build(desktop): reduce installed app size by ~300MB

scripts/build-desktop-artifact.test.ts

@@ -13,7 +13,8 @@ import {
   createStageWorkspaceConfig,
   createStagePatchedDependencies,
   createBuildConfig,
-  DESKTOP_ASAR_UNPACK,
+  DESKTOP_ELECTRON_LANGUAGES,
+  DESKTOP_FILE_EXCLUSIONS,
   InvalidMacPasskeyRpDomainError,
   InvalidMacPasskeyPublishableKeyError,
   InvalidMockUpdateServerPortError,
@@ -37,6 +38,7 @@ import {
   resolvePackageManagerUserAgent,
   stageLinuxIconSize,
   STAGE_INSTALL_ARGS,
+  WINDOWS_ASAR_UNPACK,
 } from "./build-desktop-artifact.ts";
 import { BRAND_ASSET_PATHS } from "./lib/brand-assets.ts";
 import { HostProcessArchitecture, HostProcessPlatform } from "@t3tools/shared/hostProcess";
@@ -303,10 +305,53 @@ it.layer(NodeServices.layer)("build-desktop-artifact", (it) => {
     );
   });
 
-  it("unpacks the fff shared library for filesystem and FFI access", () => {
-    assert.deepStrictEqual(DESKTOP_ASAR_UNPACK, ["node_modules/@ff-labs/fff-bin-*/**/*"]);
+  it("limits Electron locales and excludes the unused Claude SDK executable", () => {
+    assert.deepStrictEqual(DESKTOP_ELECTRON_LANGUAGES, ["en-US"]);
+    assert.deepStrictEqual(DESKTOP_FILE_EXCLUSIONS, [
+      "!**/node_modules/@anthropic-ai/claude-agent-sdk-*/**/*",
+    ]);
   });
 
+  it.effect("applies platform-specific packaging to the build config", () =>
+    Effect.gen(function* () {
+      const mac = yield* createBuildConfig(
+        "mac",
+        "dmg",
+        "1.2.3",
+        false,
+        false,
+        undefined,
+        undefined,
+      );
+      const linux = yield* createBuildConfig(
+        "linux",
+        "AppImage",
+        "1.2.3",
+        false,
+        false,
+        undefined,
+        undefined,
+      );
+      const win = yield* createBuildConfig(
+        "win",
+        "nsis",
+        "1.2.3",
+        false,
+        false,
+        undefined,
+        undefined,
+      );
+
+      assert.notProperty(mac, "asarUnpack");
+      assert.notProperty(linux, "asarUnpack");
+      assert.deepStrictEqual(win.asarUnpack, WINDOWS_ASAR_UNPACK);
+      for (const config of [mac, linux, win]) {
+        assert.deepStrictEqual(config.electronLanguages, DESKTOP_ELECTRON_LANGUAGES);
+        assert.deepStrictEqual(config.files, DESKTOP_FILE_EXCLUSIONS);
+      }
+    }).pipe(Effect.provide(ConfigProvider.layer(ConfigProvider.fromEnv({ env: {} })))),
+  );
+
   it.effect("preserves both Linux icon resize failures with structural context", () => {
     const commands: Array<{ readonly command: string; readonly args: ReadonlyArray<string> }> = [];
 

scripts/build-desktop-artifact.ts

@@ -579,7 +579,20 @@ interface StagePackageJson {
 }
 
 export const STAGE_INSTALL_ARGS = ["install", "--prod"] as const;
-export const DESKTOP_ASAR_UNPACK = ["node_modules/@ff-labs/fff-bin-*/**/*"] as const;
+export const DESKTOP_ELECTRON_LANGUAGES = ["en-US"] as const;
+export const DESKTOP_FILE_EXCLUSIONS = [
+  // T3 Code always passes the user's installed Claude executable to the SDK,
+  // so the SDK's optional platform packages (each a ~200MB bundled executable)
+  // are dead weight. The trailing dash keeps the SDK's own JS package.
+  "!**/node_modules/@anthropic-ai/claude-agent-sdk-*/**/*",
+] as const;
+// The WSL backend launches the server with plain `wsl.exe -- node`, which
+// cannot read inside an asar archive — and the server bundle externalizes its
+// runtime deps, so the whole node_modules tree must be unpacked, not just the
+// bundle (otherwise ERR_MODULE_NOT_FOUND: "Cannot find package 'effect'").
+// The Windows primary backend reads the same files through the asar redirect,
+// so nothing is duplicated.
+export const WINDOWS_ASAR_UNPACK = ["apps/server/dist/**", "**/node_modules/**"] as const;
 
 export interface MacPasskeySigningConfiguration {
   readonly appId: string;
@@ -1390,23 +1403,15 @@ export const createBuildConfig = Effect.fn("createBuildConfig")(function* (
     appId: DESKTOP_APP_ID,
     productName: resolveDesktopProductName(version),
     artifactName: "T3-Code-${version}-${arch}.${ext}",
+    electronLanguages: [...DESKTOP_ELECTRON_LANGUAGES],
+    files: [...DESKTOP_FILE_EXCLUSIONS],
     directories: {
       buildResources: "apps/desktop/resources",
     },
-    // The Windows primary backend runs the server bundle through
-    // ELECTRON_RUN_AS_NODE (asar-aware), so it reads bin.mjs straight out of
-    // app.asar. The WSL backend instead launches plain `wsl.exe -- node`, which
-    // cannot read inside an asar archive, so everything it loads must be on the
-    // real filesystem. The server bundle externalizes its runtime dependencies
-    // (effect, @effect/*, node-pty, ...) to node_modules rather than inlining
-    // them, so unpacking just the bundle + node-pty isn't enough — the Linux Node
-    // fails with ERR_MODULE_NOT_FOUND (e.g. "Cannot find package 'effect'") before
-    // it even reaches node-pty. Unpack the server bundle AND the whole
-    // node_modules tree so every import resolves (this also covers the fff native
-    // binaries in DESKTOP_ASAR_UNPACK). The Windows primary keeps reading the same
-    // files through the asar (transparently redirected to the unpacked copy), so
-    // there's no duplication.
-    asarUnpack: [...DESKTOP_ASAR_UNPACK, "apps/server/dist/**", "**/node_modules/**"],
+    // Only the Windows WSL backend needs files outside the asar (see
+    // WINDOWS_ASAR_UNPACK); macOS and Linux stay packed — smart unpack
+    // extracts native libraries, which fff-node finds in app.asar.unpacked.
+    ...(platform === "win" ? { asarUnpack: [...WINDOWS_ASAR_UNPACK] } : {}),
   };
   const updateChannel = resolveDesktopUpdateChannel(version);
   const publishConfig = yield* resolveGitHubPublishConfig(updateChannel);