Increase LibreOffice timeout to 120s, add graceful fallback to text-only email

app/api/appointments/route.ts

@@ -67,13 +67,16 @@ export async function POST(req: NextRequest) {
 
     // 3. Convert to PDF
     const pdfPath = await htmlToPdf(htmlPath);
+    const hasPdf = pdfPath && pdfPath.length > 0;
 
-    // 4. Upload PDF to PB record
-    const pdfBuf = readFileSync(pdfPath);
-    const pdfFile = new File([pdfBuf], "appointment-letter.pdf", { type: "application/pdf" });
-    await updateRecordMultipart("ysterbaard_director_appointments", record.id, {}, [{ field: "letter", file: pdfFile }]);
+    // 4. Upload PDF to PB record (only if conversion succeeded)
+    if (hasPdf) {
+      const pdfBuf = readFileSync(pdfPath);
+      const pdfFile = new File([pdfBuf], "appointment-letter.pdf", { type: "application/pdf" });
+      await updateRecordMultipart("ysterbaard_director_appointments", record.id, {}, [{ field: "letter", file: pdfFile }]);
+    }
 
-    // 5. Send email to director
+    // 5. Send email to director (with or without PDF)
     await sendAppointmentEmail({
       to: emailTo,
       directorName: fullName || "Director",
@@ -141,19 +144,22 @@ async function htmlToPdf(htmlPath: string): Promise<string> {
   const pdfPath = htmlPath.replace(".html", ".pdf");
   try {
     execSync(
-      "/Applications/LibreOffice.app/Contents/MacOS/soffice --headless --convert-to pdf --outdir /tmp/ " + JSON.stringify(htmlPath),
-      { timeout: 30 }
+      `"/Applications/LibreOffice.app/Contents/MacOS/soffice" --headless --convert-to pdf --outdir /tmp/ "${htmlPath}"`,
+      { timeout: 120 }
     );
   } catch {
-    // try soffice directly
-    execSync(
-      `soffice --headless --convert-to pdf --outdir /tmp/ "${htmlPath}"`,
-      { timeout: 30 }
-    );
+    try {
+      execSync(
+        `soffice --headless --convert-to pdf --outdir /tmp/ "${htmlPath}"`,
+        { timeout: 120 }
+      );
+    } catch {
+      // LibreOffice unavailable — return empty, email will be text-only
+      return "";
+    }
   }
   return pdfPath;
 }
-
 // ─── Email ───────────────────────────────────────────────────────────────
 
 async function sendAppointmentEmail(opts: {
@@ -163,7 +169,8 @@ async function sendAppointmentEmail(opts: {
   signUrl: string;
   pdfPath: string;
 }) {
-  const { to, directorName, companyName, signUrl } = opts;
+  const { to, directorName, companyName, signUrl, pdfPath } = opts;
+  const hasPdf = pdfPath && pdfPath.length > 0;
 
   const subject = `[${directorName}] Acceptance letter as director for ${companyName}`;
   const body = `Good day ${directorName}
@@ -177,10 +184,12 @@ ${signUrl}
 Regards`;
 
   const boundary = "----YSTERBAARD" + Date.now();
-  const pdfBuf = readFileSync(opts.pdfPath);
-  const pdfB64 = pdfBuf.toString("base64");
 
-  const eml = `To: ${to}\r
+  let eml: string;
+  if (hasPdf) {
+    const pdfBuf = readFileSync(pdfPath);
+    const pdfB64 = pdfBuf.toString("base64");
+    eml = `To: ${to}\r
 From: SJ@Dyfins.com\r
 Subject: ${subject}\r
 MIME-Version: 1.0\r
@@ -198,6 +207,16 @@ Content-Disposition: attachment; filename="appointment-letter.pdf"\r
 ${pdfB64}\r
 --${boundary}--\r
 `;
+  } else {
+    eml = `To: ${to}\r
+From: SJ@Dyfins.com\r
+Subject: ${subject}\r
+MIME-Version: 1.0\r
+Content-Type: text/plain; charset="utf-8"\r
+\r
+${body}\r
+`;
+  }
 
   const emlPath = `/tmp/appt-email-${Date.now()}.eml`;
   writeFileSync(emlPath, eml, "utf8");
@@ -206,6 +225,8 @@ ${pdfB64}\r
     execSync(`himalaya -a dyfins --backend smtp email send < "${emlPath}"`, { timeout: 30 });
   } finally {
     unlinkSync(emlPath);
-    try { unlinkSync(opts.pdfPath); } catch { /* ok */ }
+    if (pdfPath && pdfPath.length > 0) {
+      try { unlinkSync(pdfPath); } catch { /* ok */ }
+    }
   }
 }