From 8d94ed06570adb2b7300cf16fe9f43b4680e3f2b Mon Sep 17 00:00:00 2001
From: Neil <4138956+nwparker@users.noreply.github.com>
Date: Fri, 23 Oct 2026 03:16:09 -0700
Subject: [PATCH] perf(test): bundle Zod once per isolated Vitest invocation
 (#32298)

---
 config/scripts/run-vitest.mjs        | 14 ++++++++++++--
 config/scripts/vitest-zod-bundle.mjs | 28 ++++++++++++++++++++++++++++
 config/vitest.config.ts              |  3 +++
 3 files changed, 43 insertions(+), 2 deletions(-)
 create mode 100644 config/scripts/vitest-zod-bundle.mjs

diff --git a/config/scripts/run-vitest.mjs b/config/scripts/run-vitest.mjs
index 0cca629306d..1091c6ca313 100644
--- a/config/scripts/run-vitest.mjs
+++ b/config/scripts/run-vitest.mjs
@@ -1,5 +1,6 @@
 import { resolve } from 'node:path'
 import { runProcessSync } from '@orca/process-host'
+import { createVitestZodBundle } from './vitest-zod-bundle.mjs'
 import {
   checkBunVersion,
   probeBunVersion,
@@ -18,7 +19,9 @@ if (bunCheck.message) {
 if (!bunCheck.ok) {
   process.exitCode = 1
 } else {
+  let zodBundle
   try {
+    zodBundle = createVitestZodBundle(root)
     const result = runProcessSync({
       program: pinnedBun ?? 'bun',
       args: ['--bun', resolve(root, 'node_modules/vitest/vitest.mjs'), ...process.argv.slice(2)],
@@ -27,7 +30,8 @@ if (!bunCheck.ok) {
         ...process.env,
         ORCA_BACKGROUND_LAUNCH: '1',
         ORCA_TEST_NODE_EXECUTABLE: process.execPath,
-        ORCA_TEST_NODE_VERSION: process.versions.node
+        ORCA_TEST_NODE_VERSION: process.versions.node,
+        ORCA_UNIT_ZOD_BUNDLE: zodBundle.path
       },
       stdio: 'inherit',
       timeoutMs: null
@@ -35,7 +39,13 @@ if (!bunCheck.ok) {
 
     process.exitCode = result.code ?? 1
   } catch (error) {
-    console.error('Could not start Vitest. Install the Bun version in config/.bun-version.', error)
+    console.error('Could not prepare or start Vitest:', error)
     process.exitCode = 1
+  } finally {
+    try {
+      zodBundle?.cleanup()
+    } catch (error) {
+      console.warn('Could not remove the temporary Vitest Zod bundle:', error)
+    }
   }
 }
diff --git a/config/scripts/vitest-zod-bundle.mjs b/config/scripts/vitest-zod-bundle.mjs
new file mode 100644
index 00000000000..e51cdb5de98
--- /dev/null
+++ b/config/scripts/vitest-zod-bundle.mjs
@@ -0,0 +1,28 @@
+import { mkdirSync, mkdtempSync, rmSync } from 'node:fs'
+import { join } from 'node:path'
+import { fileURLToPath } from 'node:url'
+import { buildSync } from 'esbuild'
+
+export function createVitestZodBundle(root) {
+  const temporary = join(root, '.tmp')
+  mkdirSync(temporary, { recursive: true })
+  const directory = mkdtempSync(join(temporary, 'vitest-zod-'))
+  const path = join(directory, 'zod.mjs')
+  const cleanup = () => rmSync(directory, { recursive: true, force: true, maxRetries: 3 })
+  try {
+    buildSync({
+      absWorkingDir: root,
+      entryPoints: [fileURLToPath(import.meta.resolve('zod'))],
+      outfile: path,
+      bundle: true,
+      platform: 'node',
+      format: 'esm',
+      target: 'node24',
+      sourcemap: true
+    })
+    return { path, cleanup }
+  } catch (error) {
+    cleanup()
+    throw error
+  }
+}
diff --git a/config/vitest.config.ts b/config/vitest.config.ts
index fb2b889a7dc..aac0a83051f 100644
--- a/config/vitest.config.ts
+++ b/config/vitest.config.ts
@@ -39,6 +39,9 @@ const transforms = {
   },
   resolve: {
     alias: [
+      ...(process.env.ORCA_UNIT_ZOD_BUNDLE
+        ? [{ find: /^zod$/, replacement: process.env.ORCA_UNIT_ZOD_BUNDLE }]
+        : []),
       ...createWorkspaceSourceResolver().aliases,
       { find: '@renderer', replacement: resolve('src/renderer/src') },
       { find: '@', replacement: resolve('src/renderer/src') },