fix(test): bound startup build helpers

scripts/ensure-cli-startup-build.mjs

@@ -8,6 +8,20 @@ import { fileURLToPath, pathToFileURL } from "node:url";
 const repoRoot = path.resolve(path.dirname(fileURLToPath(import.meta.url)), "..");
 const entryCandidates = ["dist/entry.js", "dist/entry.mjs"];
 const startupMetadataPath = "dist/cli-startup-metadata.json";
+const DEFAULT_BUILD_TIMEOUT_MS = 10 * 60 * 1000;
+
+function positiveEnvInt(name, env, fallback) {
+  const raw = env[name]?.trim();
+  if (raw === undefined || raw === "" || !/^[0-9]+$/.test(raw)) {
+    return fallback;
+  }
+  const value = Number.parseInt(raw, 10);
+  return Number.isSafeInteger(value) && value > 0 ? value : fallback;
+}
+
+export function resolveCliStartupBuildTimeoutMs(env = process.env) {
+  return positiveEnvInt("OPENCLAW_CLI_STARTUP_BUILD_TIMEOUT_MS", env, DEFAULT_BUILD_TIMEOUT_MS);
+}
 
 export function hasCliStartupBuild(params = {}) {
   const rootDir = params.rootDir ?? repoRoot;
@@ -32,7 +46,9 @@ export function ensureCliStartupBuild(params = {}) {
   const result = spawn(nodeExecPath, [buildScript, "cliStartup"], {
     cwd: rootDir,
     env: params.env ?? process.env,
+    killSignal: params.killSignal ?? "SIGKILL",
     stdio: params.stdio ?? "inherit",
+    timeout: params.timeoutMs ?? resolveCliStartupBuildTimeoutMs(params.env ?? process.env),
   });
   if (result.error) {
     throw result.error;

scripts/ensure-extension-memory-build.mjs

@@ -10,6 +10,24 @@ import {
 } from "./lib/bundled-plugin-build-entries.mjs";
 
 const repoRoot = path.resolve(path.dirname(fileURLToPath(import.meta.url)), "..");
+const DEFAULT_BUILD_TIMEOUT_MS = 10 * 60 * 1000;
+
+function positiveEnvInt(name, env, fallback) {
+  const raw = env[name]?.trim();
+  if (raw === undefined || raw === "" || !/^[0-9]+$/.test(raw)) {
+    return fallback;
+  }
+  const value = Number.parseInt(raw, 10);
+  return Number.isSafeInteger(value) && value > 0 ? value : fallback;
+}
+
+export function resolveExtensionMemoryBuildTimeoutMs(env = process.env) {
+  return positiveEnvInt(
+    "OPENCLAW_EXTENSION_MEMORY_BUILD_TIMEOUT_MS",
+    env,
+    DEFAULT_BUILD_TIMEOUT_MS,
+  );
+}
 
 function collectExpectedExtensionMemoryEntryIds(rootDir, env) {
   try {
@@ -80,7 +98,9 @@ export function ensureExtensionMemoryBuild(params = {}) {
   const result = spawn(nodeExecPath, [buildScript, "cliStartup"], {
     cwd: rootDir,
     env: params.env ?? process.env,
+    killSignal: params.killSignal ?? "SIGKILL",
     stdio: params.stdio ?? "inherit",
+    timeout: params.timeoutMs ?? resolveExtensionMemoryBuildTimeoutMs(params.env ?? process.env),
   });
   if (result.error) {
     throw result.error;

scripts/openclaw-npm-release-check.ts

@@ -302,8 +302,8 @@ export function utcCalendarDayDistance(left: Date, right: Date): number {
 }
 
 function positiveEnvInt(name: string, env: NodeJS.ProcessEnv, fallback: number): number {
-  const raw = env[name];
-  if (raw === undefined || raw === "") {
+  const raw = env[name]?.trim();
+  if (raw === undefined || raw === "" || !/^[0-9]+$/u.test(raw)) {
     return fallback;
   }
   const value = Number.parseInt(raw, 10);

scripts/openclaw-prepack.ts

@@ -93,8 +93,8 @@ function ensurePreparedArtifacts(): void {
 }
 
 function positiveEnvInt(name: string, env: NodeJS.ProcessEnv, fallback: number): number {
-  const raw = env[name];
-  if (raw === undefined || raw === "") {
+  const raw = env[name]?.trim();
+  if (raw === undefined || raw === "" || !/^[0-9]+$/u.test(raw)) {
     return fallback;
   }
   const value = Number.parseInt(raw, 10);

scripts/release-check.ts

@@ -175,8 +175,8 @@ const PACKED_PLUGIN_SDK_TYPESCRIPT_SMOKE_FIXTURE = resolve(
 );
 
 function positiveEnvInt(name: string, fallback: number): number {
-  const raw = process.env[name];
-  if (raw === undefined || raw === "") {
+  const raw = process.env[name]?.trim();
+  if (raw === undefined || raw === "" || !/^[0-9]+$/u.test(raw)) {
     return fallback;
   }
   const value = Number.parseInt(raw, 10);

test/openclaw-npm-release-check.test.ts

@@ -471,6 +471,14 @@ describe("resolveNpmReleaseCheckCommandTimeoutMs", () => {
       }),
     ).toBe(10 * 60 * 1000);
   });
+
+  it("falls back when the environment timeout has a numeric prefix", () => {
+    expect(
+      resolveNpmReleaseCheckCommandTimeoutMs({
+        OPENCLAW_NPM_RELEASE_CHECK_COMMAND_TIMEOUT_MS: "10m",
+      }),
+    ).toBe(10 * 60 * 1000);
+  });
 });
 
 describe("parseNpmPackJsonOutput", () => {

test/openclaw-prepack.test.ts

@@ -64,4 +64,10 @@ describe("resolvePrepackCommandTimeoutMs", () => {
       30 * 60 * 1000,
     );
   });
+
+  it("falls back when the environment timeout has a numeric prefix", () => {
+    expect(resolvePrepackCommandTimeoutMs({ OPENCLAW_PREPACK_COMMAND_TIMEOUT_MS: "10m" })).toBe(
+      30 * 60 * 1000,
+    );
+  });
 });

test/scripts/ensure-cli-startup-build.test.ts

@@ -5,6 +5,7 @@ import { afterEach, describe, expect, it } from "vitest";
 import {
   ensureCliStartupBuild,
   hasCliStartupBuild,
+  resolveCliStartupBuildTimeoutMs,
 } from "../../scripts/ensure-cli-startup-build.mjs";
 
 const tempRoots: string[] = [];
@@ -80,7 +81,9 @@ describe("ensure-cli-startup-build", () => {
         args: [path.join(root, "scripts", "build-all.mjs"), "cliStartup"],
         options: expect.objectContaining({
           cwd: root,
+          killSignal: "SIGKILL",
           stdio: "pipe",
+          timeout: 10 * 60 * 1000,
         }),
       },
     ]);
@@ -107,12 +110,37 @@ describe("ensure-cli-startup-build", () => {
         args: [path.join(root, "scripts", "build-all.mjs"), "cliStartup"],
         options: expect.objectContaining({
           cwd: root,
+          killSignal: "SIGKILL",
           stdio: "pipe",
+          timeout: 10 * 60 * 1000,
         }),
       },
     ]);
   });
 
+  it("uses the configured cliStartup build timeout", () => {
+    const root = makeTempRoot();
+    const calls: unknown[] = [];
+
+    ensureCliStartupBuild({
+      rootDir: root,
+      env: { OPENCLAW_CLI_STARTUP_BUILD_TIMEOUT_MS: "1234" },
+      spawnSync: (command, args, options) => {
+        calls.push({ command, args, options });
+        return { status: 0 };
+      },
+      stdio: "pipe",
+    });
+
+    expect(calls).toEqual([
+      expect.objectContaining({
+        options: expect.objectContaining({
+          timeout: 1234,
+        }),
+      }),
+    ]);
+  });
+
   it("fails when the cliStartup build profile fails", () => {
     const root = makeTempRoot();
 
@@ -137,3 +165,23 @@ describe("ensure-cli-startup-build", () => {
     ).toThrow("spawn denied");
   });
 });
+
+describe("resolveCliStartupBuildTimeoutMs", () => {
+  it("uses a positive environment timeout", () => {
+    expect(resolveCliStartupBuildTimeoutMs({ OPENCLAW_CLI_STARTUP_BUILD_TIMEOUT_MS: "4321" })).toBe(
+      4321,
+    );
+  });
+
+  it("falls back when the environment timeout is invalid", () => {
+    expect(resolveCliStartupBuildTimeoutMs({ OPENCLAW_CLI_STARTUP_BUILD_TIMEOUT_MS: "nope" })).toBe(
+      10 * 60 * 1000,
+    );
+  });
+
+  it("falls back when the environment timeout has a numeric prefix", () => {
+    expect(resolveCliStartupBuildTimeoutMs({ OPENCLAW_CLI_STARTUP_BUILD_TIMEOUT_MS: "10m" })).toBe(
+      10 * 60 * 1000,
+    );
+  });
+});

test/scripts/ensure-extension-memory-build.test.ts

@@ -5,6 +5,7 @@ import { afterEach, describe, expect, it } from "vitest";
 import {
   ensureExtensionMemoryBuild,
   hasBuiltExtensionMemoryEntries,
+  resolveExtensionMemoryBuildTimeoutMs,
 } from "../../scripts/ensure-extension-memory-build.mjs";
 
 const tempRoots: string[] = [];
@@ -97,12 +98,38 @@ describe("ensure-extension-memory-build", () => {
         args: [path.join(root, "scripts", "build-all.mjs"), "cliStartup"],
         options: expect.objectContaining({
           cwd: root,
+          killSignal: "SIGKILL",
           stdio: "pipe",
+          timeout: 10 * 60 * 1000,
         }),
       },
     ]);
   });
 
+  it("uses the configured extension memory build timeout", () => {
+    const root = makeTempRoot();
+    const calls: unknown[] = [];
+
+    ensureExtensionMemoryBuild({
+      rootDir: root,
+      env: { OPENCLAW_EXTENSION_MEMORY_BUILD_TIMEOUT_MS: "1234" },
+      requiredExtensionIds: ["discord"],
+      spawnSync: (command, args, options) => {
+        calls.push({ command, args, options });
+        return { status: 0 };
+      },
+      stdio: "pipe",
+    });
+
+    expect(calls).toEqual([
+      expect.objectContaining({
+        options: expect.objectContaining({
+          timeout: 1234,
+        }),
+      }),
+    ]);
+  });
+
   it("fails when the cliStartup build profile fails", () => {
     const root = makeTempRoot();
 
@@ -115,3 +142,29 @@ describe("ensure-extension-memory-build", () => {
     ).toThrow("cliStartup build profile failed with exit code 1");
   });
 });
+
+describe("resolveExtensionMemoryBuildTimeoutMs", () => {
+  it("uses a positive environment timeout", () => {
+    expect(
+      resolveExtensionMemoryBuildTimeoutMs({
+        OPENCLAW_EXTENSION_MEMORY_BUILD_TIMEOUT_MS: "4321",
+      }),
+    ).toBe(4321);
+  });
+
+  it("falls back when the environment timeout is invalid", () => {
+    expect(
+      resolveExtensionMemoryBuildTimeoutMs({
+        OPENCLAW_EXTENSION_MEMORY_BUILD_TIMEOUT_MS: "nope",
+      }),
+    ).toBe(10 * 60 * 1000);
+  });
+
+  it("falls back when the environment timeout has a numeric prefix", () => {
+    expect(
+      resolveExtensionMemoryBuildTimeoutMs({
+        OPENCLAW_EXTENSION_MEMORY_BUILD_TIMEOUT_MS: "10m",
+      }),
+    ).toBe(10 * 60 * 1000);
+  });
+});