fix(orchestrator): fall back to release binaries during npm install (#1080)

Co-authored-by: Omar McAdam <omar@OpenWork-Studio.localdomain>

.github/workflows/release-macos-aarch64.yml

@@ -678,10 +678,12 @@ jobs:
             echo "exists=false" >> "$GITHUB_OUTPUT"
           fi
 
-      - name: Build sidecar artifacts
+      - name: Build orchestrator release artifacts
         env:
           SOURCE_DATE_EPOCH: ${{ steps.source-date.outputs.epoch }}
-        run: pnpm --filter openwork-orchestrator build:sidecars
+        run: |
+          pnpm --filter openwork-orchestrator build:bin:all
+          pnpm --filter openwork-orchestrator build:sidecars
 
       - name: Release review (strict)
         env:
@@ -702,12 +704,12 @@ jobs:
             --notes "$notes" \
             --latest=false
 
-      - name: Upload sidecar assets
+      - name: Upload orchestrator release assets
         env:
           GH_TOKEN: ${{ github.token }}
         run: |
           tag="openwork-orchestrator-v${{ steps.sidecar-versions.outputs.orchestrator }}"
-          gh release upload "$tag" apps/orchestrator/dist/sidecars/* --repo "$GITHUB_REPOSITORY" --clobber
+          gh release upload "$tag" apps/orchestrator/dist/bin/* apps/orchestrator/dist/sidecars/* --repo "$GITHUB_REPOSITORY" --clobber
 
   publish-npm:
     name: Publish npm packages

apps/orchestrator/README.md

@@ -20,6 +20,10 @@ openwork serve --workspace /path/to/workspace
 
 `openwork` ships as a compiled binary, so Bun is not required at runtime.
 
+If npm skips the optional platform package, `postinstall` falls back to downloading the matching
+binary from the `openwork-orchestrator-v<version>` GitHub release. Override the download host with
+`OPENWORK_ORCHESTRATOR_DOWNLOAD_BASE_URL` when you need to use a mirror.
+
 `openwork` downloads and caches the `openwork-server`, `opencode-router`, and `opencode` sidecars on
 first run using a SHA-256 manifest. Use `--sidecar-dir` or `OPENWORK_SIDECAR_DIR` to control the
 cache location, and `--sidecar-base-url` / `--sidecar-manifest` to point at a custom host.

apps/orchestrator/bin/openwork

@@ -1,6 +1,7 @@
 #!/usr/bin/env node
 
 const childProcess = require("child_process")
+const fs = require("fs")
 const os = require("os")
 const path = require("path")
 
@@ -45,14 +46,18 @@ if (!arch) {
 
 const pkg = `openwork-orchestrator-${platform}-${arch}`
 const binary = platform === "windows" ? "openwork.exe" : "openwork"
+const fallback = path.join(__dirname, "..", "dist", "bin", binary)
 
 let pkgJsonPath
 try {
   pkgJsonPath = require.resolve(`${pkg}/package.json`)
 } catch {
+  if (fs.existsSync(fallback)) {
+    run(fallback)
+  }
   console.error(
     `openwork: no prebuilt binary package found for ${platform}/${arch}.\n` +
-      `Try installing the platform package manually: ${pkg}`,
+      `Try reinstalling openwork-orchestrator or installing the platform package manually: ${pkg}`,
   )
   process.exit(1)
 }

apps/orchestrator/scripts/postinstall.mjs

@@ -1,9 +1,13 @@
 #!/usr/bin/env node
 
+import { chmodSync, existsSync, mkdirSync, readFileSync, writeFileSync } from "node:fs"
+import { dirname, join } from "node:path"
 import os from "os"
 import { createRequire } from "module"
+import { fileURLToPath } from "node:url"
 
 const require = createRequire(import.meta.url)
+const rootDir = dirname(fileURLToPath(import.meta.url))
 
 function detect() {
   const platformMap = {
@@ -22,21 +26,90 @@ function detect() {
   return { platform, arch }
 }
 
-function name() {
+function packageName() {
   const { platform, arch } = detect()
   return `openwork-orchestrator-${platform}-${arch}`
 }
 
-try {
-  const pkg = name()
-  require.resolve(`${pkg}/package.json`)
-  console.log(`openwork-orchestrator: verified platform package: ${pkg}`)
-} catch (error) {
-  const pkg = name()
-  console.error(
-    `openwork-orchestrator: failed to locate platform binary package (${pkg}).\n` +
-      `Your package manager may have skipped optionalDependencies.\n` +
-      `Try installing it manually: npm i -g ${pkg}`,
-  )
-  process.exit(1)
+function binaryName() {
+  const { platform } = detect()
+  return platform === "windows" ? "openwork.exe" : "openwork"
 }
+
+function fallbackAssetName() {
+  const { platform, arch } = detect()
+  return `openwork-bun-${platform}-${arch}${platform === "windows" ? ".exe" : ""}`
+}
+
+function fallbackBinaryPath() {
+  return join(rootDir, "dist", "bin", binaryName())
+}
+
+function readOwnVersion() {
+  const pkg = JSON.parse(readFileSync(join(rootDir, "package.json"), "utf8"))
+  const version = String(pkg.version || "").trim()
+  if (!version) {
+    throw new Error("openwork-orchestrator: package version is missing")
+  }
+  return version
+}
+
+function resolveFallbackBaseUrl(version) {
+  const override = String(process.env.OPENWORK_ORCHESTRATOR_DOWNLOAD_BASE_URL || "").trim()
+  if (override) {
+    return override.replace(/\/$/, "")
+  }
+  return `https://github.com/different-ai/openwork/releases/download/openwork-orchestrator-v${version}`
+}
+
+async function downloadFallbackBinary() {
+  const version = readOwnVersion()
+  const asset = fallbackAssetName()
+  const url = `${resolveFallbackBaseUrl(version)}/${asset}`
+  const destination = fallbackBinaryPath()
+
+  console.log(`openwork-orchestrator: downloading fallback binary ${asset}`)
+  const response = await fetch(url)
+  if (!response.ok) {
+    throw new Error(`download failed (${response.status} ${response.statusText}) from ${url}`)
+  }
+
+  const buffer = Buffer.from(await response.arrayBuffer())
+  mkdirSync(dirname(destination), { recursive: true })
+  writeFileSync(destination, buffer)
+  if (binaryName() !== "openwork.exe") {
+    chmodSync(destination, 0o755)
+  }
+
+  console.log(`openwork-orchestrator: installed fallback binary at ${destination}`)
+}
+
+async function main() {
+  try {
+    const pkg = packageName()
+    require.resolve(`${pkg}/package.json`)
+    console.log(`openwork-orchestrator: verified platform package: ${pkg}`)
+    return
+  } catch {
+    if (existsSync(fallbackBinaryPath())) {
+      console.log(`openwork-orchestrator: using existing fallback binary at ${fallbackBinaryPath()}`)
+      return
+    }
+  }
+
+  try {
+    await downloadFallbackBinary()
+  } catch (error) {
+    const pkg = packageName()
+    const message = error instanceof Error ? error.message : String(error)
+    console.error(
+      `openwork-orchestrator: failed to locate platform binary package (${pkg}).\n` +
+        `Your package manager may have skipped optionalDependencies, or the package asset is unavailable.\n` +
+        `Fallback download failed: ${message}\n` +
+        `Try installing it manually: npm i -g ${pkg}`,
+    )
+    process.exit(1)
+  }
+}
+
+await main()

apps/orchestrator/scripts/publish-npm.mjs

@@ -117,7 +117,7 @@ writeJson(join(meta, "package.json"), {
     "openwork-orchestrator": "./bin/openwork",
   },
   scripts: {
-    postinstall: "bun ./postinstall.mjs || node ./postinstall.mjs",
+    postinstall: "node ./postinstall.mjs",
   },
   optionalDependencies,
   files: ["bin", "postinstall.mjs", "constants.json"],