fix (desktop): build issue with ringtones/sounds directory

apps/desktop/electron-builder.ts

@@ -30,9 +30,13 @@ const config: Configuration = {
 		buildResources: join(pkg.resources, "build"),
 	},
 
-	// ASAR configuration for native modules
+	// ASAR configuration for native modules and external resources
 	asar: true,
-	asarUnpack: ["**/node_modules/node-pty/**/*"],
+	asarUnpack: [
+		"**/node_modules/node-pty/**/*",
+		// Sound files must be unpacked so external audio players (afplay, paplay, etc.) can access them
+		"**/resources/sounds/**/*",
+	],
 
 	files: [
 		"dist/**/*",

apps/desktop/electron.vite.config.ts

@@ -1,10 +1,12 @@
+import { cpSync, existsSync, mkdirSync, rmSync } from "node:fs";
 import { dirname, normalize, resolve } from "node:path";
 import tailwindcss from "@tailwindcss/vite";
 import reactPlugin from "@vitejs/plugin-react";
 import { codeInspectorPlugin } from "code-inspector-plugin";
 import { config } from "dotenv";
 import { defineConfig, externalizeDepsPlugin } from "electron-vite";
 import injectProcessEnvPlugin from "rollup-plugin-inject-process-env";
+import type { Plugin } from "vite";
 import tsconfigPathsPlugin from "vite-tsconfig-paths";
 import { main, resources } from "./package.json";
 
@@ -22,9 +24,35 @@ const tsconfigPaths = tsconfigPathsPlugin({
 	projects: [resolve("tsconfig.json")],
 });
 
+/**
+ * Plugin to copy resources (like sounds) to the dist folder for preview mode.
+ * In preview mode, __dirname resolves relative to dist/main, so resources
+ * need to be at dist/resources/sounds for the main process to access them.
+ *
+ * Cleans the destination first to avoid stale files from previous builds.
+ */
+function copyResourcesPlugin(): Plugin {
+	return {
+		name: "copy-resources",
+		writeBundle() {
+			const srcDir = resolve(resources, "sounds");
+			const destDir = resolve(devPath, "resources/sounds");
+
+			if (existsSync(srcDir)) {
+				// Clean destination to avoid stale files
+				if (existsSync(destDir)) {
+					rmSync(destDir, { recursive: true });
+				}
+				mkdirSync(destDir, { recursive: true });
+				cpSync(srcDir, destDir, { recursive: true });
+			}
+		},
+	};
+}
+
 export default defineConfig({
 	main: {
-		plugins: [tsconfigPaths],
+		plugins: [tsconfigPaths, copyResourcesPlugin()],
 
 		build: {
 			rollupOptions: {

apps/desktop/src/lib/electron-router-dom.ts

@@ -1,9 +1,46 @@
+import type { BrowserWindow } from "electron";
 import { createElectronRouter } from "electron-router-dom";
 import { PORTS } from "shared/constants";
 
-export const { Router, registerRoute, settings } = createElectronRouter({
+const electronRouter = createElectronRouter({
 	port: PORTS.VITE_DEV_SERVER,
 	types: {
 		ids: ["main", "about"],
 	},
 });
+
+export const { Router, settings } = electronRouter;
+
+/** Window IDs defined in the router configuration */
+type WindowId = "main" | "about";
+
+/**
+ * Custom registerRoute that uses NODE_ENV instead of app.isPackaged.
+ * This allows `electron-vite preview` (bun start) to load built files
+ * instead of trying to connect to a dev server.
+ *
+ * - Development (NODE_ENV=development): loads from dev server
+ * - Preview/Production: loads from built HTML file
+ */
+export function registerRoute(props: {
+	id: WindowId;
+	browserWindow: BrowserWindow;
+	htmlFile: string;
+	query?: Record<string, string>;
+}): void {
+	const isDev = process.env.NODE_ENV === "development";
+
+	if (isDev) {
+		// Development: use the library's default behavior (loads from dev server)
+		electronRouter.registerRoute(props);
+	} else {
+		// Preview or Production: load from file with hash routing
+		const windowId = props.id || "main";
+		let url = `/${windowId}`;
+		if (props.query) {
+			const query = new URLSearchParams(props.query).toString();
+			url = `${url}?${query}`;
+		}
+		props.browserWindow.loadFile(props.htmlFile, { hash: url });
+	}
+}

apps/desktop/src/lib/trpc/routers/ringtone/index.ts

@@ -1,9 +1,11 @@
 import type { ChildProcess } from "node:child_process";
 import { execFile } from "node:child_process";
 import { existsSync, readdirSync } from "node:fs";
-import { join } from "node:path";
-import { app } from "electron";
 import { z } from "zod";
+import {
+	getSoundPath,
+	getSoundsDirectory,
+} from "../../../../main/lib/sound-paths";
 import { publicProcedure, router } from "../..";
 
 /**
@@ -17,31 +19,6 @@ let currentSession: {
 } | null = null;
 let nextSessionId = 0;
 
-/**
- * Gets the path to a ringtone sound file.
- * In development, reads from src/resources. In production, reads from the bundled resources.
- */
-function getRingtonePath(filename: string): string {
-	const isDev = !app.isPackaged;
-
-	if (isDev) {
-		return join(app.getAppPath(), "src/resources/sounds", filename);
-	}
-	return join(process.resourcesPath, "resources/sounds", filename);
-}
-
-/**
- * Gets the directory containing ringtone files
- */
-function getRingtonesDirectory(): string {
-	const isDev = !app.isPackaged;
-
-	if (isDev) {
-		return join(app.getAppPath(), "src/resources/sounds");
-	}
-	return join(process.resourcesPath, "resources/sounds");
-}
-
 /**
  * Stops the currently playing sound and invalidates the session
  */
@@ -127,7 +104,7 @@ export const createRingtoneRouter = () => {
 					return { success: true as const };
 				}
 
-				const soundPath = getRingtonePath(input.filename);
+				const soundPath = getSoundPath(input.filename);
 				playSoundFile(soundPath);
 				return { success: true as const };
 			}),
@@ -144,7 +121,7 @@ export const createRingtoneRouter = () => {
 		 * Get the list of available ringtone files from the sounds directory
 		 */
 		list: publicProcedure.query(() => {
-			const ringtonesDir = getRingtonesDirectory();
+			const ringtonesDir = getSoundsDirectory();
 			const files: string[] = [];
 
 			// Add ringtones from the sounds directory if it exists
@@ -172,6 +149,6 @@ export function playNotificationRingtone(filename: string): void {
 		return; // No sound for "none" option
 	}
 
-	const soundPath = getRingtonePath(filename);
+	const soundPath = getSoundPath(filename);
 	playSoundFile(soundPath);
 }

apps/desktop/src/main/lib/notification-sound.ts

@@ -1,25 +1,11 @@
 import { execFile } from "node:child_process";
 import { existsSync } from "node:fs";
-import { join } from "node:path";
-import { app } from "electron";
 import {
 	DEFAULT_RINGTONE_ID,
 	getRingtoneFilename,
 } from "../../shared/ringtones";
 import { db } from "./db";
-
-/**
- * Gets the path to a ringtone sound file.
- * In development, reads from src/resources. In production, reads from the bundled resources.
- */
-function getRingtonePath(filename: string): string {
-	const isDev = !app.isPackaged;
-
-	if (isDev) {
-		return join(app.getAppPath(), "src/resources/sounds", filename);
-	}
-	return join(process.resourcesPath, "resources/sounds", filename);
-}
+import { getSoundPath } from "./sound-paths";
 
 /**
  * Gets the selected ringtone filename from the database.
@@ -83,6 +69,6 @@ export function playNotificationSound(): void {
 		return;
 	}
 
-	const soundPath = getRingtonePath(filename);
+	const soundPath = getSoundPath(filename);
 	playSoundFile(soundPath);
 }

apps/desktop/src/main/lib/sound-paths.ts

@@ -0,0 +1,58 @@
+import { existsSync } from "node:fs";
+import { join } from "node:path";
+import { app } from "electron";
+
+/**
+ * Gets the path to a ringtone sound file.
+ *
+ * Path resolution strategy:
+ * - Production (packaged .app): app.asar.unpacked/resources/sounds/
+ * - Development (NODE_ENV=development): src/resources/sounds/
+ * - Preview (electron-vite preview): dist/resources/sounds/ (relative to __dirname)
+ *
+ * Sound files are unpacked from asar so external audio players (afplay, etc.) can access them.
+ */
+export function getSoundPath(filename: string): string {
+	const dir = getSoundsDirectory();
+	return join(dir, filename);
+}
+
+/**
+ * Gets the directory containing ringtone sound files.
+ *
+ * In preview mode, uses __dirname (dist/main) to reliably resolve to dist/resources/sounds,
+ * avoiding dependency on app.getAppPath() or process.cwd() which may vary.
+ */
+export function getSoundsDirectory(): string {
+	if (app.isPackaged) {
+		// Production: unpacked from asar for external audio players
+		return join(process.resourcesPath, "app.asar.unpacked/resources/sounds");
+	}
+
+	const isDev = process.env.NODE_ENV === "development";
+
+	if (isDev) {
+		// Development: source files in project
+		return join(app.getAppPath(), "src/resources/sounds");
+	}
+
+	// Preview mode: __dirname is dist/main, so go up one level to dist/resources/sounds
+	// This is the most reliable path in preview since it's relative to the bundle location
+	const previewPath = join(__dirname, "../resources/sounds");
+	if (existsSync(previewPath)) {
+		return previewPath;
+	}
+
+	// Fallback: try source directory (in case sounds weren't copied to dist)
+	const srcPath = join(app.getAppPath(), "src/resources/sounds");
+	if (existsSync(srcPath)) {
+		console.warn(
+			"[sound-paths] Using src/resources/sounds as fallback - sounds may not have been copied to dist",
+		);
+		return srcPath;
+	}
+
+	// Return the expected preview path even if missing (will fail gracefully in playback)
+	console.warn(`[sound-paths] Sounds directory not found at: ${previewPath}`);
+	return previewPath;
+}