fix(coding-agent,ai): fallback to /proc/self/environ in Bun sandbox (#3801)

Bun compiled binaries have an empty process.env when running inside
sandbox environments (e.g. nono on Linux/macOS). This broke API key
detection and model discovery because all process.env.* lookups returned
undefined.

- Add restoreSandboxEnv() helper that reads /proc/self/environ when Bun
  is detected and process.env is empty, populating process.env before
  any other code runs (coding-agent/src/bun/cli.ts entry point)
- Add getProcEnv() fallback in env-api-keys.ts for direct @mariozechner/pi-ai
  consumers that may not go through the coding-agent entry point
- Add unit tests for restoreSandboxEnv

packages/ai/src/env-api-keys.ts

@@ -25,6 +25,39 @@ if (typeof process !== "undefined" && (process.versions?.node || process.version
 
 import type { KnownProvider } from "./types.js";
 
+let _procEnvCache: Map<string, string> | null = null;
+
+/**
+ * Fallback for https://github.com/oven-sh/bun/issues/27802
+ * Bun compiled binaries have an empty `process.env` inside sandbox
+ * environments on Linux. We can recover the env from `/proc/self/environ`.
+ */
+function getProcEnv(key: string): string | undefined {
+	if (!process.versions?.bun) return undefined;
+	if (typeof process === "undefined") return undefined;
+
+	// If process.env already has entries, the bug is not triggered.
+	if (Object.keys(process.env).length > 0) return undefined;
+
+	if (_procEnvCache === null) {
+		_procEnvCache = new Map();
+		try {
+			const { readFileSync } = require("node:fs") as typeof import("node:fs");
+			const data = readFileSync("/proc/self/environ", "utf-8");
+			for (const entry of data.split("\0")) {
+				const idx = entry.indexOf("=");
+				if (idx > 0) {
+					_procEnvCache.set(entry.slice(0, idx), entry.slice(idx + 1));
+				}
+			}
+		} catch {
+			// /proc/self/environ may not be readable.
+		}
+	}
+
+	return _procEnvCache.get(key);
+}
+
 let cachedVertexAdcCredentialsExists: boolean | null = null;
 
 function hasVertexAdcCredentials(): boolean {
@@ -42,7 +75,7 @@ function hasVertexAdcCredentials(): boolean {
 		}
 
 		// Check GOOGLE_APPLICATION_CREDENTIALS env var first (standard way)
-		const gacPath = process.env.GOOGLE_APPLICATION_CREDENTIALS;
+		const gacPath = process.env.GOOGLE_APPLICATION_CREDENTIALS || getProcEnv("GOOGLE_APPLICATION_CREDENTIALS");
 		if (gacPath) {
 			cachedVertexAdcCredentialsExists = _existsSync(gacPath);
 		} else {
@@ -104,7 +137,7 @@ export function findEnvKeys(provider: string): string[] | undefined {
 	const envVars = getApiKeyEnvVars(provider);
 	if (!envVars) return undefined;
 
-	const found = envVars.filter((envVar) => !!process.env[envVar]);
+	const found = envVars.filter((envVar) => !!process.env[envVar] || !!getProcEnv(envVar));
 	return found.length > 0 ? found : undefined;
 }
 
@@ -117,14 +150,21 @@ export function getEnvApiKey(provider: KnownProvider): string | undefined;
 export function getEnvApiKey(provider: string): string | undefined;
 export function getEnvApiKey(provider: string): string | undefined {
 	const envKeys = findEnvKeys(provider);
-	if (envKeys?.[0]) return process.env[envKeys[0]];
+	if (envKeys?.[0]) {
+		return process.env[envKeys[0]] || getProcEnv(envKeys[0]);
+	}
 
 	// Vertex AI supports either an explicit API key or Application Default Credentials.
 	// Auth is configured via `gcloud auth application-default login`.
 	if (provider === "google-vertex") {
 		const hasCredentials = hasVertexAdcCredentials();
-		const hasProject = !!(process.env.GOOGLE_CLOUD_PROJECT || process.env.GCLOUD_PROJECT);
-		const hasLocation = !!process.env.GOOGLE_CLOUD_LOCATION;
+		const hasProject = !!(
+			process.env.GOOGLE_CLOUD_PROJECT ||
+			process.env.GCLOUD_PROJECT ||
+			getProcEnv("GOOGLE_CLOUD_PROJECT") ||
+			getProcEnv("GCLOUD_PROJECT")
+		);
+		const hasLocation = !!(process.env.GOOGLE_CLOUD_LOCATION || getProcEnv("GOOGLE_CLOUD_LOCATION"));
 
 		if (hasCredentials && hasProject && hasLocation) {
 			return "<authenticated>";
@@ -145,7 +185,13 @@ export function getEnvApiKey(provider: string): string | undefined {
 			process.env.AWS_BEARER_TOKEN_BEDROCK ||
 			process.env.AWS_CONTAINER_CREDENTIALS_RELATIVE_URI ||
 			process.env.AWS_CONTAINER_CREDENTIALS_FULL_URI ||
-			process.env.AWS_WEB_IDENTITY_TOKEN_FILE
+			process.env.AWS_WEB_IDENTITY_TOKEN_FILE ||
+			getProcEnv("AWS_PROFILE") ||
+			(getProcEnv("AWS_ACCESS_KEY_ID") && getProcEnv("AWS_SECRET_ACCESS_KEY")) ||
+			getProcEnv("AWS_BEARER_TOKEN_BEDROCK") ||
+			getProcEnv("AWS_CONTAINER_CREDENTIALS_RELATIVE_URI") ||
+			getProcEnv("AWS_CONTAINER_CREDENTIALS_FULL_URI") ||
+			getProcEnv("AWS_WEB_IDENTITY_TOKEN_FILE")
 		) {
 			return "<authenticated>";
 		}

packages/coding-agent/src/bun/cli.ts

@@ -4,5 +4,9 @@ import { APP_NAME } from "../config.js";
 process.title = APP_NAME;
 process.emitWarning = (() => {}) as typeof process.emitWarning;
 
+import { restoreSandboxEnv } from "./restore-sandbox-env.js";
+
+restoreSandboxEnv();
+
 await import("./register-bedrock.js");
 await import("../cli.js");

packages/coding-agent/src/bun/restore-sandbox-env.ts

@@ -0,0 +1,32 @@
+/**
+ * Workaround for https://github.com/oven-sh/bun/issues/27802
+ *
+ * Bun compiled binaries have an empty `process.env` when running inside
+ * sandbox environments (e.g. nono on Linux/macOS). On Linux we can recover
+ * the environment from `/proc/self/environ`.
+ */
+
+import { readFileSync } from "node:fs";
+
+/**
+ * Restore environment variables from `/proc/self/environ` when running
+ * inside a sandbox where Bun's `process.env` is empty.
+ */
+export function restoreSandboxEnv(): void {
+	if (!process.versions?.bun) return;
+
+	// If process.env already has entries, nothing to fix.
+	if (Object.keys(process.env).length > 0) return;
+
+	try {
+		const data = readFileSync("/proc/self/environ", "utf-8");
+		for (const entry of data.split("\0")) {
+			const idx = entry.indexOf("=");
+			if (idx > 0) {
+				process.env[entry.slice(0, idx)] = entry.slice(idx + 1);
+			}
+		}
+	} catch {
+		// /proc/self/environ may not be readable; ignore.
+	}
+}

packages/coding-agent/test/restore-sandbox-env.test.ts

@@ -0,0 +1,77 @@
+import { describe, expect, it, vi } from "vitest";
+
+const readFileSync = vi.fn();
+
+vi.mock("node:fs", () => ({
+	readFileSync,
+}));
+
+const { restoreSandboxEnv } = await import("../src/bun/restore-sandbox-env.js");
+
+describe("restoreSandboxEnv", () => {
+	it("does nothing when not running under bun", () => {
+		const originalVersions = Object.getOwnPropertyDescriptor(process, "versions");
+		Object.defineProperty(process, "versions", {
+			value: { node: "20.0.0" },
+		});
+		const envBefore = { ...process.env };
+
+		restoreSandboxEnv();
+
+		expect(process.env).toEqual(envBefore);
+
+		if (originalVersions) {
+			Object.defineProperty(process, "versions", originalVersions);
+		}
+	});
+
+	it("does nothing when process.env already has entries", () => {
+		const originalVersions = Object.getOwnPropertyDescriptor(process, "versions");
+		Object.defineProperty(process, "versions", {
+			value: { bun: "1.2.0", node: "20.0.0" },
+		});
+		process.env.RESTORE_SANDBOX_ENV_TEST = "1";
+		const envBefore = { ...process.env };
+
+		restoreSandboxEnv();
+
+		expect(process.env).toEqual(envBefore);
+		delete process.env.RESTORE_SANDBOX_ENV_TEST;
+
+		if (originalVersions) {
+			Object.defineProperty(process, "versions", originalVersions);
+		}
+	});
+
+	it("restores environment from /proc/self/environ when bun env is empty", () => {
+		const originalVersions = Object.getOwnPropertyDescriptor(process, "versions");
+		Object.defineProperty(process, "versions", {
+			value: { bun: "1.2.0", node: "20.0.0" },
+		});
+
+		// Clear env to simulate the bun sandbox bug.
+		const envBackup = { ...process.env };
+		for (const key of Object.keys(process.env)) {
+			delete process.env[key];
+		}
+
+		readFileSync.mockReturnValue("FOO=bar\0BAZ=qux\0");
+
+		restoreSandboxEnv();
+
+		expect(readFileSync).toHaveBeenCalledWith("/proc/self/environ", "utf-8");
+		expect(process.env.FOO).toBe("bar");
+		expect(process.env.BAZ).toBe("qux");
+
+		// Restore.
+		for (const key of Object.keys(process.env)) {
+			delete process.env[key];
+		}
+		Object.assign(process.env, envBackup);
+
+		if (originalVersions) {
+			Object.defineProperty(process, "versions", originalVersions);
+		}
+		readFileSync.mockReset();
+	});
+});