fix: bundle sherpa-onnx native packages in packaged app

sherpa-onnx-node native addon was not included in the dist build because
it lives in pnpm's virtual store as an optionalDependency. This caused
local TTS (Kitten) and STT (Parakeet) to fail in the packaged app.

- Add sherpa-onnx platform packages as extraResources in electron-builder
- Update getSherpaLibraryPath() in kitten-tts.ts and parakeet-stt.ts to
  check process.resourcesPath first when app is packaged
- Wrap builder config sherpa logic in try-catch for electron-vite compat

Author: aj47

apps/desktop/electron-builder.config.cjs

@@ -1,5 +1,87 @@
 // @ts-check
 
+// Resolve sherpa-onnx native package paths for bundling into the packaged app.
+// sherpa-onnx is an optionalDependency that pnpm hoists to the root .pnpm store,
+// so electron-builder doesn't include it automatically. We find and bundle it via extraResources.
+//
+// This block is wrapped in try-catch because electron-vite also loads this config file
+// (to read appId/productName) and converts require() calls to ESM imports that fail
+// for Node built-ins. When that happens, we just return empty arrays (no sherpa bundling needed
+// during the vite build step — only during electron-builder packaging).
+let _sherpaResources = {};
+try {
+  const _path = require('path');
+  const _fs = require('fs');
+
+  /**
+   * @param {string} platform
+   * @param {string} arch
+   * @returns {string | null}
+   */
+  function _findSherpaPackagePath(platform, arch) {
+    const platformPackage = `sherpa-onnx-${platform}-${arch}`;
+
+    // Check pnpm virtual store (monorepo root)
+    const rootPnpmBase = _path.join(__dirname, '..', '..', 'node_modules', '.pnpm');
+    if (_fs.existsSync(rootPnpmBase)) {
+      try {
+        const dirs = _fs.readdirSync(rootPnpmBase);
+        const platformDir = dirs.find(d => d.startsWith(`${platformPackage}@`));
+        if (platformDir) {
+          const libPath = _path.join(rootPnpmBase, platformDir, 'node_modules', platformPackage);
+          if (_fs.existsSync(libPath)) return libPath;
+        }
+      } catch { /* ignore */ }
+    }
+
+    // Check local pnpm store
+    const localPnpmBase = _path.join(__dirname, 'node_modules', '.pnpm');
+    if (_fs.existsSync(localPnpmBase)) {
+      try {
+        const dirs = _fs.readdirSync(localPnpmBase);
+        const platformDir = dirs.find(d => d.startsWith(`${platformPackage}@`));
+        if (platformDir) {
+          const libPath = _path.join(localPnpmBase, platformDir, 'node_modules', platformPackage);
+          if (_fs.existsSync(libPath)) return libPath;
+        }
+      } catch { /* ignore */ }
+    }
+
+    // Check standard node_modules
+    const standardPath = _path.join(__dirname, 'node_modules', platformPackage);
+    if (_fs.existsSync(standardPath)) return standardPath;
+
+    const rootStandardPath = _path.join(__dirname, '..', '..', 'node_modules', platformPackage);
+    if (_fs.existsSync(rootStandardPath)) return rootStandardPath;
+
+    console.warn(`[electron-builder] Could not find ${platformPackage} - local TTS/STT may not work in packaged app`);
+    return null;
+  }
+
+  /**
+   * @param {string} platform
+   * @param {string} arch
+   * @returns {Array<{from: string, to: string, filter: string[]}>}
+   */
+  function _sherpaExtraResources(platform, arch) {
+    const sherpaPath = _findSherpaPackagePath(platform, arch);
+    if (!sherpaPath) return [];
+    console.log(`[electron-builder] Bundling sherpa-onnx from: ${sherpaPath}`);
+    return [{ from: sherpaPath, to: `sherpa-onnx-${platform}-${arch}`, filter: ['**/*'] }];
+  }
+
+  _sherpaResources = {
+    macArm64: _sherpaExtraResources('darwin', 'arm64'),
+    macX64: _sherpaExtraResources('darwin', 'x64'),
+    winX64: _sherpaExtraResources('win', 'x64'),
+    linuxX64: _sherpaExtraResources('linux', 'x64'),
+    linuxArm64: _sherpaExtraResources('linux', 'arm64'),
+  };
+} catch {
+  // Running inside electron-vite ESM context — sherpa bundling not needed here
+  _sherpaResources = { macArm64: [], macX64: [], winX64: [], linuxX64: [], linuxArm64: [] };
+}
+
 /** @type {import('electron-builder').Configuration} */
 module.exports = {
   appId: "app.speakmcp",
@@ -59,7 +141,9 @@ module.exports = {
         from: "resources/bundled-skills",
         to: "bundled-skills",
         filter: ["**/*"]
-      }
+      },
+      // sherpa-onnx native libraries for local TTS/STT
+      ..._sherpaResources.winX64,
     ]
   },
   nsis: {
@@ -85,7 +169,10 @@ module.exports = {
         from: "resources/bundled-skills",
         to: "bundled-skills",
         filter: ["**/*"]
-      }
+      },
+      // sherpa-onnx native libraries for local TTS/STT
+      ..._sherpaResources.macArm64,
+      ..._sherpaResources.macX64,
     ],
     artifactName: "${productName}-${version}-${arch}.${ext}",
     entitlementsInherit: "build/entitlements.mac.plist",
@@ -244,7 +331,10 @@ module.exports = {
         from: "resources/bundled-skills",
         to: "bundled-skills",
         filter: ["**/*"]
-      }
+      },
+      // sherpa-onnx native libraries for local TTS/STT
+      ..._sherpaResources.linuxX64,
+      ..._sherpaResources.linuxArm64,
     ]
   },
   deb: {

apps/desktop/src/main/kitten-tts.ts

@@ -138,8 +138,12 @@ function getSherpaLibraryPath(): string | null {
 
   const possiblePaths: string[] = []
 
-  // For packaged app, check resources directory
+  // For packaged app, check extraResources directory first (bundled by electron-builder)
   if (app.isPackaged) {
+    possiblePaths.push(
+      path.join(process.resourcesPath, platformPackage)
+    )
+    // Legacy: also check node_modules in case it was bundled there
     possiblePaths.push(
       path.join(process.resourcesPath, "app", "node_modules", platformPackage)
     )

apps/desktop/src/main/parakeet-stt.ts

@@ -126,9 +126,12 @@ function getSherpaLibraryPath(): string | null {
 
   const possiblePaths: string[] = []
 
-  // For packaged app, check resources directory
+  // For packaged app, check extraResources directory first (bundled by electron-builder)
   if (app.isPackaged) {
-    // In packaged app, node_modules is in resources/app/node_modules
+    possiblePaths.push(
+      path.join(process.resourcesPath, platformPackage)
+    )
+    // Legacy: also check node_modules in case it was bundled there
     possiblePaths.push(
       path.join(process.resourcesPath, "app", "node_modules", platformPackage)
     )