orca/.github/workflows/mobile-ios-release.yml

name: Mobile iOS Release

# Release iOS independently so App Store review cannot block Android.
on:
  push:
    tags:
      - 'mobile-ios-v*'
  workflow_dispatch:
    inputs:
      bump_patch_version:
        description: 'Use the first open iOS patch version after the checked-in version, skipping versions already closed on the App Store.'
        required: false
        default: false
        type: boolean
      release_version:
        description: 'Optional exact iOS marketing version override, e.g. 0.0.15'
        required: false
        type: string
      testflight_changelog:
        description: 'Optional TestFlight external tester changelog'
        required: false
        type: string

permissions:
  contents: read

jobs:
  ios-build:
    # Xcode 27.1's iOS SDK enables iPhone Duo resizing; Expo SDK 55 requires Swift 6 syntax.
    runs-on: xcode-27
    # Archive + upload is ~30–40m when healthy; 90m leaves margin for setup.
    timeout-minutes: 90

    env:
      # Freeze Gemfile.lock in both jobs; installs ~25min apart must not resolve different fastlane versions.
      BUNDLE_FROZEN: 'true'

    outputs:
      release_version: ${{ steps.release_metadata.outputs.version }}
      build_number: ${{ steps.release_metadata.outputs.build_number }}

    defaults:
      run:
        working-directory: mobile

    steps:
      - name: Checkout
        uses: actions/checkout@v6

      - name: Select Xcode
        uses: maxim-lobanov/setup-xcode@v1
        with:
          # iOS 27.1 SDK: iPhone Duo resizing and reserved (fold/camera) regions.
          xcode-version: '27.1'

      - name: Setup Node.js
        uses: actions/setup-node@v6
        with:
          node-version: 24
          check-latest: true

      - name: Setup pnpm
        uses: pnpm/setup@v2
        with:
          install: false

      - name: Install dependencies
        run: pnpm install --frozen-lockfile

      - name: Setup Ruby and fastlane
        uses: ruby/setup-ruby@v1
        with:
          ruby-version: '3.3'
          bundler-cache: true
          working-directory: mobile

      - name: Resolve release version and build number
        env:
          ASC_KEY_ID: ${{ secrets.ASC_KEY_ID }}
          ASC_ISSUER_ID: ${{ secrets.ASC_ISSUER_ID }}
          ASC_API_KEY_P8: ${{ secrets.ASC_API_KEY_P8 }}
          MOBILE_IOS_RELEASE_VERSION: ${{ github.event.inputs.release_version }}
          MOBILE_IOS_BUMP_PATCH_VERSION: ${{ github.event.inputs.bump_patch_version }}
          FASTLANE_SKIP_UPDATE_CHECK: '1'
          FASTLANE_HIDE_CHANGELOG: '1'
        run: bundle exec fastlane ios prepare_release_version version:"$MOBILE_IOS_RELEASE_VERSION" bump_patch:"$MOBILE_IOS_BUMP_PATCH_VERSION"

      - name: Capture release metadata
        id: release_metadata
        run: node -e 'const fs = require("node:fs"); const { expo } = require("./app.json"); fs.appendFileSync(process.env.GITHUB_OUTPUT, `version=${expo.version}\nbuild_number=${expo.ios.buildNumber}\n`)'

      - name: Expo prebuild
        env:
          ORCA_IOS_APS_ENVIRONMENT: production
        run: npx expo prebuild --platform ios --no-install

      - name: Install CocoaPods
        working-directory: mobile/ios
        run: bundle exec pod install

      # Import exported distribution .p12 into ephemeral runner keychain: provisioning updates/API key cannot recreate its private key.
      - name: Import distribution certificate
        env:
          IOS_DIST_CERT_P12: ${{ secrets.IOS_DIST_CERT_P12 }}
          IOS_DIST_CERT_PASSWORD: ${{ secrets.IOS_DIST_CERT_PASSWORD }}
        run: |
          set -euo pipefail
          KEYCHAIN_PATH="$RUNNER_TEMP/orca-signing.keychain-db"
          # Random per-run keychain password; never persisted.
          KEYCHAIN_PASSWORD="$(openssl rand -base64 24)"
          CERT_PATH="$RUNNER_TEMP/orca-dist-cert.p12"

          echo "$IOS_DIST_CERT_P12" | base64 --decode > "$CERT_PATH"

          security create-keychain -p "$KEYCHAIN_PASSWORD" "$KEYCHAIN_PATH"
          security set-keychain-settings -lut 21600 "$KEYCHAIN_PATH"
          security unlock-keychain -p "$KEYCHAIN_PASSWORD" "$KEYCHAIN_PATH"
          security import "$CERT_PATH" -P "$IOS_DIST_CERT_PASSWORD" \
            -A -t cert -f pkcs12 -k "$KEYCHAIN_PATH"
          # Allow codesign/xcodebuild to use the key without an interactive prompt.
          security set-key-partition-list -S apple-tool:,apple: \
            -k "$KEYCHAIN_PASSWORD" "$KEYCHAIN_PATH" >/dev/null
          # Put our keychain in the search list so xcodebuild can find the identity.
          security list-keychains -d user -s "$KEYCHAIN_PATH" login.keychain-db
          rm -f "$CERT_PATH"

      - name: Build and upload to TestFlight
        env:
          ASC_KEY_ID: ${{ secrets.ASC_KEY_ID }}
          ASC_ISSUER_ID: ${{ secrets.ASC_ISSUER_ID }}
          ASC_API_KEY_P8: ${{ secrets.ASC_API_KEY_P8 }}
          APPLE_TEAM_ID: ${{ secrets.APPLE_TEAM_ID }}
          # Keep fastlane non-interactive and quiet about analytics in CI.
          FASTLANE_SKIP_UPDATE_CHECK: '1'
          FASTLANE_HIDE_CHANGELOG: '1'
          # Metro's release transform of the 3.6 MB Mermaid module needs >2 GB heap; the runner's default cap sits at that edge.
          NODE_OPTIONS: --max-old-space-size=4096
        run: bundle exec fastlane ios build_and_upload

      - name: Upload .ipa artifact
        if: always()
        uses: actions/upload-artifact@v7
        with:
          name: orca-mobile-ipa
          path: mobile/build/*.ipa
          if-no-files-found: ignore

  ios-distribute:
    name: Distribute to external TestFlight testers
    needs: ios-build
    runs-on: ubuntu-latest
    # Fastlane's processing wait fails after 20m; this outer bound leaves setup
    # margin without allowing App Store Connect polling to hang for hours.
    timeout-minutes: 30

    env:
      # Same fastlane as ios-build, or fail before touching App Store Connect.
      BUNDLE_FROZEN: 'true'

    defaults:
      run:
        working-directory: mobile

    steps:
      - name: Checkout
        uses: actions/checkout@v6

      - name: Setup Ruby and fastlane
        uses: ruby/setup-ruby@v1
        with:
          ruby-version: '3.3'
          bundler-cache: true
          working-directory: mobile

      - name: Wait for processing and distribute to peeps
        env:
          ASC_KEY_ID: ${{ secrets.ASC_KEY_ID }}
          ASC_ISSUER_ID: ${{ secrets.ASC_ISSUER_ID }}
          ASC_API_KEY_P8: ${{ secrets.ASC_API_KEY_P8 }}
          TESTFLIGHT_CHANGELOG: ${{ github.event.inputs.testflight_changelog }}
          MOBILE_IOS_RELEASE_VERSION: ${{ needs.ios-build.outputs.release_version }}
          MOBILE_IOS_BUILD_NUMBER: ${{ needs.ios-build.outputs.build_number }}
          FASTLANE_SKIP_UPDATE_CHECK: '1'
          FASTLANE_HIDE_CHANGELOG: '1'
        run: |
          if ! bundle exec fastlane ios distribute_testflight \
            version:"$MOBILE_IOS_RELEASE_VERSION" \
            build_number:"$MOBILE_IOS_BUILD_NUMBER"; then
            echo "::error::TestFlight $MOBILE_IOS_RELEASE_VERSION ($MOBILE_IOS_BUILD_NUMBER) was uploaded but not distributed to peeps. If App Store Connect is still processing it, rerun only this failed job after the build becomes Ready; otherwise inspect the Fastlane error above."
            exit 1
          fi