Import Claude Design ZIP silently fails: RangeError on 0-byte entries (Node 24) and MAX_FILES=500 too low #590

Summary

POST /api/import/claude-design (the Import Claude Design ZIP button in the New Project panel) silently fails for valid .zip files in two distinct ways:

1. Crash on zero-byte entries (Node 24). inflateRawSync(compressed, { maxOutputLength: 0 }) throws RangeError [ERR_OUT_OF_RANGE] on Node 24 because maxOutputLength must be >= 1. Any entry whose central-directory uncompressedSize is 0 (empty files, common when the zip uses data descriptors — e.g. macOS Archive Utility, streaming zips) breaks the whole import.
2. MAX_FILES = 500 rejects medium-sized exports. Design-system / prototype exports commonly exceed 500 files (the test asset that surfaced this is 561 files / ~4.4 MB). The existing MAX_TOTAL_BYTES = 100 MB and MAX_FILE_BYTES = 25 MB guards already cover pathological inputs.

The web UI surfaces neither error: apps/web/src/state/projects.ts returns null on !resp.ok, and apps/web/src/App.tsx's handleImportClaudeDesign does if (!result) return;. After picking a file, the button appears to "do nothing".

Reproduction

1. Build (or use an existing) zip with either:
   • any entry whose central-directory uncompressedSize is 0, or
   • more than 500 entries.
2. In the running app, click Import Claude Design ZIP in the New Project panel and pick the file.
3. UI shows nothing.
4. From a terminal, the underlying daemon error is visible:

   curl -i -F "file=@./your.zip" http://127.0.0.1:<daemon-port>/api/import/claude-design

   HTTP/1.1 400 Bad Request
   {"error":"RangeError [ERR_OUT_OF_RANGE]: The value of \"options.maxOutputLength\" is out of range. It must be >= 1 and <= 9007199254740991. Received 0"}
   

   or

   {"error":"Error: zip contains too many files"}
   

Root cause

apps/daemon/src/claude-design-import.ts:

// L11
const MAX_FILES = 500;

// L104-117 readEntryBody (...):
//   compressed = zip.slice(bodyStart, bodyEnd)  // bodyEnd-bodyStart === entry.compressedSize
//   ...
return inflateRawSync(compressed, { maxOutputLength: entry.uncompressedSize });

Node 24's zlib option validator now requires maxOutputLength >= 1, so the value 0 (legal in earlier versions) throws synchronously.

Suggested fix

Two-line patch in apps/daemon/src/claude-design-import.ts:

-const MAX_FILES = 500;
+const MAX_FILES = 5000;
@@
-  if (entry.method === 0) return Buffer.from(compressed);
-  return inflateRawSync(compressed, { maxOutputLength: entry.uncompressedSize });
+  if (entry.method === 0) return Buffer.from(compressed);
+  if (entry.uncompressedSize === 0) return Buffer.alloc(0);
+  return inflateRawSync(compressed, { maxOutputLength: entry.uncompressedSize });

Bytes-per-file and total-bytes guards already cap risk; MAX_FILES = 5000 is closer to what real design-system / prototype exports look like.

Related UX gap (separate but worth fixing together)

The web layer should surface the daemon's error field instead of swallowing it:

apps/web/src/state/projects.ts (importClaudeDesignZip): return the parsed JSON (including error) instead of null on !resp.ok, and have apps/web/src/App.tsx's handleImportClaudeDesign push the message into a toast. Without this, any future failure in the importer remains invisible to the user.

Environment

• Node v24.15.0
• pnpm 10.33.2
• macOS (darwin-arm64)
• Repo HEAD: c69dee7 on main

Test asset

Reproduced consistently with a 4.4 MB / 561-file zip containing 74 HTML files at preview/**/*.html, plus one zero-byte docs/components/chip-removable.md. Both failure modes were confirmed: the zero-byte entry triggers (1), and even after patching (1), (2) blocks the import. Both fixes together let the import succeed end-to-end.