From bd10f7d1471038b0869471c36fbb31f6882be04e Mon Sep 17 00:00:00 2001
From: Twest2 <git@twestbrook.com>
Date: Tue, 23 Jun 2026 18:02:24 -0500
Subject: [PATCH] lazy load ocr dependency

---
 app/text-intel.js             | 17 +++++++++++++++--
 tests/unit/text-intel.test.js | 23 +++++++++++++++++++++++
 2 files changed, 38 insertions(+), 2 deletions(-)

diff --git a/app/text-intel.js b/app/text-intel.js
index 0d305a4..2e1e08d 100644
--- a/app/text-intel.js
+++ b/app/text-intel.js
@@ -4,7 +4,6 @@ const fs = require('node:fs');
 const path = require('node:path');
 const { execFileSync } = require('node:child_process');
 
-const { createWorker } = require('tesseract.js');
 const {
   buildCaptureTitle,
   normalizeOllamaHost,
@@ -33,6 +32,16 @@ function clamp(v, min, max) {
   return Math.min(max, Math.max(min, v));
 }
 
+let createWorkerImpl = null;
+function loadCreateWorker() {
+  if (createWorkerImpl) return createWorkerImpl;
+  // OCR is optional at startup; lazy-load it so the app can still boot when
+  // the dependency has not been installed yet.
+  // eslint-disable-next-line global-require
+  ({ createWorker: createWorkerImpl } = require('tesseract.js'));
+  return createWorkerImpl;
+}
+
 class TextIntelService {
   constructor({
     store,
@@ -81,8 +90,9 @@ class TextIntelService {
   async getWorker() {
     if (this.workerPromise) return this.workerPromise;
     this.workerPromise = (async () => {
+      const workerFactory = loadCreateWorker();
       const langPath = this.ensureLangData();
-      const worker = await createWorker('eng', 1, {
+      const worker = await workerFactory('eng', 1, {
         langPath,
       });
       await worker.setParameters({
@@ -91,6 +101,9 @@ class TextIntelService {
       this.worker = worker;
       return worker;
     })();
+    this.workerPromise.catch(() => {
+      this.workerPromise = null;
+    });
     return this.workerPromise;
   }
 
diff --git a/tests/unit/text-intel.test.js b/tests/unit/text-intel.test.js
index 861e322..63f254e 100644
--- a/tests/unit/text-intel.test.js
+++ b/tests/unit/text-intel.test.js
@@ -83,6 +83,29 @@ test('ocr crop rectangles clamp to the image bounds', (t) => {
   assert.deepEqual(bottomRight, { x: 580, y: 280, width: 420, height: 220 });
 });
 
+test('ocr failures fall back to empty text instead of crashing', async (t) => {
+  const root = makeTmpDir('text-intel-ocr-fallback');
+  t.after(() => rmrf(root));
+  const service = new TextIntelService({
+    store: { settingsDir: root },
+    settings: makeSettings(),
+    getWindow: () => null,
+    dataDir: root,
+    fetchImpl: global.fetch,
+  });
+  service.getWorker = async () => {
+    throw new Error('tesseract missing');
+  };
+
+  const result = await service.ocrAroundClick({
+    image: {},
+    size: { width: 100, height: 100 },
+    display: { bounds: { x: 0, y: 0, width: 100, height: 100 } },
+  }, { x: 50, y: 50 });
+
+  assert.deepEqual(result, { text: '', confidence: null });
+});
+
 test('ai response normalization and application keeps fields structured', () => {
   const patch = normalizeAiPatch(JSON.stringify({
     title: 'Open settings',