Improve Studio packaging build performance

apps/cli/package.json

@@ -65,7 +65,7 @@
 		"build": "vite build --config ./vite.config.dev.ts",
 		"build:prod": "vite build --config ./vite.config.prod.ts",
 		"build:npm": "vite build --config ./vite.config.npm.ts",
-		"install:bundle": "npm install --omit=dev --no-package-lock --no-progress --install-links --no-workspaces && patch-package && node ../../scripts/remove-fs-ext-other-platform-binaries.mjs",
+		"install:bundle": "npm install --omit=dev --no-audit --no-fund --no-package-lock --no-progress --install-links --no-workspaces && node ../../scripts/apply-available-patches.mjs patches && node ../../scripts/remove-fs-ext-other-platform-binaries.mjs",
 		"package": "npm run install:bundle && npm run build:prod",
 		"lint": "eslint .",
 		"watch": "vite build --config ./vite.config.dev.ts --watch",

apps/studio/forge.config.ts

@@ -18,6 +18,8 @@ const bundledPhpBinaryRoot = path.join( __dirname, 'php-bin' );
 const config: ForgeConfig = {
 	packagerConfig: {
 		asar: true,
+		// prePackage installs the self-contained production dependency tree.
+		prune: false,
 		extraResource: [
 			path.join( __dirname, 'assets' ),
 			path.join( __dirname, 'bin' ),
@@ -199,6 +201,8 @@ const config: ForgeConfig = {
 			console.log( 'Installing Studio app dependencies for bundling ...' );
 			// NOTE: The `app:install:bundle` script mutates the `apps/studio/node_modules` directory. You
 			// may need to rerun `npm ci` from the repo root to reset the dependency tree after packaging.
+			const studioNodeModules = path.join( repoRoot, 'apps', 'studio', 'node_modules' );
+			fs.rmSync( studioNodeModules, { recursive: true, force: true } );
 			await execAsync( [ 'npm', 'run', 'app:install:bundle' ] );
 
 			if ( process.env.SKIP_LANGUAGE_PACKS ) {
@@ -211,6 +215,8 @@ const config: ForgeConfig = {
 			console.log( 'Building CLI (with bundled node_modules) ...' );
 			// NOTE: The `cli:package` script mutates the `apps/cli/node_modules` directory. You may need to
 			// rerun `npm ci` from the repo root to reset the dependency tree after packaging.
+			const cliNodeModulesSource = path.join( repoRoot, 'apps', 'cli', 'node_modules' );
+			fs.rmSync( cliNodeModulesSource, { recursive: true, force: true } );
 			await execAsync( [ 'npm', 'run', 'cli:package' ] );
 
 			// Remove native binaries for other platforms from CLI's node_modules.
@@ -283,10 +289,14 @@ const config: ForgeConfig = {
 			// and @mistralai's ~200-char generated filenames, nested under pi-coding-agent, blow
 			// past Windows' 260-char path limit and crash the Squirrel maker.
 			console.log( 'Removing unused AI provider SDKs from CLI bundle...' );
-			const unusedProviderPaths = globSync(
+			const unusedProviderPatterns = [
+				'{@mistralai,@aws-sdk,@aws-crypto,@smithy,@google/genai}/',
 				'**/node_modules/{@mistralai,@aws-sdk,@aws-crypto,@smithy,@google/genai}/',
-				{ cwd: cliNodeModules, absolute: true }
-			);
+			];
+			const unusedProviderPaths = globSync( unusedProviderPatterns, {
+				cwd: cliNodeModules,
+				absolute: true,
+			} );
 			for ( const providerPath of unusedProviderPaths ) {
 				fs.rmSync( providerPath, { recursive: true, force: true } );
 				console.log( `Removed ${ providerPath }` );
@@ -295,10 +305,10 @@ const config: ForgeConfig = {
 				// Verify the prune succeeded — a leftover provider tree on Windows resurfaces as
 				// the PathTooLongException the prune exists to prevent. Fail now with context
 				// instead of letting the Squirrel maker crash later.
-				const remaining = globSync(
-					'**/node_modules/{@mistralai,@aws-sdk,@aws-crypto,@smithy,@google/genai}/',
-					{ cwd: cliNodeModules, absolute: true }
-				);
+				const remaining = globSync( unusedProviderPatterns, {
+					cwd: cliNodeModules,
+					absolute: true,
+				} );
 				if ( remaining.length > 0 ) {
 					throw new Error(
 						`Could not prune ${ remaining.length } provider director(ies) that exceed ` +

apps/studio/package.json

@@ -21,7 +21,7 @@
 		"make:macos-arm64": "electron-vite build --config ./electron.vite.config.ts --outDir=dist && tsx ../../scripts/build-desks-renderer.ts && SKIP_DMG=true FILE_ARCHITECTURE=arm64 electron-forge make . --arch=arm64 --platform=darwin",
 		"make:linux-x64": "electron-vite build --config ./electron.vite.config.ts --outDir=dist && tsx ../../scripts/build-desks-renderer.ts && electron-forge make . --arch=x64 --platform=linux",
 		"make:linux-arm64": "electron-vite build --config ./electron.vite.config.ts --outDir=dist && tsx ../../scripts/build-desks-renderer.ts && electron-forge make . --arch=arm64 --platform=linux",
-		"install:bundle": "npm install --no-package-lock --no-progress --install-links --no-workspaces && patch-package && node ../../scripts/remove-fs-ext-other-platform-binaries.mjs",
+		"install:bundle": "npm install --omit=dev --no-audit --no-fund --no-package-lock --no-progress --install-links --no-workspaces && node ../../scripts/apply-available-patches.mjs patches && node ../../scripts/remove-fs-ext-other-platform-binaries.mjs",
 		"lint": "eslint src e2e",
 		"package": "electron-vite build --config ./electron.vite.config.ts --outDir=dist && tsx ../../scripts/build-desks-renderer.ts && electron-forge package .",
 		"publish": "electron-forge publish .",

scripts/apply-available-patches.mjs

@@ -0,0 +1,70 @@
+import { spawnSync } from 'child_process';
+import fs from 'fs';
+import path from 'path';
+
+// Bundle installs can omit dev dependencies. Apply only patches whose target package is present
+// instead of failing on patches for packages that are intentionally absent from the bundle.
+const patchDir = process.argv[ 2 ];
+
+if ( ! patchDir ) {
+	throw new Error( 'Usage: node scripts/apply-available-patches.mjs <patch-dir>' );
+}
+
+const cwd = process.cwd();
+const sourcePatchDir = path.resolve( cwd, patchDir );
+const patchFiles = fs
+	.readdirSync( sourcePatchDir )
+	.filter( ( file ) => file.endsWith( '.patch' ) )
+	.sort();
+
+function getPackageName( patchFile ) {
+	const parts = patchFile.replace( /\.patch$/, '' ).split( '+' );
+	return parts[ 0 ].startsWith( '@' ) ? `${ parts[ 0 ] }/${ parts[ 1 ] }` : parts[ 0 ];
+}
+
+function hasPackage( packageName ) {
+	return fs.existsSync( path.join( cwd, 'node_modules', ...packageName.split( '/' ) ) );
+}
+
+const availablePatchFiles = patchFiles.filter( ( patchFile ) =>
+	hasPackage( getPackageName( patchFile ) )
+);
+const skippedPatchFiles = patchFiles.filter(
+	( patchFile ) => ! availablePatchFiles.includes( patchFile )
+);
+
+for ( const patchFile of skippedPatchFiles ) {
+	console.log( `Skipping patch for missing package: ${ getPackageName( patchFile ) }` );
+}
+
+if ( availablePatchFiles.length === 0 ) {
+	console.log( 'No applicable patches found.' );
+	process.exit( 0 );
+}
+
+const tempPatchDir = fs.mkdtempSync( path.join( cwd, '.studio-patches-' ) );
+const relativeTempPatchDir = path.relative( cwd, tempPatchDir );
+
+try {
+	for ( const patchFile of availablePatchFiles ) {
+		fs.copyFileSync( path.join( sourcePatchDir, patchFile ), path.join( tempPatchDir, patchFile ) );
+	}
+
+	const result = spawnSync(
+		'npx',
+		[ '--no-install', 'patch-package', '--patch-dir', relativeTempPatchDir ],
+		{
+			cwd,
+			stdio: 'inherit',
+			shell: process.platform === 'win32',
+		}
+	);
+
+	if ( result.status !== 0 ) {
+		throw new Error(
+			`Command failed: npx --no-install patch-package --patch-dir ${ relativeTempPatchDir }`
+		);
+	}
+} finally {
+	fs.rmSync( tempPatchDir, { recursive: true, force: true } );
+}

scripts/package-in-isolation.ts

@@ -15,6 +15,10 @@
  *
  * In CI, where we have a clean, ephemeral environment, we short-circuit the behavior and run the
  * relevant script in place.
+ *
+ * Local packaging installs the build toolchain with a lockfile-accurate `npm ci --ignore-scripts`
+ * and reuses bundled WordPress/server files when they already exist. Set `STUDIO_PACKAGE_FRESH=1`
+ * to run a full `npm ci` instead, with postinstall re-downloading all bundled files.
  */
 
 import { spawnSync, type SpawnSyncOptions } from 'child_process';
@@ -25,6 +29,9 @@ import { z } from 'zod';
 
 const REPO_ROOT = path.resolve( import.meta.dirname, '..' );
 const STUDIO_APP_PACKAGE_JSON = path.join( REPO_ROOT, 'apps', 'studio', 'package.json' );
+const COPY_MODE = fs.constants.COPYFILE_FICLONE;
+const BUILD_OUTPUT_DIRS = new Set( [ 'out', 'dist', 'test-results' ] );
+const useFreshLocalPackage = process.env.STUDIO_PACKAGE_FRESH === '1';
 
 const STUDIO_APP_PACKAGE_JSON_SCHEMA = z.object( {
 	scripts: z.record( z.string(), z.string() ),
@@ -49,8 +56,59 @@ function runOrFail( command: string, args: string[], cwd: string ) {
 
 	const result = spawnSync( command, args, options );
 	if ( result.status !== 0 ) {
-		process.exit( result.status ?? 1 );
+		throw new Error( `Command failed: ${ [ command, ...args ].join( ' ' ) }` );
+	}
+}
+
+function ensureBuildToolchain( stagingRoot: string ) {
+	if ( useFreshLocalPackage ) {
+		console.log( 'Installing lockfile-fresh workspace dependencies in packaging directory ...' );
+		runOrFail( 'npm', [ 'ci' ], stagingRoot );
+		return;
+	}
+
+	// `--ignore-scripts` skips the root postinstall, which would re-download bundled server files
+	// the staging copy already has. The postinstall steps that are still required (patches, fs-ext
+	// binary filtering) run explicitly below.
+	console.log( 'Installing workspace dependencies in packaging directory ...' );
+	runOrFail(
+		'npm',
+		[ 'ci', '--ignore-scripts', '--no-audit', '--no-fund', '--no-progress' ],
+		stagingRoot
+	);
+	runOrFail( 'npx', [ 'patch-package', '--patch-dir', 'apps/cli/patches' ], stagingRoot );
+	runOrFail( 'npx', [ 'patch-package', '--patch-dir', 'apps/studio/patches' ], stagingRoot );
+	runOrFail( 'node', [ './scripts/remove-fs-ext-other-platform-binaries.mjs' ], stagingRoot );
+}
+
+function hasBundledServerFiles( repoRoot: string ): boolean {
+	// Marker paths for artifacts produced by download-wp-server-files.ts,
+	// download-available-site-translations.mjs, and download-agent-skills.ts.
+	const requiredPaths = [
+		'wp-files/latest/wordpress/wp-includes/version.php',
+		'wp-files/latest/available-site-translations.json',
+		'wp-files/sqlite-database-integration/db.copy',
+		'wp-files/wp-cli/wp-cli.phar',
+		'wp-files/sqlite-command/command.php',
+		'wp-files/phpmyadmin/index.php',
+		'wp-files/reprint/reprint.phar',
+		'wp-files/skills/wp-plugin-development/SKILL.md',
+	];
+
+	return requiredPaths.every( ( requiredPath ) =>
+		fs.existsSync( path.join( repoRoot, requiredPath ) )
+	);
+}
+
+function ensureBundledServerFiles( stagingRoot: string ) {
+	if ( hasBundledServerFiles( stagingRoot ) ) {
+		return;
 	}
+
+	console.log( 'Downloading missing bundled server files in packaging directory ...' );
+	runOrFail( 'npx', [ 'tsx', './scripts/download-wp-server-files.ts' ], stagingRoot );
+	runOrFail( 'node', [ './scripts/download-available-site-translations.mjs' ], stagingRoot );
+	runOrFail( 'npx', [ 'tsx', './scripts/download-agent-skills.ts' ], stagingRoot );
 }
 
 function shouldCopyToStaging( sourcePath: string ): boolean {
@@ -60,9 +118,32 @@ function shouldCopyToStaging( sourcePath: string ): boolean {
 	const pathSegments = relativePath.split( path.sep );
 	if ( pathSegments.includes( '.git' ) ) return false;
 	if ( pathSegments.includes( 'node_modules' ) ) return false;
+	if ( BUILD_OUTPUT_DIRS.has( pathSegments[ 0 ] ) ) return false;
+	if ( pathSegments[ 0 ] === 'apps' && BUILD_OUTPUT_DIRS.has( pathSegments[ 2 ] ) ) {
+		return false;
+	}
+	if ( pathSegments[ 0 ] === 'tools' && BUILD_OUTPUT_DIRS.has( pathSegments[ 2 ] ) ) {
+		return false;
+	}
 
-	const topLevelDir = pathSegments[ 0 ];
-	return topLevelDir !== 'out' && topLevelDir !== 'dist' && topLevelDir !== 'test-results';
+	return true;
+}
+
+function moveOrCopySync( from: string, to: string ) {
+	fs.rmSync( to, { recursive: true, force: true } );
+	fs.mkdirSync( path.dirname( to ), { recursive: true } );
+
+	try {
+		fs.renameSync( from, to );
+	} catch {
+		fs.cpSync( from, to, {
+			recursive: true,
+			force: true,
+			verbatimSymlinks: true,
+			mode: COPY_MODE,
+		} );
+		fs.rmSync( from, { recursive: true, force: true } );
+	}
 }
 
 function copyArtifactsBack( stagingRoot: string ) {
@@ -80,9 +161,7 @@ function copyArtifactsBack( stagingRoot: string ) {
 
 	for ( const [ from, to ] of artifactPaths ) {
 		if ( ! fs.existsSync( from ) ) continue;
-		fs.rmSync( to, { recursive: true, force: true } );
-		fs.mkdirSync( path.dirname( to ), { recursive: true } );
-		fs.cpSync( from, to, { recursive: true, force: true, verbatimSymlinks: true } );
+		moveOrCopySync( from, to );
 	}
 }
 
@@ -116,10 +195,13 @@ function main() {
 		fs.cpSync( REPO_ROOT, stagingRoot, {
 			recursive: true,
 			filter: shouldCopyToStaging,
+			mode: COPY_MODE,
 		} );
 
-		console.log( 'Installing workspace dependencies in packaging directory ...' );
-		runOrFail( 'npm', [ 'ci' ], stagingRoot );
+		ensureBuildToolchain( stagingRoot );
+		if ( ! useFreshLocalPackage ) {
+			ensureBundledServerFiles( stagingRoot );
+		}
 
 		console.log( `Running script "${ scriptName }" in packaging directory ...` );
 		runOrFail( 'npm', [ '-w', 'studio-app', 'run', scriptName ], stagingRoot );