[worker] Keep legacy cache failures non-fatal

packages/worker/src/CacheManager.ts

@@ -12,6 +12,8 @@ import nullthrows from 'nullthrows';
 import path from 'path';
 import * as tar from 'tar';
 
+import Sentry from './sentry';
+
 export class GCSCacheManager implements CacheManager {
   private skipCacheUpdate = false;
 
@@ -39,14 +41,8 @@ export class GCSCacheManager implements CacheManager {
         },
         paths
       );
-    } catch (err: any) {
-      ctx.logger.error({ err }, 'Failed to create cache archive');
-      return;
-    }
-
-    const archiveSize = (await fs.stat(archivePath)).size;
+      const archiveSize = (await fs.stat(archivePath)).size;
 
-    try {
       await uploadCacheAsync({
         logger: ctx.logger,
         jobId: nullthrows(ctx.env.EAS_BUILD_ID, 'EAS_BUILD_ID is not set'),
@@ -63,7 +59,8 @@ export class GCSCacheManager implements CacheManager {
         force: ctx.job.cache?.clear,
       });
     } catch (err: any) {
-      ctx.logger.error({ err });
+      ctx.logger.error({ err }, 'Failed to save cache');
+      Sentry.capture('Failed to save legacy build cache', err, { level: 'warning' });
     }
   }
 
@@ -99,7 +96,8 @@ export class GCSCacheManager implements CacheManager {
       if (err?.response?.status === 404) {
         ctx.logger.info('No cache found for this key');
       } else {
-        ctx.logger.error({ err });
+        ctx.logger.error({ err }, 'Failed to download cache');
+        Sentry.capture('Failed to download legacy build cache', err, { level: 'warning' });
         this.skipCacheUpdate = true; // if restore failed we don't want to update cache with new values
       }
       return;
@@ -123,6 +121,7 @@ export class GCSCacheManager implements CacheManager {
       );
     } catch (err: any) {
       ctx.logger.error({ err }, 'Failed to extract cache archive');
+      Sentry.capture('Failed to extract legacy build cache', err, { level: 'warning' });
       this.skipCacheUpdate = true;
     }
   }

packages/worker/src/__unit__/CacheManager.test.ts

@@ -4,6 +4,8 @@ import fs from 'fs-extra';
 import os from 'os';
 import path from 'path';
 
+import Sentry from '../sentry';
+
 // These tests use real fs and directories in os.tmpdir().
 // Something about tar v7 makes mocking fs with memfs problematic.
 // Mocking all variants of fs/node:fs/fs/promises does not help.
@@ -31,6 +33,7 @@ describe(GCSCacheManager, () => {
     await fs.rm(outsideDir, { recursive: true, force: true });
     jest.mocked(uploadCacheAsync).mockReset();
     jest.mocked(downloadCacheAsync).mockReset();
+    jest.mocked(Sentry.capture).mockReset();
   });
 
   function createMockCtx(cacheConfig: Partial<Cache>) {
@@ -250,6 +253,7 @@ describe(GCSCacheManager, () => {
     await manager.saveCache(mockCtx);
 
     expect(mockCtx.logger.info).toHaveBeenCalledWith('No cache found for this key');
+    expect(Sentry.capture).not.toHaveBeenCalled();
     const requestedKey = jest.mocked(downloadCacheAsync).mock.calls[0][0].key;
     expect(uploadCacheAsync).toHaveBeenCalledWith(
       expect.objectContaining({
@@ -269,6 +273,52 @@ describe(GCSCacheManager, () => {
     await manager.saveCache(mockCtx);
 
     expect(uploadCacheAsync).not.toHaveBeenCalled();
+    expect(Sentry.capture).toHaveBeenCalledWith(
+      'Failed to download legacy build cache',
+      expect.any(Error),
+      { level: 'warning' }
+    );
+  });
+
+  test('does not fail the build when saving cache fails', async () => {
+    const manager = new GCSCacheManager();
+    const mockCtx = createMockCtx({ paths: ['index.ts'] });
+    await fs.outputFile(path.join(tmpDir, 'build', 'index.ts'), 'index.ts');
+    const statSpy = jest.spyOn(fs, 'stat').mockImplementationOnce(() => {
+      throw new Error('stat failed');
+    });
+
+    await expect(manager.saveCache(mockCtx)).resolves.toBeUndefined();
+
+    expect(uploadCacheAsync).not.toHaveBeenCalled();
+    expect(Sentry.capture).toHaveBeenCalledWith(
+      'Failed to save legacy build cache',
+      expect.any(Error),
+      { level: 'warning' }
+    );
+    statSpy.mockRestore();
+  });
+
+  test('does not save when cache extraction fails', async () => {
+    const manager = new GCSCacheManager();
+    const mockCtx = createMockCtx({ paths: ['index.ts'] });
+    const downloadDir = await fs.mkdtemp(path.join(os.tmpdir(), 'eas-cache-download-'));
+    const archivePath = path.join(downloadDir, 'cache.tar.gz');
+    await fs.writeFile(archivePath, 'invalid archive');
+    jest.mocked(downloadCacheAsync).mockResolvedValue({
+      archivePath,
+      matchedKey: 'matched-cache-key',
+    });
+
+    await manager.restoreCache(mockCtx);
+    await manager.saveCache(mockCtx);
+
+    expect(uploadCacheAsync).not.toHaveBeenCalled();
+    expect(Sentry.capture).toHaveBeenCalledWith(
+      'Failed to extract legacy build cache',
+      expect.any(Error),
+      { level: 'warning' }
+    );
   });
 
   test('cache key is stable when clear changes and job cache is not mutated', async () => {