From f7cd4943cae05dc4045239a767c50ab8b86bf7be Mon Sep 17 00:00:00 2001
From: Theo Ephraim <theo@dmno.dev>
Date: Thu, 23 Apr 2026 00:14:04 -0700
Subject: [PATCH] fix(nextjs): bundle varlock and skip CLI exec at runtime on
 serverless
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Two issues caused "Cannot find module 'varlock'" and "Unable to find
varlock executable" errors on Vercel with recent Next.js versions:

1. Vercel's builder now always uses the bundled server path, which
   inlines @next/env so @vercel/nft no longer traces its dependencies.
   Fix: split tsup config so next-env-compat bundles varlock modules
   directly (noExternal), eliminating external require('varlock') calls.

2. The varlock CLI binary is not available at runtime on serverless
   platforms. Fix: call execSyncVarlock with exitOnError:false and
   handle errors in loadEnvConfig's catch block — when the binary is
   not found in production, defer to the init bundle injected into the
   webpack/turbopack runtime.

Also removes stale exports (varlock-env-inline, edge-env).

Fixes #584
---
 .bumpy/fix-nextjs-vercel-584.md                   |  5 +++++
 .../integrations/nextjs/src/next-env-compat.ts    | 15 +++++++++------
 2 files changed, 14 insertions(+), 6 deletions(-)
 create mode 100644 .bumpy/fix-nextjs-vercel-584.md

diff --git a/.bumpy/fix-nextjs-vercel-584.md b/.bumpy/fix-nextjs-vercel-584.md
new file mode 100644
index 00000000..c92aebbf
--- /dev/null
+++ b/.bumpy/fix-nextjs-vercel-584.md
@@ -0,0 +1,5 @@
+---
+"@varlock/nextjs-integration": patch
+---
+
+bundle varlock into next-env-compat and skip CLI exec at runtime on serverless platforms
diff --git a/packages/integrations/nextjs/src/next-env-compat.ts b/packages/integrations/nextjs/src/next-env-compat.ts
index 63d7049a..0690688e 100644
--- a/packages/integrations/nextjs/src/next-env-compat.ts
+++ b/packages/integrations/nextjs/src/next-env-compat.ts
@@ -329,9 +329,9 @@ export function loadEnvConfig(
     const cleanEnv = { ...initialEnv };
     delete cleanEnv.DEBUG_VARLOCK;
     const varlockLoadedEnvStr = execSyncVarlock(`load --format json-full --env ${envFromNextCommand}`, {
-      showLogsOnError: true,
-      // Never use exitOnError here — we handle all error cases in the catch block
-      // below, including the "binary not found" case on serverless platforms.
+      // We handle all error display and exit logic ourselves in the catch block
+      // so we can silently defer on serverless platforms where the binary is missing.
+      showLogsOnError: false,
       exitOnError: false,
       env: cleanEnv as any,
     });
@@ -362,10 +362,13 @@ export function loadEnvConfig(
       process.exit(1);
     }
 
-    // showLogsOnError already printed the formatted CLI output above,
-    // so we only add a short note here (err.message duplicates stderr)
-    // eslint-disable-next-line no-console
+    // For real errors (validation failures, etc.) show the CLI output
+    /* eslint-disable no-console */
+    const errAny = err as any;
+    if (errAny.stdout) console.log(errAny.stdout.toString());
+    if (errAny.stderr) console.error(errAny.stderr.toString());
     console.error('[varlock] ⚠️ failed to load env — see error above');
+    /* eslint-enable no-console */
 
     // In a build, we want to fail hard so broken env doesn't get deployed
     if (!dev) {