use a .env.mjs file for the vars

Author: james-elicx

packages/cloudflare/env.d.ts

@@ -7,6 +7,8 @@ declare global {
       NEXT_PRIVATE_DEBUG_CACHE?: string;
       __OPENNEXT_KV_BINDING_NAME: string;
       OPEN_NEXT_ORIGIN: string;
+      NODE_ENV?: string;
+      __OPENNEXT_PROCESSED_ENV?: string;
     }
   }
 }

packages/cloudflare/src/cli/build/bundle-server.ts

@@ -7,6 +7,7 @@ import type { BuildOptions } from "@opennextjs/aws/build/helper.js";
 import { build, Plugin } from "esbuild";
 
 import { Config } from "../config";
+import { copyEnvFiles } from "./patches/investigated/copy-env-files";
 import { copyPackageCliFiles } from "./patches/investigated/copy-package-cli-files";
 import { patchCache } from "./patches/investigated/patch-cache";
 import { patchRequire } from "./patches/investigated/patch-require";
@@ -31,7 +32,8 @@ export async function bundleServer(config: Config, openNextOptions: BuildOptions
   // Copy over prerendered assets (e.g. SSG routes)
   copyPrerenderedRoutes(config);
 
-  await copyPackageCliFiles(packageDistDir, config, openNextOptions);
+  copyPackageCliFiles(packageDistDir, config, openNextOptions);
+  copyEnvFiles(openNextOptions);
 
   const nextConfigStr =
     fs

packages/cloudflare/src/cli/build/patches/investigated/copy-env-files.ts

@@ -0,0 +1,18 @@
+import fs from "node:fs";
+import path from "node:path";
+
+import { BuildOptions } from "@opennextjs/aws/build/helper.js";
+
+import { extractProjectEnvVars } from "../../utils";
+
+/**
+ * Copies the values extracted from the project's env files to the output directory for use in the worker.
+ */
+export function copyEnvFiles(options: BuildOptions) {
+  ["production", "development", "test"].forEach((mode) =>
+    fs.appendFileSync(
+      path.join(options.outputDir, `.env.mjs`),
+      `export const ${mode} = ${JSON.stringify(extractProjectEnvVars(mode, options))};\n`
+    )
+  );
+}

packages/cloudflare/src/cli/build/patches/investigated/copy-package-cli-files.ts

@@ -2,39 +2,21 @@ import fs from "node:fs";
 import path from "node:path";
 
 import type { BuildOptions } from "@opennextjs/aws/build/helper.js";
-import { build } from "esbuild";
 
 import { Config } from "../../../config";
-import { extractProjectEnvVars } from "../../utils";
 
 /**
- * Copies the template files present in the cloudflare adapter package into the
- * standalone node_modules folder and applies necessary transformations.
+ * Copies the template files present in the cloudflare adapter package into the standalone node_modules folder.
  */
-export async function copyPackageCliFiles(
-  packageDistDir: string,
-  config: Config,
-  openNextConfig: BuildOptions
-) {
+export function copyPackageCliFiles(packageDistDir: string, config: Config, openNextConfig: BuildOptions) {
   console.log("# copyPackageTemplateFiles");
   const sourceDir = path.join(packageDistDir, "cli");
   const destinationDir = path.join(config.paths.internal.package, "cli");
 
   fs.cpSync(sourceDir, destinationDir, { recursive: true });
 
-  const devEnvVars = extractProjectEnvVars("development", openNextConfig);
-  const prodEnvVars = extractProjectEnvVars("production", openNextConfig);
-
-  await build({
-    entryPoints: [path.join(packageDistDir, "cli", "templates", "worker.ts")],
-    outfile: path.join(openNextConfig.outputDir, "worker.js"),
-    format: "esm",
-    target: "esnext",
-    bundle: false,
-    minify: false,
-    define: {
-      __OPENNEXT_BUILD_TIME_DEV_ENV: JSON.stringify(devEnvVars),
-      __OPENNEXT_BUILD_TIME_PROD_ENV: JSON.stringify(prodEnvVars),
-    },
-  });
+  fs.copyFileSync(
+    path.join(packageDistDir, "cli", "templates", "worker.ts"),
+    path.join(openNextConfig.outputDir, "worker.ts")
+  );
 }

packages/cloudflare/src/cli/build/utils/extract-project-env-vars.ts

@@ -29,6 +29,6 @@ function readEnvFiles(fileNames: string[], { monorepoRoot, appPath }: BuildOptio
  * In a monorepo, the env files in an app's directory will take precedence over
  * the env files at the root of the monorepo.
  */
-export function extractProjectEnvVars(mode: "development" | "production", options: BuildOptions) {
+export function extractProjectEnvVars(mode: string, options: BuildOptions) {
   return readEnvFiles([".env", `.env.${mode}`, ".env.local", `.env.${mode}.local`], options);
 }

packages/cloudflare/src/cli/templates/worker.ts

@@ -21,15 +21,19 @@ const cloudflareContextALS = new AsyncLocalStorage<CloudflareContext>();
   }
 );
 
-declare const __OPENNEXT_BUILD_TIME_DEV_ENV: Record<string, string>;
-declare const __OPENNEXT_BUILD_TIME_PROD_ENV: Record<string, string>;
+async function applyProjectEnvVars(mode = "production") {
+  if (process.env.__OPENNEXT_PROCESSED_ENV === "1") return;
 
-function applyBuildTimeEnv(mode?: string) {
-  const secrets = mode === "development" ? __OPENNEXT_BUILD_TIME_DEV_ENV : __OPENNEXT_BUILD_TIME_PROD_ENV;
+  // @ts-expect-error: resolved by wrangler build
+  const secrets = await import("./.env.mjs");
 
-  for (const key in secrets) {
-    process.env[key] = secrets[key];
+  if (secrets[mode]) {
+    for (const key in secrets[mode]) {
+      process.env[key] = secrets[key];
+    }
   }
+
+  process.env.__OPENNEXT_PROCESSED_ENV = "1";
 }
 
 export default {
@@ -45,7 +49,7 @@ export default {
         },
       });
 
-      applyBuildTimeEnv(env["NEXTJS_ENV"]);
+      await applyProjectEnvVars(env.NEXTJS_ENV ?? globalThis.process.env.NODE_ENV);
 
       // The Middleware handler can return either a `Response` or a `Request`:
       // - `Response`s should be returned early