can detect "manifest
+   * frozen at last-good after error → user fix in non-route file → no
+   * rediscovery trigger" scenarios.
+   */
+  lastDiscoveryError?: { message: string; at: number } | null;
 }
 
 export function createDiscoveryState(
@@ -87,6 +128,8 @@ export function createDiscoveryState(
     projectRoot: "",
     isBuildMode: false,
     userResolveAlias: undefined,
+    userRunnerConfig: undefined,
+    userResolvePlugins: [],
     scanFilter: undefined,
     cachedRouterFiles: undefined,
     opts,
@@ -113,5 +156,6 @@ export function createDiscoveryState(
     devServer: null,
     selfWrittenGenFiles: new Map(),
     SELF_WRITE_WINDOW_MS: 5_000,
+    lastDiscoveryError: null,
   };
 }

package/src/vite/discovery/virtual-module-codegen.ts

@@ -49,7 +49,6 @@ export function generateRoutesManifestModule(state: DiscoveryState): string {
         );
         genFileVars.push(varName);
       } else {
-        // Routers without sourceFile: inline their manifest data directly
         routersWithoutGenFile.push({
           id: entry.id,
           manifest: entry.routeManifest,
@@ -58,7 +57,7 @@ export function generateRoutesManifestModule(state: DiscoveryState): string {
     }
 
     const lines = [
-      `import { setCachedManifest, setPrecomputedEntries, setRouteTrie, setRouterManifest, registerRouterManifestLoader, clearAllRouterData } from "@rangojs/router/server";`,
+      `import { setCachedManifest, setRouterManifest, registerRouterManifestLoader, clearAllRouterData } from "@rangojs/router/server";`,
       ...genFileImports,
       // Clear stale per-router cached data (manifest, trie, precomputed entries)
       // before re-populating. In Cloudflare dev mode, program reloads re-evaluate
@@ -68,14 +67,12 @@ export function generateRoutesManifestModule(state: DiscoveryState): string {
       `clearAllRouterData();`,
     ];
 
-    // Flatten NamedRoutes entries: search schema objects -> plain string paths
     if (genFileVars.length > 0) {
       lines.push(
         `function __flat(r) { const o = {}; for (const [k, v] of Object.entries(r)) o[k] = typeof v === "string" ? v : v.path; return o; }`,
       );
     }
 
-    // Build the merged manifest from gen file imports + inlined data
     if (genFileVars.length === 1 && routersWithoutGenFile.length === 0) {
       lines.push(`setCachedManifest(__flat(${genFileVars[0]}));`);
     } else {
@@ -86,7 +83,6 @@ export function generateRoutesManifestModule(state: DiscoveryState): string {
       lines.push(`setCachedManifest({ ${parts.join(", ")} });`);
     }
 
-    // Set per-router manifests
     let genVarIdx = 0;
     for (const entry of state.perRouterManifests) {
       if (entry.sourceFile) {
@@ -101,31 +97,19 @@ export function generateRoutesManifestModule(state: DiscoveryState): string {
       }
     }
 
-    // In dev mode, skip trie and precomputed entries injection. These are
-    // computed once during initial discovery and become stale after route
-    // changes. A stale trie would incorrectly match removed routes. The
-    // handler falls back to Phase 2 regex matching against the live
-    // router.urlpatterns, which is always correct after a program reload.
-    // In build mode, the trie is always fresh (built from the final route
-    // tree) so it's safe to inject.
-    if (state.isBuildMode) {
-      if (
-        state.mergedPrecomputedEntries &&
-        state.mergedPrecomputedEntries.length > 0
-      ) {
-        lines.push(
-          `setPrecomputedEntries(${jsonParseExpression(state.mergedPrecomputedEntries)});`,
-        );
-      }
-      if (state.mergedRouteTrie) {
-        lines.push(
-          `setRouteTrie(${jsonParseExpression(state.mergedRouteTrie)});`,
-        );
-      }
-    }
+    // Per-router trie and precomputedEntries are NOT inlined eagerly.
+    // They live in the per-router lazy chunks (generatePerRouterModule) and
+    // are loaded via ensureRouterManifest(routerId), which is awaited before
+    // every request in router.fetch() and before findMatch is reached.
+    // Inlining the merged versions here would duplicate the per-router data
+    // (the merged trie/precomputedEntries equal the per-router data for
+    // single-router apps; for multi-router, the merged trie is dead code
+    // because find-match.ts only consumes per-router tries).
+    //
+    // In dev mode, the handler also falls back to Phase 2 regex matching
+    // against live router.urlpatterns, which is always correct after a
+    // program reload.
 
-    // Register lazy loaders for per-router manifest modules.
-    // Each import() uses a static string literal so Rollup creates separate chunks.
     for (const routerId of state.perRouterManifestDataMap.keys()) {
       lines.push(
         `registerRouterManifestLoader(${JSON.stringify(routerId)}, () => import(${JSON.stringify(VIRTUAL_ROUTES_MANIFEST_ID + "/" + routerId)}));`,
@@ -139,9 +123,6 @@ export function generateRoutesManifestModule(state: DiscoveryState): string {
     return lines.join("\n");
   }
 
-  // No manifest: either discovery hasn't completed or no runner (Cloudflare dev).
-  // Still inject __PRERENDER_DEV_URL so the prerender store can fetch on-demand.
-  // Re-resolve origin now since the server is listening by module load time.
   if (!state.isBuildMode) {
     const origin =
       state.devServerOrigin ||
@@ -170,7 +151,6 @@ export function generatePerRouterModule(
   const lines: string[] = [];
 
   if (routerEntry?.sourceFile) {
-    // Import manifest from the gen file so HMR auto-propagates
     const routerDir = dirname(routerEntry.sourceFile);
     const routerBasename = basename(routerEntry.sourceFile).replace(
       /\.(tsx?|jsx?)$/,
@@ -199,5 +179,5 @@ export function generatePerRouterModule(
       `export const precomputedEntries = ${jsonParseExpression(entries)};`,
     );
   }
-  return lines.join("\n") || "// empty router manifest";
+  return lines.join("\n") || "";
 }

package/src/vite/index.ts

@@ -13,6 +13,8 @@ export type {
   RangoNodeOptions,
   RangoCloudflareOptions,
   RangoOptions,
+  ClientChunks,
+  ClientChunkMeta,
   BuildEnvOption,
   BuildEnvFactory,
   BuildEnvFactoryContext,