fix(windows): bundle vulkan-1.dll to fix startup crash

.github/workflows/pr-preview-builds.yml

@@ -87,13 +87,50 @@ jobs:
         with:
           bun-version-file: "package.json"
 
+      # Install Vulkan SDK with runtime (vulkan-1.dll) for Windows builds
+      # Using jakoch/install-vulkan-sdk-action because it supports install_runtime option
+      # which provides vulkan-1.dll needed for users without GPU drivers
       - name: Install Vulkan SDK
         if: matrix.platform == 'windows-latest'
-        uses: humbletim/install-vulkan-sdk@v1.2
+        uses: jakoch/install-vulkan-sdk-action@v1
         with:
-          version: 1.4.309.0
+          vulkan_version: 1.4.309.0
+          install_runtime: true
           cache: true
 
+      # Bundle Vulkan DLL for Windows users without Vulkan runtime
+      # The DLL is placed in src-tauri where tauri.windows.conf.json resources config picks it up
+      # This fixes the "vulkan-1.dll not found" error on Windows systems without GPU/Vulkan drivers
+      - name: Bundle Vulkan DLL (Windows)
+        if: matrix.platform == 'windows-latest'
+        shell: pwsh
+        run: |
+          Write-Host "VULKAN_SDK: $env:VULKAN_SDK"
+
+          # With jakoch/install-vulkan-sdk-action and install_runtime: true,
+          # vulkan-1.dll is located in the runtime/x64 subdirectory
+          $vulkanDll = "$env:VULKAN_SDK\runtime\x64\vulkan-1.dll"
+
+          if (-not (Test-Path $vulkanDll)) {
+            Write-Host "ERROR: vulkan-1.dll not found at expected path: $vulkanDll"
+            Write-Host "Searching for vulkan-1.dll in SDK directory..."
+            $found = Get-ChildItem -Path $env:VULKAN_SDK -Recurse -Filter "vulkan-1.dll" -ErrorAction SilentlyContinue
+            if ($found) {
+              Write-Host "Found vulkan-1.dll at:"
+              $found | ForEach-Object { Write-Host "  $($_.FullName)" }
+            } else {
+              Write-Host "vulkan-1.dll not found anywhere in SDK"
+              Write-Host "Directory contents:"
+              Get-ChildItem -Path $env:VULKAN_SDK -Recurse -Depth 2 | ForEach-Object { Write-Host $_.FullName }
+            }
+            exit 1
+          }
+
+          Write-Host "Found vulkan-1.dll at: $vulkanDll"
+          $destination = "apps/whispering/src-tauri/vulkan-1.dll"
+          Copy-Item $vulkanDll $destination
+          Write-Host "Vulkan DLL bundled successfully to: $destination"
+
       - name: setup node
         uses: actions/setup-node@v4
         with:

.github/workflows/publish-tauri-releases.yml

@@ -117,14 +117,50 @@ jobs:
         with:
           bun-version-file: "package.json"
 
-      # Windows Vulkan SDK installation
+      # Install Vulkan SDK with runtime (vulkan-1.dll) for Windows builds
+      # Using jakoch/install-vulkan-sdk-action because it supports install_runtime option
+      # which provides vulkan-1.dll needed for users without GPU drivers
       - name: Install Vulkan SDK
         if: matrix.platform == 'windows-latest'
-        uses: humbletim/install-vulkan-sdk@v1.2
+        uses: jakoch/install-vulkan-sdk-action@v1
         with:
-          version: 1.4.309.0
+          vulkan_version: 1.4.309.0
+          install_runtime: true
           cache: true
 
+      # Bundle Vulkan DLL for Windows users without Vulkan runtime
+      # The DLL is placed in src-tauri where tauri.windows.conf.json resources config picks it up
+      # This fixes the "vulkan-1.dll not found" error on Windows systems without GPU/Vulkan drivers
+      - name: Bundle Vulkan DLL (Windows)
+        if: matrix.platform == 'windows-latest'
+        shell: pwsh
+        run: |
+          Write-Host "VULKAN_SDK: $env:VULKAN_SDK"
+
+          # With jakoch/install-vulkan-sdk-action and install_runtime: true,
+          # vulkan-1.dll is located in the runtime/x64 subdirectory
+          $vulkanDll = "$env:VULKAN_SDK\runtime\x64\vulkan-1.dll"
+
+          if (-not (Test-Path $vulkanDll)) {
+            Write-Host "ERROR: vulkan-1.dll not found at expected path: $vulkanDll"
+            Write-Host "Searching for vulkan-1.dll in SDK directory..."
+            $found = Get-ChildItem -Path $env:VULKAN_SDK -Recurse -Filter "vulkan-1.dll" -ErrorAction SilentlyContinue
+            if ($found) {
+              Write-Host "Found vulkan-1.dll at:"
+              $found | ForEach-Object { Write-Host "  $($_.FullName)" }
+            } else {
+              Write-Host "vulkan-1.dll not found anywhere in SDK"
+              Write-Host "Directory contents:"
+              Get-ChildItem -Path $env:VULKAN_SDK -Recurse -Depth 2 | ForEach-Object { Write-Host $_.FullName }
+            }
+            exit 1
+          }
+
+          Write-Host "Found vulkan-1.dll at: $vulkanDll"
+          $destination = "apps/whispering/src-tauri/vulkan-1.dll"
+          Copy-Item $vulkanDll $destination
+          Write-Host "Vulkan DLL bundled successfully to: $destination"
+
       # Setup Node.js for compatibility
       - name: setup node
         uses: actions/setup-node@v4

apps/whispering/src-tauri/.gitignore

@@ -9,3 +9,6 @@
 # Environment variables
 .env
 .env.local
+
+# Vulkan DLL copied during CI build (not committed, generated from VULKAN_SDK)
+vulkan-1.dll

apps/whispering/src-tauri/nsis/installer-hooks.nsh

@@ -0,0 +1,21 @@
+; Whispering NSIS Installer Hooks
+; This file is included by the Tauri NSIS installer to handle custom installation tasks
+
+; NSIS_HOOK_POSTINSTALL
+; Called after all files are installed to $INSTDIR
+; We need to move vulkan-1.dll from resources/ to the exe directory
+; because Windows needs DLLs next to the executable for load-time linking
+!macro NSIS_HOOK_POSTINSTALL
+  ; Check if the DLL exists in resources and copy it to exe directory
+  ${If} ${FileExists} "$INSTDIR\resources\vulkan-1.dll"
+    CopyFiles /SILENT "$INSTDIR\resources\vulkan-1.dll" "$INSTDIR\vulkan-1.dll"
+    Delete "$INSTDIR\resources\vulkan-1.dll"
+  ${EndIf}
+!macroend
+
+; NSIS_HOOK_POSTUNINSTALL
+; Called after uninstallation to clean up any remaining files
+!macro NSIS_HOOK_POSTUNINSTALL
+  ; Clean up the DLL if it exists
+  Delete "$INSTDIR\vulkan-1.dll"
+!macroend

apps/whispering/src-tauri/tauri.windows.conf.json

@@ -0,0 +1,11 @@
+{
+	"$schema": "https://schema.tauri.app/config/2",
+	"bundle": {
+		"resources": ["vulkan-1.dll"],
+		"windows": {
+			"nsis": {
+				"installerHooks": "nsis/installer-hooks.nsh"
+			}
+		}
+	}
+}