fix(config): robust TS cypress-config compile in NX monorepos (SDK-6463)

When the cypress config is TypeScript and lives in an NX/monorepo, the extends temp tsconfig inherited base options (noEmit / emitDeclarationOnly / composite / noEmitOnError) that suppress or redirect the compiled JS, and any tsc type-error short-circuited the '&&'-chained tsc-alias so path aliases were left un-rewritten. The compiled config then could not be found/required, the error was silently swallowed, and getNumberOfSpecFiles fell back to a default glob that found 0 specs -> setParallels collapsed parallels to 1.

Force emit-friendly overrides in the extends temp tsconfig and run tsc-alias unconditionally (& / ; instead of &&). Adds regression tests covering the emit-override and unconditional-alias behavior.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

Author: Bhargavi-BS

bin/helpers/readCypressConfigUtil.js

@@ -90,7 +90,20 @@ function generateTscCommandAndTempTsConfig(bsConfig, bstack_node_modules_path, c
         "listEmittedFiles": true,
         // Ensure these are always set regardless of base tsconfig
         "allowSyntheticDefaultImports": true,
-        "esModuleInterop": true
+        "esModuleInterop": true,
+        // Force a clean, self-contained JS emit even when the extended tsconfig
+        // (common in NX / monorepo setups) sets options that suppress or redirect
+        // the JS output. Without these overrides, base options such as
+        // noEmit / emitDeclarationOnly / composite / noEmitOnError leave the
+        // compiled cypress config missing, surfacing as
+        // "Cypress config file not found at: ...tmpBstackCompiledJs/..." (SDK-6463).
+        "noEmit": false,
+        "emitDeclarationOnly": false,
+        "composite": false,
+        "declaration": false,
+        "declarationMap": false,
+        "noEmitOnError": false,
+        "incremental": false
       },
       include: [cypress_config_filepath]
     };
@@ -135,13 +148,25 @@ function generateTscCommandAndTempTsConfig(bsConfig, bstack_node_modules_path, c
       ? `set NODE_PATH=${bstack_node_modules_path}`
       : `NODE_PATH="${bstack_node_modules_path}"`;
 
-    const tscCommand = `${setNodePath} && node "${typescript_path}" --project "${tempTsConfigPath}" && ${setNodePath} && node "${tsc_alias_path}" --project "${tempTsConfigPath}" --verbose`;
+    // Use '&' (unconditional) instead of '&&' between tsc and tsc-alias so the alias
+    // rewrite ALWAYS runs even when tsc exits non-zero. tsc returns a non-zero exit
+    // code on any type error (very common when a single config file is compiled out of
+    // its normal monorepo project context), which with '&&' would skip tsc-alias and
+    // leave path aliases (e.g. @org/lib) un-rewritten -> the compiled config fails to
+    // require -> "Cypress config file not found" (SDK-6463). convertTsConfig already
+    // tolerates tsc errors by parsing the emitted-files output.
+    const tscCommand = `${setNodePath} && node "${typescript_path}" --project "${tempTsConfigPath}" & ${setNodePath} && node "${tsc_alias_path}" --project "${tempTsConfigPath}" --verbose`;
     logger.info(`TypeScript compilation command: ${tscCommand}`);
     return { tscCommand, tempTsConfigPath };
   } else {
-    // Unix/Linux/macOS: Use ; to separate commands or && to chain
+    // Unix/Linux/macOS: Use ';' (unconditional) between tsc and tsc-alias so the alias
+    // rewrite ALWAYS runs even when tsc exits non-zero (type errors are common when a
+    // single config file is compiled out of its monorepo context). With '&&', a tsc
+    // error would skip tsc-alias and leave path aliases (e.g. @org/lib) un-rewritten,
+    // making the compiled config impossible to require (SDK-6463). convertTsConfig
+    // already tolerates tsc errors by parsing the emitted-files output.
     const nodePathPrefix = `NODE_PATH=${bstack_node_modules_path}`;
-    const tscCommand = `${nodePathPrefix} node "${typescript_path}" --project "${tempTsConfigPath}" && ${nodePathPrefix} node "${tsc_alias_path}" --project "${tempTsConfigPath}" --verbose`;
+    const tscCommand = `${nodePathPrefix} node "${typescript_path}" --project "${tempTsConfigPath}" ; ${nodePathPrefix} node "${tsc_alias_path}" --project "${tempTsConfigPath}" --verbose`;
     logger.info(`TypeScript compilation command: ${tscCommand}`);
     return { tscCommand, tempTsConfigPath };
   }

test/unit/bin/helpers/readCypressConfigUtil.js

@@ -304,10 +304,58 @@ describe("readCypressConfigUtil", () => {
             const writeFileSyncStub = sandbox.stub(fs, 'writeFileSync');
 
             const result = generateTscCommandAndTempTsConfig(bsConfig, 'path/to/tmpBstackPackages', 'path/to/tmpBstackCompiledJs', 'path/to/cypress.config.ts');
-            
+
             expect(result.tscCommand).to.include('NODE_PATH=path/to/tmpBstackPackages');
             expect(result.tscCommand).to.include('tsc-alias');
         });
+
+        // SDK-6463: NX/monorepo base tsconfigs can set noEmit/emitDeclarationOnly/composite/
+        // noEmitOnError, which suppress or redirect the compiled cypress config JS and break
+        // the read. The extends temp tsconfig must force a clean self-contained JS emit.
+        it('should force emit-friendly compilerOptions overrides in extends approach (SDK-6463)', () => {
+            const bsConfig = { run_settings: { ts_config_file_path: 'existing/tsconfig.json' } };
+            const existsSyncStub = sandbox.stub(fs, 'existsSync');
+            existsSyncStub.withArgs(path.resolve('existing/tsconfig.json')).returns(true);
+            sandbox.stub(fs, 'readFileSync').returns('{}');
+            const writeFileSyncStub = sandbox.stub(fs, 'writeFileSync');
+
+            generateTscCommandAndTempTsConfig(bsConfig, 'path/to/tmpBstackPackages', 'path/to/tmpBstackCompiledJs', 'path/to/cypress.config.ts');
+
+            const tempConfig = JSON.parse(writeFileSyncStub.getCall(0).args[1]);
+            expect(tempConfig.extends).to.eql(path.resolve('existing/tsconfig.json'));
+            expect(tempConfig.compilerOptions.noEmit).to.be.false;
+            expect(tempConfig.compilerOptions.emitDeclarationOnly).to.be.false;
+            expect(tempConfig.compilerOptions.composite).to.be.false;
+            expect(tempConfig.compilerOptions.noEmitOnError).to.be.false;
+            expect(tempConfig.compilerOptions.declaration).to.be.false;
+        });
+
+        // SDK-6463: tsc returns a non-zero exit code on any type error (common when a single
+        // config file is compiled out of its monorepo context). With '&&', tsc-alias would be
+        // skipped and path aliases left un-rewritten. tsc-alias must run unconditionally.
+        it('should run tsc-alias unconditionally on Unix (";" not "&&") (SDK-6463)', () => {
+            sinon.stub(process, 'platform').value('linux');
+            const bsConfig = { run_settings: {} };
+            sandbox.stub(fs, 'existsSync').returns(false);
+            sandbox.stub(fs, 'writeFileSync');
+
+            const result = generateTscCommandAndTempTsConfig(bsConfig, 'path/to/tmpBstackPackages', 'path/to/tmpBstackCompiledJs', 'path/to/cypress.config.ts');
+
+            expect(result.tscCommand).to.not.include('&&');
+            expect(result.tscCommand).to.match(/--project "[^"]*" ; NODE_PATH=/);
+        });
+
+        it('should run tsc-alias unconditionally on Windows ("&" between tsc and tsc-alias) (SDK-6463)', () => {
+            sinon.stub(process, 'platform').value('win32');
+            const bsConfig = { run_settings: {} };
+            sandbox.stub(fs, 'existsSync').returns(false);
+            sandbox.stub(fs, 'writeFileSync');
+
+            const result = generateTscCommandAndTempTsConfig(bsConfig, 'path/to/tmpBstackPackages', 'path/to/tmpBstackCompiledJs', 'path/to/cypress.config.ts');
+
+            // unconditional '&' connects the tsc invocation to the tsc-alias invocation
+            expect(result.tscCommand).to.match(/--project "[^"]*" & set NODE_PATH=/);
+        });
     });
 
     describe('convertTsConfig', () => {