musistudio/claude-code-router · warning

[export] Failed to process exported PNG: ${formatError(error

Error message

[export] Failed to process exported PNG: ${formatError(error)}

What it means

Post-processing a captured PNG (decoding, resizing, or applying the rounded-corner alpha mask) failed, so the code falls back to native-image resizing or returns the raw PNG.

Source

Thrown at packages/electron/src/main/ipc.ts:710

  }

  try {
    const decoded = decodePngPixels(png);
    let width = decoded.width;
    let height = decoded.height;
    let rgba = pngPixelsToRgba(decoded);
    if (outputWidth && outputHeight && (outputWidth !== width || outputHeight !== height)) {
      rgba = resizeRgbaBilinear(rgba, width, height, outputWidth, outputHeight);
      width = outputWidth;
      height = outputHeight;
    }
    if (radius > 0 && cssWidth > 0) {
      const pixelRadius = Math.min(width / 2, height / 2, radius * width / cssWidth);
      applyRoundedAlphaMask(rgba, width, height, pixelRadius);
    }
    return encodeRgbaPng(width, height, rgba);
  } catch (error) {
    console.warn(`[export] Failed to process exported PNG: ${formatError(error)}`);
    const resized = resizePngWithNativeImage(png, outputWidth, outputHeight);
    if (resized) {
      return resized;
    }
    return png;
  }
}

function resizePngWithNativeImage(png: Buffer, width?: number, height?: number): Buffer | undefined {
  if (!width || !height) {
    return undefined;
  }
  try {
    const image = nativeImage.createFromBuffer(png);
    if (image.isEmpty()) {
      return undefined;
    }
    return image.resize({ height, width }).toPNG();

View on GitHub (pinned to 99f24806c6)

Solutions

1. Sanitize outputWidth/outputHeight with sanitizePngOutputDimension before calling
2. Ensure the captured element has non-zero size and is visible
3. Pass radius=0 to skip mask processing and test whether mask math is the cause

Example fix

// before
pngWithExportProcessing(png, { width, height, radius, cssWidth });
// after
pngWithExportProcessing(png, {
  width: sanitizePngOutputDimension(width) ?? png.width,
  height: sanitizePngOutputDimension(height) ?? png.height,
  radius, cssWidth
});

const w = sanitizePngOutputDimension(outputWidth); const h = sanitizePngOutputDimension(outputHeight); if (!w || !h || w * h > 50_000_000) throw new RangeError('bad dims');

const isFinitePositive = (n: unknown): n is number => typeof n === 'number' && Number.isFinite(n) && n > 0;

catch (error) { warn; return resizePngWithNativeImage(png, w, h) ?? png; }

When it happens

Trigger: captureElementPng/renderHtmlPng with extreme dimensions (0 or huge width/height), corrupt PNG bytes from capturePage, or a radius larger than the image producing invalid Math in the mask step.

Common situations: Capturing a hidden/zero-size element, outputWidth/outputHeight passed as 0 from unsanitized IPC input, or non-PNG bytes returned offscreen-render.

Related errors

• [export] Failed to resize exported PNG fallback: ${formatErr
• [export] Failed to include ${file}: ${formatError(error)}

AI-assisted analysis of musistudio/claude-code-router@99f24806c6 (2026-08-27). Data as JSON: /api/errors/1abc6e8f0b98fb46. Report an issue: GitHub.