fix(tanstackstart-react): Externalize sentry dependencies in nitro build

dev-packages/e2e-tests/test-applications/tanstackstart-react/package.json

@@ -16,6 +16,7 @@
     "@sentry/tanstackstart-react": "latest || *",
     "@tanstack/react-start": "^1.136.0",
     "@tanstack/react-router": "^1.136.0",
+    "nitro": "latest",
     "react": "^19.2.0",
     "react-dom": "^19.2.0"
   },
@@ -29,7 +30,6 @@
     "typescript": "^5.9.0",
     "vite": "7.2.0",
     "vite-tsconfig-paths": "^5.1.4",
-    "nitro": "^3.0.0",
     "@playwright/test": "~1.56.0",
     "@sentry-internal/test-utils": "link:../../../test-utils"
   },

packages/tanstackstart-react/src/vite/nitro.ts

@@ -0,0 +1,23 @@
+import type { Plugin, UserConfig } from 'vite';
+
+/**
+ * Creates a Vite plugin that configures Nitro to treat `@sentry/*` packages as external dependencies.
+ *
+ * We need this to prevent build issues we were seeing with recent versions of Nitro.
+ */
+export function makeNitroSentryExternalPlugin(): Plugin {
+  return {
+    name: 'sentry-tanstack-start-nitro-external',
+    enforce: 'pre',
+    config() {
+      // The `nitro` property is not part of Vite's UserConfig type but is read by the Nitro Vite plugin
+      return {
+        nitro: {
+          rollupConfig: {
+            external: [/^@sentry\//],
+          },
+        },
+      } as UserConfig;
+    },
+  };
+}

packages/tanstackstart-react/src/vite/sentryTanstackStart.ts

@@ -1,6 +1,7 @@
 import type { BuildTimeOptionsBase } from '@sentry/core';
 import type { Plugin } from 'vite';
 import { makeAutoInstrumentMiddlewarePlugin } from './autoInstrumentMiddleware';
+import { makeNitroSentryExternalPlugin } from './nitro';
 import { makeAddSentryVitePlugin, makeEnableSourceMapsVitePlugin } from './sourceMaps';
 
 /**
@@ -51,7 +52,7 @@ export function sentryTanstackStart(options: SentryTanstackStartOptions = {}): P
     return [];
   }
 
-  const plugins: Plugin[] = [...makeAddSentryVitePlugin(options)];
+  const plugins: Plugin[] = [makeNitroSentryExternalPlugin(), ...makeAddSentryVitePlugin(options)];
 
   // middleware auto-instrumentation
   if (options.autoInstrumentMiddleware !== false) {

packages/tanstackstart-react/test/vite/nitro.test.ts

@@ -0,0 +1,17 @@
+import { describe, expect, it } from 'vitest';
+import { makeNitroSentryExternalPlugin } from '../../src/vite/nitro';
+
+describe('makeNitroSentryExternalPlugin()', () => {
+  it('returns nitro config to externalize @sentry/* packages', () => {
+    const plugin = makeNitroSentryExternalPlugin();
+    const config = (plugin.config as () => unknown)();
+
+    expect(config).toEqual({
+      nitro: {
+        rollupConfig: {
+          external: [/^@sentry\//],
+        },
+      },
+    });
+  });
+});

packages/tanstackstart-react/test/vite/sentryTanstackStart.test.ts

@@ -28,6 +28,11 @@ const mockMiddlewarePlugin: Plugin = {
   transform: vi.fn(),
 };
 
+const expectedNitroExternalPlugin = expect.objectContaining({
+  name: 'sentry-tanstack-start-nitro-external',
+  config: expect.any(Function),
+});
+
 vi.mock('../../src/vite/sourceMaps', () => ({
   makeAddSentryVitePlugin: vi.fn(() => [mockSourceMapsConfigPlugin, mockSentryVitePlugin]),
   makeEnableSourceMapsVitePlugin: vi.fn(() => [mockEnableSourceMapsPlugin]),
@@ -51,7 +56,12 @@ describe('sentryTanstackStart()', () => {
     it('returns source maps plugins in production mode', () => {
       const plugins = sentryTanstackStart({ autoInstrumentMiddleware: false });
 
-      expect(plugins).toEqual([mockSourceMapsConfigPlugin, mockSentryVitePlugin, mockEnableSourceMapsPlugin]);
+      expect(plugins).toEqual([
+        expectedNitroExternalPlugin,
+        mockSourceMapsConfigPlugin,
+        mockSentryVitePlugin,
+        mockEnableSourceMapsPlugin,
+      ]);
     });
 
     it('returns no plugins in development mode', () => {
@@ -68,7 +78,7 @@ describe('sentryTanstackStart()', () => {
         sourcemaps: { disable: true },
       });
 
-      expect(plugins).toEqual([mockSourceMapsConfigPlugin, mockSentryVitePlugin]);
+      expect(plugins).toEqual([expectedNitroExternalPlugin, mockSourceMapsConfigPlugin, mockSentryVitePlugin]);
     });
 
     it('returns Sentry Vite plugins but not enable source maps plugin when sourcemaps.disable is "disable-upload"', () => {
@@ -77,7 +87,7 @@ describe('sentryTanstackStart()', () => {
         sourcemaps: { disable: 'disable-upload' },
       });
 
-      expect(plugins).toEqual([mockSourceMapsConfigPlugin, mockSentryVitePlugin]);
+      expect(plugins).toEqual([expectedNitroExternalPlugin, mockSourceMapsConfigPlugin, mockSentryVitePlugin]);
     });
 
     it('returns Sentry Vite plugins and enable source maps plugin when sourcemaps.disable is false', () => {
@@ -86,15 +96,25 @@ describe('sentryTanstackStart()', () => {
         sourcemaps: { disable: false },
       });
 
-      expect(plugins).toEqual([mockSourceMapsConfigPlugin, mockSentryVitePlugin, mockEnableSourceMapsPlugin]);
+      expect(plugins).toEqual([
+        expectedNitroExternalPlugin,
+        mockSourceMapsConfigPlugin,
+        mockSentryVitePlugin,
+        mockEnableSourceMapsPlugin,
+      ]);
     });
   });
 
   describe('middleware auto-instrumentation', () => {
     it('includes middleware plugin by default', () => {
       const plugins = sentryTanstackStart({ sourcemaps: { disable: true } });
 
-      expect(plugins).toEqual([mockSourceMapsConfigPlugin, mockSentryVitePlugin, mockMiddlewarePlugin]);
+      expect(plugins).toEqual([
+        expectedNitroExternalPlugin,
+        mockSourceMapsConfigPlugin,
+        mockSentryVitePlugin,
+        mockMiddlewarePlugin,
+      ]);
     });
 
     it('includes middleware plugin when autoInstrumentMiddleware is true', () => {
@@ -103,7 +123,12 @@ describe('sentryTanstackStart()', () => {
         sourcemaps: { disable: true },
       });
 
-      expect(plugins).toEqual([mockSourceMapsConfigPlugin, mockSentryVitePlugin, mockMiddlewarePlugin]);
+      expect(plugins).toEqual([
+        expectedNitroExternalPlugin,
+        mockSourceMapsConfigPlugin,
+        mockSentryVitePlugin,
+        mockMiddlewarePlugin,
+      ]);
     });
 
     it('does not include middleware plugin when autoInstrumentMiddleware is false', () => {
@@ -112,7 +137,7 @@ describe('sentryTanstackStart()', () => {
         sourcemaps: { disable: true },
       });
 
-      expect(plugins).toEqual([mockSourceMapsConfigPlugin, mockSentryVitePlugin]);
+      expect(plugins).toEqual([expectedNitroExternalPlugin, mockSourceMapsConfigPlugin, mockSentryVitePlugin]);
     });
 
     it('passes correct options to makeAutoInstrumentMiddlewarePlugin', () => {