Bundle cua-cli with tsdown; smoke-test the bin in CI

[rgarcia]

Summary

The packed-tarball smoke test (runbook step 4) fails with ERR_MODULE_NOT_FOUND: ...dist/cli-harness. packages/cli used extensionless relative imports and shipped raw tsc output — legal under the repo's moduleResolution: "Bundler" and resolvable by vitest, but Node ESM requires fully-specified relative specifiers, so the published bin could never run. Nothing caught it because the only bin smoke test lives in the release workflow, which only runs on cua-cli/v* tags.

Fix: bundle the cli with tsdown, the same build the other published packages (cua-ai, cua-agent) already use. Bundling rewrites specifiers, so source imports stay extensionless.

• packages/cli builds with tsdown (dist/cli.js + split chunk for the dynamically imported TUI; deps externalized; shebang preserved). tsc -b becomes declaration-only emit to dist-tsc/ for typechecking, mirroring packages/agent.
• Root build bundles the cli after tsc -b, so npm ci && npm run build produces a runnable bin.
• Dropped the types field — it's a binary, and tsdown no longer emits cli.d.ts.
• Mirror the release workflow's packed-tarball cua --help smoke test into the cli-unit CI job so the real binary executes on every PR.

Test plan

• Reproduced the failure from the packed tarball before the fix
• After fix: npm pack → install into a temp project → ./node_modules/.bin/cua --help prints usage, exit 0; tarball ships dist/cli.js + chunks
• Fresh root npm run build passes (incl. ptywright native via zig)
• npx tsc -b clean
• PTYWRIGHT_REQUIRED=1 npm test --workspace @onkernel/cua-cli — 33/33
• CI green, including the new bin smoke step

🤖 Generated with Claude Code

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Note

Medium Risk
Changes the published CLI artifact and build pipeline; low runtime risk for library consumers but high impact if the bundled bin or pack layout is wrong—mitigated by the new CI smoke test.

Overview
Fixes published @onkernel/cua-cli failing at runtime under Node ESM by bundling the CLI with tsdown instead of shipping raw tsc output with extensionless relative imports.

packages/cli now builds dist/cli.js via tsdown (aligned with cua-ai / cua-agent), uses declaration-only tsc into dist-tsc/ for typechecking, drops the types field, and adds tsdown as a dev dependency. The root build script runs the cli workspace build after tsc -b.

CI (cli-unit) adds steps to build the cli, npm pack, install the tarball in a temp project, and smoke-test cua --help so the real binary is exercised on every PR—not only on release tags.

^{Reviewed by Cursor Bugbot for commit 1e0664b. Bugbot is set up for automated code reviews on this repo. Configure here.}

[firetiger-agent]

Created a monitoring plan for this PR.

What this PR does: Fixes the cua CLI binary so it actually runs after npm install — the previous build emitted raw TypeScript output that Node ESM couldn't execute. Adds a bin smoke test to CI so this class of breakage is caught on every PR going forward, not just at release time.

Intended effect:

• cli-unit CI smoke test: baseline — step did not exist; confirmed if the new "CLI bin smoke test" step passes (packs tarball, installs, runs cua --help, exits 0).
• Root build command: baseline — npm run build silently skipped CLI bundling; confirmed if packages/cli/dist/cli.js is produced and executable after a fresh root build.

No production telemetry signal exists for this change — @onkernel/cua-cli is a locally-installed CLI with no server-side component.

Risks:

• Dynamic TUI import missing from bundle — tsdown emits a split chunk for the dynamically imported TUI; if the chunk is missing or misnamed, cua crashes on first interactive use. Signal: runtime error on TUI invocation; alert if any ERR_MODULE_NOT_FOUND after npm install of the published package.
• CI timeout regression — cli-unit has a 15-min limit; new build/pack/smoke steps add overhead alongside the existing Zig native build. Alert if the job times out (conclusion = timed_out in CI events).
• Release workflow failure on next tag — the Release CUA CLI workflow mirrors the new smoke test; a CI pass is strong evidence the release will succeed, but alert if the Release CUA CLI workflow's conclusion is failure on the next cua-cli/v* tag.

Status updates will be posted automatically on this PR as monitoring progresses.

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