Improve driver injection error handling and resilience

Enhances the driver installation process to be more resilient by allowing non-critical driver injection failures to not halt the entire deployment. Key improvements include:

- Adds `IgnoreExitCode` and `PassThruExitCode` parameters to the process invocation function, enabling callers to handle non-zero exit codes without throwing exceptions.

- Modifies driver injection logic (both WIM and folder-based) to capture exit codes and log warnings instead of failing the deployment when drivers fail to inject.

- Automatically collects and preserves diagnostic logs (dism.log and setupapi.offline.log) to the USB drive when driver installation encounters issues, aiding post-deployment troubleshooting.

- Wraps cleanup operations in try-catch blocks to ensure temporary resources are released even if unmounting or deletion fails.

- Fixes code formatting inconsistencies and indentation throughout the script for improved readability.

This approach prioritizes deployment completion while preserving critical diagnostic information when driver-related issues occur.

FFUDevelopment/WinPEDeployFFUFiles/ApplyFFU.ps1

@@ -23,7 +23,7 @@ function Get-HardDrive() {
     if ($manufacturer -eq 'Microsoft Corporation' -and $model -eq 'Virtual Machine') {
         WriteLog 'Running in a Hyper-V VM. Getting virtual disk on Index 0 and SCSILogicalUnit 0'
         $diskDriveCandidates = @(Get-CimInstance -Class 'Win32_DiskDrive' | Where-Object { $_.MediaType -eq 'Fixed hard disk media' `
-                -and $_.Model -eq 'Microsoft Virtual Disk'
+                    -and $_.Model -eq 'Microsoft Virtual Disk' `
                     -and $_.Index -eq 0 `
                     -and $_.SCSILogicalUnit -eq 0
             })
@@ -74,7 +74,13 @@ function Invoke-Process {
 
         [Parameter()]
         [ValidateNotNullOrEmpty()]
-        [string]$ArgumentList
+        [string]$ArgumentList,
+
+        [Parameter()]
+        [switch]$IgnoreExitCode,
+
+        [Parameter()]
+        [switch]$PassThruExitCode
     )
 
     $ErrorActionPreference = 'Stop'
@@ -96,19 +102,39 @@ function Invoke-Process {
             $cmd = Start-Process @startProcessParams
             $cmdOutput = Get-Content -Path $stdOutTempFile -Raw
             $cmdError = Get-Content -Path $stdErrTempFile -Raw
+
             if ($cmd.ExitCode -ne 0) {
+                # Non-terminating mode: capture output to Scriptlog and continue
+                if ($IgnoreExitCode) {
+                    if ([string]::IsNullOrEmpty($cmdOutput) -eq $false) {
+                        WriteLog $cmdOutput
+                    }
+                    if ([string]::IsNullOrEmpty($cmdError) -eq $false) {
+                        WriteLog $cmdError
+                    }
+                    if ($PassThruExitCode) {
+                        return $cmd.ExitCode
+                    }
+                    return
+                }
+
                 if ($cmdError) {
                     throw $cmdError.Trim()
                 }
                 if ($cmdOutput) {
                     throw $cmdOutput.Trim()
                 }
+                throw "Process failed. ExitCode = $($cmd.ExitCode)."
             }
             else {
                 if ([string]::IsNullOrEmpty($cmdOutput) -eq $false) {
                     WriteLog $cmdOutput
                 }
             }
+
+            if ($PassThruExitCode) {
+                return $cmd.ExitCode
+            }
         }
     }
     catch {
@@ -748,9 +774,9 @@ function Test-DriverFolderHasInstallableContent {
         WriteLog "Failed to inspect driver folder '$Path': $($_.Exception.Message)"
         return $false
     }
-    }
+}
     
-    function Get-AvailableDriveLetter {
+function Get-AvailableDriveLetter {
     $usedLetters = (Get-PSDrive -PSProvider FileSystem).Name | ForEach-Object { $_.ToUpperInvariant() }
     for ($ascii = [int][char]'Z'; $ascii -ge [int][char]'A'; $ascii--) {
         $candidate = [char]$ascii
@@ -759,9 +785,9 @@ function Test-DriverFolderHasInstallableContent {
         }
     }
     return $null
-    }
+}
     
-    function New-DriverSubstMapping {
+function New-DriverSubstMapping {
     [CmdletBinding()]
     param(
         [Parameter(Mandatory = $true)]
@@ -784,9 +810,9 @@ function Test-DriverFolderHasInstallableContent {
         DriveName   = $driveName
         DrivePath   = $mappedPath
     }
-    }
+}
     
-    function Remove-DriverSubstMapping {
+function Remove-DriverSubstMapping {
     [CmdletBinding()]
     param(
         [Parameter(Mandatory = $true)]
@@ -802,9 +828,9 @@ function Test-DriverFolderHasInstallableContent {
     catch {
         WriteLog "Failed to remove SUBST drive $($driveName): $_"
     }
-    }
+}
         
-    #Get USB Drive and create log file
+#Get USB Drive and create log file
 $LogFileName = 'ScriptLog.txt'
 $USBDrive = Get-USBDrive
 New-item -Path $USBDrive -Name $LogFileName -ItemType "file" -Force | Out-Null
@@ -1577,65 +1603,182 @@ if ($null -ne $DriverSourcePath) {
         Write-Host "Installing drivers from WIM: $DriverSourcePath"
         $TempDriverDir = "W:\TempDrivers"
         try {
+            # Create working folder for WIM-based drivers
             WriteLog "Creating temporary directory for drivers at $TempDriverDir"
             New-Item -Path $TempDriverDir -ItemType Directory -Force | Out-Null
             
+            # Mount the driver WIM read-only so DISM can recurse the extracted INF tree
             WriteLog "Mounting WIM contents to $TempDriverDir"
             Write-Host "Mounting WIM contents to $TempDriverDir"
             # For some reason can't use /mount-image with invoke-process, so using dism.exe directly
             dism.exe /Mount-Image /ImageFile:$DriverSourcePath /Index:1 /MountDir:$TempDriverDir /ReadOnly /optimize
+            $mountExitCode = $LASTEXITCODE
+            if ($mountExitCode -ne 0) {
+                throw "DISM WIM mount failed. LastExitCode = $mountExitCode."
+            }
             WriteLog "WIM mount successful."
 
+            # Inject drivers into the offline Windows image; failures here should not stop deployment
             WriteLog "Injecting drivers from $TempDriverDir"
             Write-Host "Injecting drivers from $TempDriverDir"
             Write-Host "This may take a while, please be patient."
-            Invoke-Process dism.exe "/image:W:\ /Add-Driver /Driver:""$TempDriverDir"" /Recurse"
-            WriteLog "Driver injection from WIM succeeded."
-            Write-Host "Driver injection from WIM succeeded."
+            $driverInjectExitCode = Invoke-Process -FilePath dism.exe -ArgumentList "/image:W:\ /Add-Driver /Driver:""$TempDriverDir"" /Recurse" -IgnoreExitCode -PassThruExitCode
+            if ($driverInjectExitCode -ne 0) {
+                $warningMessage = "Warning: One or more drivers failed to inject from WIM. ExitCode = $driverInjectExitCode. Continuing deployment."
+                WriteLog $warningMessage
+                Write-Host $warningMessage -ForegroundColor Yellow
 
+                # Copy setupapi.offline.log to the USB drive when driver injection fails
+
+                $setupApiLogPath = 'W:\Windows\INF\setupapi.offline.log'
+                if (Test-Path -Path $setupApiLogPath) {
+                    try {
+                        Invoke-Process xcopy.exe """$setupApiLogPath"" ""$USBDrive"" /Y"
                     }
                     catch {
-            WriteLog "An error occurred during WIM driver installation: $_"
-            # Copy DISM log to USBDrive for debugging
-            invoke-process xcopy.exe "X:\Windows\logs\dism\dism.log $USBDrive /Y"
-            throw $_
+                        WriteLog "Warning: Failed to copy setupapi.offline.log to $USBDrive. "
+                    }
+                }
+                else {
+                    WriteLog "Warning: setupapi.offline.log not found at $setupApiLogPath"
+                }
+            }
+            else {
+                WriteLog "Driver injection from WIM succeeded."
+                Write-Host "Driver injection from WIM succeeded."
+            }
+        }
+        catch {
+            $warningMessage = "Warning: An error occurred during WIM driver installation. Continuing deployment."
+            WriteLog $warningMessage
+            Write-Host $warningMessage -ForegroundColor Yellow
+
+            # Copy troubleshooting logs to the USB drive when driver installation fails
+            try {
+                Invoke-Process cmd.exe "/c copy /Y ""X:\Windows\logs\dism\dism.log"" ""$($USBDrive)dism_driverinject.log"""
+            }
+            catch {
+                WriteLog "Warning: Failed to copy dism.log to $USBDrive."
+            }
+
+            $setupApiLogPath = 'W:\Windows\INF\setupapi.offline.log'
+            if (Test-Path -Path $setupApiLogPath) {
+                try {
+                    Invoke-Process xcopy.exe """$setupApiLogPath"" ""$USBDrive"" /Y"
+                }
+                catch {
+                    WriteLog "Warning: Failed to copy setupapi.offline.log to $USBDrive."
+                }
+            }
+            else {
+                WriteLog "Warning: setupapi.offline.log not found at $setupApiLogPath"
+            }
         }
         finally {
             if (Test-Path -Path $TempDriverDir) {
+                # Always attempt to unmount and clean up; unmount failures should not stop deployment
                 WriteLog "Unmounting WIM from $TempDriverDir"
                 Write-Host "Unmounting WIM from $TempDriverDir"
+                try {
                     Invoke-Process dism.exe "/Unmount-Image /MountDir:""$TempDriverDir"" /Discard"
                     WriteLog "Unmount successful."
                     Write-Host "Unmount successful."
+                }
+                catch {
+                    $warningMessage = "Warning: Failed to unmount WIM from $TempDriverDir. Continuing cleanup."
+                    WriteLog $warningMessage
+                    Write-Host $warningMessage -ForegroundColor Yellow
+                }
+
                 WriteLog "Cleaning up temporary driver directory: $TempDriverDir"
                 Write-Host "Cleaning up temporary driver directory: $TempDriverDir"
+                try {
                     Remove-Item -Path $TempDriverDir -Recurse -Force
                     WriteLog "Cleanup successful."
                     Write-Host "Cleanup successful."
                 }
+                catch {
+                    $warningMessage = "Warning: Failed to clean up temporary driver directory: $TempDriverDir."
+                    WriteLog $warningMessage
+                    Write-Host $warningMessage -ForegroundColor Yellow
+                }
+            }
         }
     }
     elseif ($DriverSourceType -eq 'Folder') {
         $substMapping = $null
         try {
+            # Use SUBST to shorten long paths for DISM /Add-Driver
             $substMapping = New-DriverSubstMapping -SourcePath $DriverSourcePath
             $shortDriverPath = $substMapping.DrivePath
             WriteLog "Injecting drivers from folder via SUBST. Source: $DriverSourcePath, Mapped: $($substMapping.DriveName)"
             Write-Host "Injecting drivers from folder: $shortDriverPath"
             Write-Host "This may take a while, please be patient."
-            Invoke-Process dism.exe "/image:W:\ /Add-Driver /Driver:$shortDriverPath /Recurse"
+
+            # Inject drivers into the offline Windows image; failures here should not stop deployment
+            $driverInjectExitCode = Invoke-Process -FilePath dism.exe -ArgumentList "/image:W:\ /Add-Driver /Driver:$shortDriverPath /Recurse" -IgnoreExitCode -PassThruExitCode
+            if ($driverInjectExitCode -ne 0) {
+                $warningMessage = "Warning: One or more drivers failed to inject from folder. ExitCode = $driverInjectExitCode. Continuing deployment."
+                WriteLog $warningMessage
+                Write-Host $warningMessage -ForegroundColor Yellow
+
+                # Copy setupapi.offline.log to the USB drive when driver injection fails
+                $setupApiLogPath = 'W:\Windows\INF\setupapi.offline.log'
+                if (Test-Path -Path $setupApiLogPath) {
+                    try {
+                        Invoke-Process xcopy.exe """$setupApiLogPath"" ""$USBDrive"" /Y"
+                    }
+                    catch {
+                        WriteLog "Warning: Failed to copy setupapi.offline.log to $USBDrive. "
+                    }
+                }
+                else {
+                    WriteLog "Warning: setupapi.offline.log not found at $setupApiLogPath"
+                }
+            }
+            else {
                 WriteLog "Driver injection from folder succeeded."
                 Write-Host "Driver injection from folder succeeded."
             }
+        }
         catch {
-            WriteLog "An error occurred during folder driver installation: $_"
+            $warningMessage = "Warning: An error occurred during folder driver installation. Continuing deployment."
+            WriteLog $warningMessage
+            Write-Host $warningMessage -ForegroundColor Yellow
+
+            # Copy troubleshooting logs to the USB drive when driver installation fails
+            try {
                 Invoke-Process xcopy.exe "X:\Windows\logs\dism\dism.log $USBDrive /Y"
-            throw $_
+            }
+            catch {
+                WriteLog "Warning: Failed to copy dism.log to $USBDrive."
+            }
+
+            $setupApiLogPath = 'W:\Windows\INF\setupapi.offline.log'
+            if (Test-Path -Path $setupApiLogPath) {
+                try {
+                    Invoke-Process xcopy.exe """$setupApiLogPath"" ""$USBDrive"" /Y"
+                }
+                catch {
+                    WriteLog "Warning: Failed to copy setupapi.offline.log to $USBDrive."
+                }
+            }
+            else {
+                WriteLog "Warning: setupapi.offline.log not found at $setupApiLogPath"
+            }
         }
         finally {
+            # Always attempt to remove SUBST mapping; failures here should not stop deployment
             if ($null -ne $substMapping) {
+                try {
                     Remove-DriverSubstMapping -DriveLetter $substMapping.DriveLetter
                 }
+                catch {
+                    $warningMessage = "Warning: Failed to remove SUBST mapping $($substMapping.DriveLetter). Continuing deployment."
+                    WriteLog $warningMessage
+                    Write-Host $warningMessage -ForegroundColor Yellow
+                }
+            }
         }
     }
 }