fix(ui): split control ui runtime chunks

CHANGELOG.md

@@ -8,6 +8,7 @@ Docs: https://docs.openclaw.ai
 
 ### Fixes
 
+- Control UI: split large build-time runtime dependencies into stable chunks so Linux/Docker install and package builds stay below the app chunk warning threshold.
 - Scripts: run the optional Discord native opus installer through the shared pnpm launcher and Windows CI coverage so native Windows installs avoid shell-mode package-manager shims.
 - Agents/MCP: bound bundled MCP `tools/list` catalog discovery so hung MCP servers do not block session tool materialization. (#85063) Thanks @nxmxbbd.
 - Scripts: run generated-module formatting through the shared pnpm launcher and Windows CI coverage so native Windows generator checks avoid shell-mode package-manager shims.

ui/build/chunking.ts

@@ -0,0 +1,49 @@
+export function normalizeModuleId(id: string): string {
+  return id.replace(/\\/g, "/");
+}
+
+export function moduleIdIncludesPackage(id: string, packageName: string): boolean {
+  const normalized = normalizeModuleId(id);
+  return (
+    normalized.includes(`/node_modules/${packageName}/`) ||
+    normalized.includes(`/openclaw-pnpm-node-modules/${packageName}/`)
+  );
+}
+
+export function controlUiManualChunk(id: string): string | undefined {
+  if (
+    moduleIdIncludesPackage(id, "lit") ||
+    moduleIdIncludesPackage(id, "lit-html") ||
+    moduleIdIncludesPackage(id, "@lit/reactive-element")
+  ) {
+    return "lit-runtime";
+  }
+
+  if (
+    moduleIdIncludesPackage(id, "highlight.js") ||
+    moduleIdIncludesPackage(id, "markdown-it") ||
+    moduleIdIncludesPackage(id, "markdown-it-task-lists") ||
+    moduleIdIncludesPackage(id, "dompurify") ||
+    moduleIdIncludesPackage(id, "entities") ||
+    moduleIdIncludesPackage(id, "linkify-it") ||
+    moduleIdIncludesPackage(id, "mdurl") ||
+    moduleIdIncludesPackage(id, "punycode.js") ||
+    moduleIdIncludesPackage(id, "uc.micro")
+  ) {
+    return "markdown-runtime";
+  }
+
+  if (moduleIdIncludesPackage(id, "zod") || moduleIdIncludesPackage(id, "json5")) {
+    return "config-runtime";
+  }
+
+  if (
+    moduleIdIncludesPackage(id, "@noble/ed25519") ||
+    moduleIdIncludesPackage(id, "@noble/hashes") ||
+    moduleIdIncludesPackage(id, "ipaddr.js")
+  ) {
+    return "gateway-runtime";
+  }
+
+  return undefined;
+}

ui/src/ui/control-ui-chunking.test.ts

@@ -0,0 +1,35 @@
+import { describe, expect, it } from "vitest";
+import { controlUiManualChunk, normalizeModuleId } from "../../build/chunking.ts";
+
+describe("Control UI build chunking", () => {
+  it("groups stable runtime dependencies into bounded chunks", () => {
+    expect(controlUiManualChunk("/repo/ui/node_modules/lit/index.js")).toBe("lit-runtime");
+    expect(controlUiManualChunk("/repo/ui/node_modules/lit-html/directives/repeat.js")).toBe(
+      "lit-runtime",
+    );
+    expect(controlUiManualChunk("/repo/ui/node_modules/highlight.js/lib/core.js")).toBe(
+      "markdown-runtime",
+    );
+    expect(
+      controlUiManualChunk("/tmp/openclaw-pnpm-node-modules/dompurify/dist/purify.es.mjs"),
+    ).toBe("markdown-runtime");
+    expect(controlUiManualChunk("/tmp/openclaw-pnpm-node-modules/zod/v4/core/schemas.js")).toBe(
+      "config-runtime",
+    );
+    expect(controlUiManualChunk("/tmp/openclaw-pnpm-node-modules/json5/dist/index.js")).toBe(
+      "config-runtime",
+    );
+    expect(controlUiManualChunk("/tmp/openclaw-pnpm-node-modules/@noble/ed25519/index.js")).toBe(
+      "gateway-runtime",
+    );
+    expect(controlUiManualChunk("/repo/ui/src/ui/app-render.ts")).toBeUndefined();
+  });
+
+  it("normalizes Windows module paths before package matching", () => {
+    expect(normalizeModuleId(String.raw`C:\repo\ui\node_modules\highlight.js\lib\core.js`)).toBe(
+      "C:/repo/ui/node_modules/highlight.js/lib/core.js",
+    );
+    expect(controlUiManualChunk(String.raw`C:\repo\ui\node_modules\highlight.js\lib\core.js`))
+      .toBe("markdown-runtime");
+  });
+});

ui/vite.config.ts

@@ -3,6 +3,7 @@ import fs from "node:fs";
 import path from "node:path";
 import { fileURLToPath } from "node:url";
 import { defineConfig, type Plugin } from "vite";
+import { controlUiManualChunk } from "./build/chunking.ts";
 
 const here = path.dirname(fileURLToPath(import.meta.url));
 const repoRoot = path.resolve(here, "..");
@@ -98,7 +99,12 @@ export default defineConfig(() => {
       outDir,
       emptyOutDir: true,
       sourcemap: true,
-      // Keep CI/onboard logs clean; current control UI chunking is intentionally above 500 kB.
+      rollupOptions: {
+        output: {
+          manualChunks: controlUiManualChunk,
+        },
+      },
+      // Keep CI/onboard logs clean; the app chunk is split into stable runtime buckets above.
       chunkSizeWarningLimit: 1024,
     },
     server: {