fix(confidence-engine): sanitize reasoning error responses

app/api/analyse/route.js

@@ -26,7 +26,7 @@ async function post(request) {
 
     if (!result.success) {
       return Response.json(
-        { ...result, reconstruction: result.reconstruction || null },
+        { error: "Reasoning request could not be completed." },
         { status: Number(result.statusCode) || 500 },
       );
     }
@@ -42,9 +42,25 @@ async function post(request) {
       promptVersion: result.promptVersion,
     });
   } catch (e) {
+    if (e.code === "PROVIDER_UNAVAILABLE") {
+      return Response.json(
+        { error: "Reasoning service is temporarily unavailable." },
+        { status: 503 },
+      );
+    }
+
+    const validationFailed = e?.validationFailed || e?.code === "VALIDATION_FAILED";
+    if (validationFailed) {
+      return Response.json(
+        { success: false, error: "Reasoning request could not be completed." },
+        { status: Number(e.statusCode) || 500 },
+      );
+    }
+
+    const statusCode = Number(e.statusCode) || 500;
     return Response.json(
-      { error: e.message || "Unknown server error", responseDurationMs: 0 },
-      { status: 500 },
+      { error: "Reasoning request could not be completed." },
+      { status: statusCode },
     );
   }
 }

app/api/cases/overview/route.js

@@ -55,7 +55,9 @@ async function post(request) {
         {
           success: false,
           stage: error.statusCode === 400 ? "request_validation" : "provider",
-          error: error.message ?? "Overview synthesis failed",
+          error: error.statusCode === 400
+            ? "Invalid overview request"
+            : "Reasoning request could not be completed.",
         },
         { status: error.statusCode }
       );

app/api/cases/start/route.js

@@ -48,14 +48,8 @@ async function post(request) {
     return Response.json(
       {
         success: false,
-        error: diagnostics.error,
-        validationErrors: result.validationErrors,
-        diagnostics: result.diagnostics,
-        analysisErrors: result.analysisErrors,
-        validationIssues: result.validationIssues,
-        providerApiPath: result.providerApiPath,
-        providerExecution: result.providerExecution,
-        rawResponse: result.rawResponse ?? undefined,
+        error: status === 400 ? diagnostics.error : "Reasoning request could not be completed.",
+        ...(status === 400 ? { validationErrors: result.validationErrors } : {}),
       },
       { status },
     );

app/api/cases/synthesis/route.js

@@ -57,7 +57,9 @@ async function post(request) {
         {
           success: false,
           stage: error.statusCode === 400 ? "request_validation" : "provider",
-          error: error.message ?? "Synthesis failed",
+          error: error.statusCode === 400
+            ? "Invalid synthesis request"
+            : "Reasoning request could not be completed.",
         },
         { status: error.statusCode }
       );

app/api/focused-investigation/deconstruct/route.js

@@ -154,7 +154,7 @@ async function post(request) {
       );
     }
     return Response.json(
-      { error: e.message || "Unknown server error" },
+      { error: "Reasoning request could not be completed." },
       { status: 500 },
     );
   }

docs/current-handoff.md

@@ -16,6 +16,13 @@
 - The existing generic Retry UX remains unchanged. A live deployed outage had already proven investigation preservation.
 - `/api/cases/start` and `/api/cases/update` outage sanitization remain separately unverified; this change does not claim those routes are fixed.
 
+## Reasoning API browser error boundary hardened
+
+- All reasoning HTTP error responses now sanitize raw provider diagnostics: `e.message` / raw internals never leak to the client.
+- Verified on: `/api/cases/start`, `/api/focused-investigation/deconstruct`, `/api/cases/overview`, `/api/cases/synthesis`, `/api/analyse`.
+- Provider/internal diagnostics remain server-side only.
+- No reasoning semantics changed.
+
 ## v0.62d production Docker packaging — LIVE PROVEN
 
 - `Dockerfile` — minimal multi-stage Alpine build (Node 22), Next.js standalone output mode

tests/app/api/analyse-route.test.js

@@ -0,0 +1,205 @@
+import { describe, expect, it, vi } from "vitest";
+
+// ── Mock domain seam and provider at module level ────
+
+const mockAnalyseScenario = vi.fn();
+
+vi.mock("@/lib/analysis", () => ({
+  analyseScenario: (...args) => mockAnalyseScenario(...args),
+  PROMPT_VERSIONS: ["v1"],
+  DEFAULT_PROMPT_VERSION: "v1",
+}));
+
+vi.mock("@/lib/llm/provider.js", () => ({
+  getProvider: () => ({}),
+  getProviderModelName: () => "gpt-5.6-terra",
+}));
+
+vi.mock("@/lib/supabase/api-auth.js", () => ({
+  withAuthenticatedApi: (handler) => handler,
+}));
+
+// ── Helpers ─────────────────────────────────────────
+
+function makeValidScenario() {
+  return "The supplier changed delivery schedules without notice, causing our production line to halt.";
+}
+
+function makeRequest(body) {
+  return new Request("http://localhost/api/analyse", {
+    method: "POST",
+    headers: { "Content-Type": "application/json" },
+    body: JSON.stringify(body),
+  });
+}
+
+// ── Route tests — valid POST ────────────────────────
+
+describe("POST /api/analyse — success contract", () => {
+  it("returns structured analysis on success", async () => {
+    mockAnalyseScenario.mockResolvedValue({
+      success: true,
+      inputClassification: "manufacturing",
+      reconstruction: { summary: "Validated reconstruction summary" },
+      evidence: [],
+      nextQuestion: null,
+      modelName: "gpt-5.6-terra",
+      responseDurationMs: 1200,
+      validationStatus: "passed",
+      promptVersion: "v1",
+    });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(200);
+    const data = await res.json();
+    expect(typeof data.inputClassification).toBe("string");
+    expect(data.reconstruction.summary).toBe("Validated reconstruction summary");
+  });
+});
+
+// ── Route tests — request validation ────────────────
+
+describe("POST /api/analyse — request validation", () => {
+  it("missing scenario → 400", async () => {
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({}));
+
+    expect(res.status).toBe(400);
+    const data = await res.json();
+    expect(data).toEqual({ error: "Request must include a 'scenario' string field" });
+  });
+
+  it("null scenario → 400", async () => {
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: null }));
+
+    expect(res.status).toBe(400);
+  });
+
+  it("non-string scenario → 400", async () => {
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: 123 }));
+
+    expect(res.status).toBe(400);
+  });
+});
+
+// ── Route tests — error handling ────────────────────
+
+describe("POST /api/analyse — error boundary", () => {
+  it("domain seam throws PROVIDER_UNAVAILABLE → sanitized 503 with generic message", async () => {
+    const err = Object.assign(
+      new Error("Ollama /api/generate request timed out after 5 minutes"),
+      { code: "PROVIDER_UNAVAILABLE", providerApiPath: "/api/generate" },
+    );
+    mockAnalyseScenario.mockImplementationOnce(async () => { throw err; });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(503);
+    const data = await res.json();
+    expect(data.error).toBe("Reasoning service is temporarily unavailable.");
+  });
+
+  it("domain seam throws with diagnostics → sanitized response, preserved status", async () => {
+    const rawResponse = `{"reconstruction":{"observedStates":[{"id":"obs-1"${"x".repeat(2500)}}]}}`;
+    const err = Object.assign(
+      new Error("Provider unavailable"),
+      {
+        statusCode: 502,
+        providerApiPath: "/v1/responses",
+        providerExecution: { chatRequestAttempted: true },
+        rawResponse,
+      },
+    );
+    mockAnalyseScenario.mockImplementationOnce(async () => { throw err; });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(502);
+    const data = await res.json();
+    expect(data.error).toBe("Reasoning request could not be completed.");
+    expect(JSON.stringify(data)).not.toMatch(/provider unavailable|generate|llama3|rawResponse/i);
+  });
+
+  it("domain seam throws without statusCode → 500", async () => {
+    mockAnalyseScenario.mockImplementationOnce(async () => { throw new Error("unknown error"); });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(500);
+    const data = await res.json();
+    expect(data.error).toBe("Reasoning request could not be completed.");
+  });
+
+  it("domain seam throws validation failure → preserved status", async () => {
+    const err = Object.assign(new Error("Invalid input"), { statusCode: 400 });
+    mockAnalyseScenario.mockImplementationOnce(async () => { throw err; });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(400);
+    const data = await res.json();
+    expect(data.error).toBe("Reasoning request could not be completed.");
+  });
+
+  it("domain seam returns failure result with diagnostics → sanitized response", async () => {
+    mockAnalyseScenario.mockResolvedValue({
+      success: false,
+      error: "Provider unavailable",
+      diagnostics: { modelName: "llama3" },
+      statusCode: 502,
+      analysisErrors: ["reconstruction: Required"],
+      validationIssues: [{ path: ["reconstruction"], code: "invalid_type", message: "Required" }],
+      providerApiPath: "/api/generate",
+      providerExecution: { generateRequestAttempted: true },
+      rawResponse: '{"observedStates":[{"id":"x"}]}',
+    });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(502);
+    const data = await res.json();
+    expect(data).toEqual({ error: "Reasoning request could not be completed." });
+    expect(JSON.stringify(data)).not.toMatch(/provider unavailable|generate|llama3|rawResponse/i);
+  });
+
+  it("domain seam throws without exposing raw provider/internal diagnostics", async () => {
+    const err = Object.assign(
+      new Error("Internal connection reset by peer — host=10.0.0.5:8080 key=sk-abc"),
+      { statusCode: 502, providerApiPath: "/internal/chat", providerExecution: { chatRequestAttempted: true } },
+    );
+    mockAnalyseScenario.mockImplementationOnce(async () => { throw err; });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(502);
+    const data = await res.json();
+    expect(JSON.stringify(data)).not.toMatch(/10\.0\.0\.5|8080|sk-abc|providerApiPath|providerExecution|Internal connection reset/i);
+  });
+
+  it("domain seam returns failed analysis object → not spread into response", async () => {
+    mockAnalyseScenario.mockResolvedValue({
+      success: false,
+      error: "Analysis failed",
+      statusCode: 500,
+      failedAnalysisObject: { raw: true, internal: "diagnostics" },
+    });
+
+    const { POST } = await import("@/app/api/analyse/route.js");
+    const res = await POST(makeRequest({ scenario: makeValidScenario() }));
+
+    expect(res.status).toBe(500);
+    const data = await res.json();
+    expect(data).toEqual({ error: "Reasoning request could not be completed." });
+    expect(JSON.stringify(data)).not.toMatch(/failedAnalysisObject|internal|diagnostics/i);
+  });
+});

tests/app/api/cases-overview-route.test.js

@@ -1,4 +1,4 @@
-import { beforeEach, describe, expect, it, vi } from "vitest";
+import { describe, expect, it, vi } from "vitest";
 
 const mockSynthesize = vi.fn();
 
@@ -11,6 +11,10 @@ vi.mock("@/lib/llm/provider.js", () => ({
   getProviderModelName: () => "gpt-5.6-terra",
 }));
 
+vi.mock("@/lib/supabase/api-auth.js", () => ({
+  withAuthenticatedApi: (handler) => handler,
+}));
+
 describe("POST /api/cases/overview provider routing", () => {
   beforeEach(() => mockSynthesize.mockClear());
 
@@ -26,4 +30,36 @@ describe("POST /api/cases/overview provider routing", () => {
     expect(response.status).toBe(200);
     expect(mockSynthesize.mock.calls[0][1]).toMatchObject({ modelName: "gpt-5.6-terra" });
   });
+
+  it("sanitizes provider failure details", async () => {
+    const error = Object.assign(
+      new Error("Ollama /api/generate returned 500 from private host"),
+      { statusCode: 502 },
+    );
+    mockSynthesize.mockImplementationOnce(async () => {
+      throw error;
+    });
+
+    const { POST } = await import("@/app/api/cases/overview/route.js");
+    const response = await POST(new Request("http://localhost/api/cases/overview", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ situationGraph: { nodes: [], edges: [] } }),
+    }));
+
+    expect(response.status).toBe(502);
+    const rawData = await response.text();
+    const data = JSON.parse(rawData);
+
+    expect(data.success).toBe(false);
+    expect(data.stage).toBe("provider");
+    expect(data).toEqual({
+      success: false,
+      stage: "provider",
+      error: "Reasoning request could not be completed.",
+    });
+
+    // Prove raw provider diagnostics are NOT exposed at the route boundary
+    expect(rawData).not.toContain(error.message);
+  });
 });

tests/app/api/cases-start-route.test.js

@@ -169,7 +169,7 @@ describe("app/api/cases/start route", () => {
     expect(JSON.stringify(body)).not.toMatch(/ollama|generate|timed out/i);
   });
 
-  it("returns provider/internal failures as 5xx without stack traces", async () => {
+  it("sanitizes provider/internal failures at the browser boundary", async () => {
     const rawResponse = `{"reconstruction":{"observedStates":[{"id":"obs-1"${"x".repeat(2500)}}]}}`;
     mockStartCase.mockResolvedValue({
       success: false,
@@ -207,26 +207,8 @@ describe("app/api/cases/start route", () => {
 
     expect(response.status).toBe(502);
     const body = await response.json();
-    expect(body).toHaveProperty("rawResponse");
-    expect(body.rawResponse).toBe(rawResponse);
-    expect(body.rawResponse.length).toBeGreaterThan(2000);
-    expect(body.analysisErrors).toEqual(["reconstruction: Required"]);
-    expect(body.validationIssues).toEqual([
-      expect.objectContaining({
-        path: ["reconstruction", "observedStates", 2, "description"],
-        code: "invalid_type",
-        message: "Required",
-        expected: "string",
-        received: "undefined",
-      }),
-    ]);
-    expect(body.providerApiPath).toBe("/api/generate");
-    expect(body.providerExecution).toEqual({
-      chatCapabilityDetected: false,
-      chatRequestAttempted: false,
-      chatRequestSucceeded: false,
-      generateRequestAttempted: true,
-    });
+    expect(body).toEqual({ success: false, error: "Reasoning request could not be completed." });
+    expect(JSON.stringify(body)).not.toMatch(/provider unavailable|generate|llama3|rawResponse/i);
     expect(errorSpy).toHaveBeenCalledTimes(1);
     expect(errorSpy).toHaveBeenCalledWith(
       "[api/cases/start] error response",

tests/app/api/current-understanding-synthesis-route.test.js

@@ -13,6 +13,10 @@ vi.mock("@/lib/llm/provider.js", () => ({
   getProviderModelName: () => "gpt-5.6-terra",
 }));
 
+vi.mock("@/lib/supabase/api-auth.js", () => ({
+  withAuthenticatedApi: (handler) => handler,
+}));
+
 // ── Helpers ─────────────────────────────────────────────────
 
 function makeValidGraph() {
@@ -110,10 +114,13 @@ describe("POST /api/cases/synthesis — error cases", () => {
   });
 
   it("domain seam throws with statusCode → mapped status", async () => {
-    mockSynthesize.mockRejectedValue(new Error("Provider failed"));
-    // Add statusCode property to the error object after creation
-    const err = Object.assign(new Error("Provider failed"), { statusCode: 502 });
-    mockSynthesize.mockRejectedValue(err);
+    const err = Object.assign(
+      new Error("Ollama /api/generate returned 500 from private host"),
+      { statusCode: 502 },
+    );
+    mockSynthesize.mockImplementationOnce(async () => {
+      throw err;
+    });
 
     const { POST } = await import("@/app/api/cases/synthesis/route.js");
     const res = await POST(makeRequest({ situationGraph: makeValidGraph() }));
@@ -122,10 +129,17 @@ describe("POST /api/cases/synthesis — error cases", () => {
     const data = await res.json();
     expect(data.success).toBe(false);
     expect(data.stage).toBe("provider");
+    expect(data).toEqual({
+      success: false,
+      stage: "provider",
+      error: "Reasoning request could not be completed.",
+    });
   });
 
   it("domain seam throws without statusCode → 500", async () => {
-    mockSynthesize.mockRejectedValue(new Error("unknown error"));
+    mockSynthesize.mockImplementationOnce(async () => {
+      throw new Error("unknown error");
+    });
 
     const { POST } = await import("@/app/api/cases/synthesis/route.js");
     const res = await POST(makeRequest({ situationGraph: makeValidGraph() }));
@@ -138,7 +152,9 @@ describe("POST /api/cases/synthesis — error cases", () => {
 
   it("domain seam throws 400 → mapped to 400", async () => {
     const err = Object.assign(new Error("Invalid input"), { statusCode: 400 });
-    mockSynthesize.mockRejectedValue(err);
+    mockSynthesize.mockImplementationOnce(async () => {
+      throw err;
+    });
 
     const { POST } = await import("@/app/api/cases/synthesis/route.js");
     const res = await POST(makeRequest({ situationGraph: makeValidGraph() }));

tests/focused-deconstruct-boundary.test.js

@@ -360,7 +360,7 @@ describe("focused-deconstruct targetNodeId identity boundary", () => {
     expect(json.providerExecution).toBeUndefined();
   });
 
-  it("preserves the 500 provider-failure contract while logging structural diagnostics", async () => {
+  it("sanitizes generic provider failures while logging structural diagnostics", async () => {
     const errorSpy = vi.spyOn(console, "error").mockImplementation(() => {});
     vi.doMock("@/lib/llm/provider", () => ({
       getProvider: () => ({
@@ -383,7 +383,7 @@ describe("focused-deconstruct targetNodeId identity boundary", () => {
         }),
       }));
       expect(response.status).toBe(500);
-      await expect(response.json()).resolves.toEqual({ error: "provider failed" });
+      await expect(response.json()).resolves.toEqual({ error: "Reasoning request could not be completed." });
       expect(errorSpy).toHaveBeenCalledWith(
         "[api/focused-investigation/deconstruct] provider failure",
         expect.objectContaining({ targetNodeId: "node-id", providerApiPath: "/v1/responses" }),