[worker] Resolve runtime cache settings from job env and fallback on npm cache failures by AbbanMustafa · Pull Request #3855 · expo/eas-cli

AbbanMustafa · 2026-06-12T00:21:33Z

Why

We want to enable npm cache proxy usage per build job, but the worker was loading runtime settings before the job environment was available. That meant job-scoped environment variables like EAS_USE_NPM_CACHE=1 https://github.com/expo/universe/pull/27727 could not control cache URL resolution.

We also need cache proxy rollout to be safe: if the proxy is unavailable or misconfigured, builds should fall back to the normal npm registry behavior instead of failing during the post-prebuild install.

How

Move worker runtime settings loading into createBuildContext, where the job env is available.
Resolve runtime cache URLs from job env plus runner cache URL fallbacks.
Set NPM_CONFIG_REGISTRY only when the job has enabled npm cache usage.
Add post-prebuild npm install fallback:
- enabled only when EAS_USE_NPM_CACHE=1
- detects install failures caused by the configured npm cache registry
- reports warning-level Sentry events
- retries the same npm install after removing only NPM_CONFIG_REGISTRY, so npm falls back to project/user/default registry settings
Add Sentry reporting for non-fatal npm cache registry errors that npm logs while still exiting 0.

Test Plan

Added unit coverage for job-env runtime cache settings resolution.
Added unit coverage for post-prebuild npm cache fallback behavior:
- retries without the cache registry when the cache install fails
- reports non-fatal cache registry errors to Sentry when npm logs an error but exits 0
- does not retry when EAS_USE_NPM_CACHE is not enabled
Validated the failure path with a local build by setting EAS_USE_NPM_CACHE=1 from www. Cache private network could not resolve/connect to the internal cache host, which reproduced the proxy failure path and confirmed the build retried through the normal npm registry behavior, and logged to sentry

https://expoio.sentry.io/issues/7511993527/?environment=development&project=1837720&query=is%3Aunresolved&referrer=issue-stream&statsPeriod=14d

NOOP when env var is not set

…npm cache failures

github-actions · 2026-06-12T00:21:49Z

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codecov · 2026-06-12T00:27:06Z

Codecov Report

❌ Patch coverage is 97.53086% with 2 lines in your changes missing coverage. Please review.
✅ Project coverage is 58.49%. Comparing base (b30dd90) to head (1e7c270).

Files with missing lines	Patch %	Lines
...ages/build-tools/src/common/installDependencies.ts	96.56%	2 Missing ⚠️

Additional details and impacted files

@@            Coverage Diff             @@
##             main    #3855      +/-   ##
==========================================
+ Coverage   58.43%   58.49%   +0.07%     
==========================================
  Files         917      919       +2     
  Lines       39996    40125     +129     
  Branches     8419     8438      +19     
==========================================
+ Hits        23368    23468     +100     
- Misses      16533    16561      +28     
- Partials       95       96       +1

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…npm cache failures

github-actions · 2026-06-12T02:01:00Z

⏩ The changelog entry check has been skipped since the "no changelog" label is present.

AbbanMustafa · 2026-06-12T03:41:50Z

+  useFrozenLockfile: boolean;
+}): Promise<void> {
+  const npmCacheUrl = env.NPM_CONFIG_REGISTRY;
+  const npmCacheErrorTracker = createNpmCacheRegistryErrorTracker({ env, npmCacheUrl });


this captures cache failures that npm only prints to stdout/stderr, like audit endpoint ENOTFOUND, so we still log them to Sentry when npm exits 0 and skips the catch/fallback path

sjchmiela

needs some polish

sjchmiela · 2026-06-12T07:00:56Z

  const cocoapodsCacheUrl = RuntimeSettings.getCocoapodsCacheUrl();

  setEnv(env, 'NPM_CACHE_URL', npmCacheUrl);
+  setEnv(env, 'NPM_CONFIG_REGISTRY', npmCacheUrl);


gosh it took me so long to find docs proving this should work lol

does this replace npm config set registry?

sjchmiela · 2026-06-12T07:12:42Z

  const childLogger = buildLogger.child({ buildId });
+  await RuntimeSettings.loadAsync({
+    environment: config.env,
+    logger: childLogger,


so actually about this logger -- i don't think we should use the build-facing logger. i don't think we need users to see "Failed to fetch worker runtime settings, using defaults", especially if it's in an "(unnamed build phase)"

i kept this logger from the start so "if we ever were to inspect logs of the service" we would have a record of this failure. maybe it was a bad idea and we should just rely only on sentry and env vars printing as distinction?

sjchmiela · 2026-06-12T07:12:53Z

+    cacheUrlFallbacks: {
+      npm: config.npmCacheUrl,
+      nodejs: config.nodeJsCacheUrl,
+      maven: config.mavenCacheUrl,
+      cocoapods: config.cocoapodsCacheUrl,
+    },


how about we land #3856 first?

sjchmiela · 2026-06-12T07:14:08Z

+  }
+}
+
+function getCacheUrl(


let's not do this, i know codex wanted to do it ssoooooo bad. we can inline variables and checks in these four places in one file

sjchmiela · 2026-06-12T07:14:33Z

  cocoapods?: string | null;
 };

+type RuntimeEnvironment = Record<string, string | undefined>;


we already have Env and BuildEnv types that should be able to denote this

sjchmiela · 2026-06-12T07:16:49Z

+      const sentryError = new Error('Non-fatal npm cache registry error during dependency install');
+      sentryError.name = 'NpmCacheRegistryNonFatalError';


wouldn't it be better if we made it a subclass of error?

sjchmiela · 2026-06-12T07:21:15Z

+    const fallbackEnv = { ...env };
+    delete fallbackEnv.NPM_CONFIG_REGISTRY;


Suggested change

const fallbackEnv = { ...env };

delete fallbackEnv.NPM_CONFIG_REGISTRY;

const { NPM_CONFIG_REGISTRY: _NPM_CONFIG_REGISTRY, ...fallbackEnv } = env;

? or maybe not. i think there were days when delete had bad rep

sjchmiela · 2026-06-12T07:22:12Z

+  const error = new Error('Failed to install dependencies using npm cache registry');
+  error.name = 'NpmCacheRegistryInstallError';


subclass

also use SystemError / UserError when possible

and i think you should be able to pass err as cause? i wish we would remove getErrorField and getErrorMessage

sjchmiela · 2026-06-12T07:23:11Z

+function getErrorOutput(err: unknown): string {
+  if (!err || typeof err !== 'object') {
+    return '';
+  }
+  const { stdout, stderr } = err as { stdout?: unknown; stderr?: unknown };
+  return [stdout, stderr]
+    .filter((output): output is string => typeof output === 'string')
+    .join('\n');
+}


i think we can check if instanceof spawnpromise?

[worker] Resolve runtime cache settings from job env and fallback on …

f575e83

…npm cache failures

AbbanMustafa added the no changelog PR that doesn't require a changelog entry label Jun 12, 2026

[worker] Resolve runtime cache settings from job env and fallback on …

1e7c270

…npm cache failures

AbbanMustafa commented Jun 12, 2026

View reviewed changes

AbbanMustafa requested a review from sjchmiela June 12, 2026 04:23

sjchmiela requested changes Jun 12, 2026

View reviewed changes

		const sentryError = new Error('Non-fatal npm cache registry error during dependency install');
		sentryError.name = 'NpmCacheRegistryNonFatalError';

		const fallbackEnv = { ...env };
		delete fallbackEnv.NPM_CONFIG_REGISTRY;

	const fallbackEnv = { ...env };
	delete fallbackEnv.NPM_CONFIG_REGISTRY;
	const { NPM_CONFIG_REGISTRY: _NPM_CONFIG_REGISTRY, ...fallbackEnv } = env;

		const error = new Error('Failed to install dependencies using npm cache registry');
		error.name = 'NpmCacheRegistryInstallError';

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AbbanMustafa commented Jun 12, 2026 •

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codecov Bot commented Jun 12, 2026 •

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