From f739e2246de8d6b272cda106f94c76d7d181aa85 Mon Sep 17 00:00:00 2001
From: Neil <4138956+nwparker@users.noreply.github.com>
Date: Sat, 30 May 2026 12:52:37 -0700
Subject: [PATCH] fix: surface speech model download failures (#3880)

---
 .../model-manager-download-error.test.ts      | 70 +++++++++++++++++++
 src/main/speech/model-manager.ts              |  5 ++
 2 files changed, 75 insertions(+)
 create mode 100644 src/main/speech/model-manager-download-error.test.ts

diff --git a/src/main/speech/model-manager-download-error.test.ts b/src/main/speech/model-manager-download-error.test.ts
new file mode 100644
index 000000000..14c33908e
--- /dev/null
+++ b/src/main/speech/model-manager-download-error.test.ts
@@ -0,0 +1,70 @@
+import { mkdtempSync, rmSync } from 'fs'
+import { tmpdir } from 'os'
+import { join } from 'path'
+import { beforeEach, describe, expect, it, vi } from 'vitest'
+import { SPEECH_MODEL_CATALOG } from './model-catalog'
+import { ModelManager } from './model-manager'
+
+const { httpsGetMock } = vi.hoisted(() => ({
+  httpsGetMock: vi.fn()
+}))
+
+vi.mock('electron', () => ({
+  app: {
+    getPath: () => '/tmp/orca-speech-models-test'
+  }
+}))
+
+vi.mock('https', async () => {
+  const actual = await vi.importActual('https')
+  return { ...(actual as Record<string, unknown>), get: httpsGetMock }
+})
+
+describe('ModelManager download failures', () => {
+  beforeEach(() => {
+    httpsGetMock.mockReset()
+  })
+
+  it('rejects failed model downloads so the caller can surface the error', async () => {
+    const dir = mkdtempSync(join(tmpdir(), 'orca-model-manager-'))
+    try {
+      const manifest = SPEECH_MODEL_CATALOG[0]
+      const errorHandlers: ((err: Error) => void)[] = []
+      const request = {
+        destroy: vi.fn(() => request),
+        setTimeout: vi.fn(() => request),
+        on: vi.fn((event: string, cb: (err: Error) => void) => {
+          if (event === 'error') {
+            errorHandlers.push(cb)
+          }
+          return request
+        }),
+        off: vi.fn((event: string, cb: (err: Error) => void) => {
+          if (event === 'error') {
+            const index = errorHandlers.indexOf(cb)
+            if (index !== -1) {
+              errorHandlers.splice(index, 1)
+            }
+          }
+          return request
+        })
+      }
+      httpsGetMock.mockImplementation(() => {
+        queueMicrotask(() => {
+          for (const handler of errorHandlers) {
+            handler(new Error('network down'))
+          }
+        })
+        return request
+      })
+      const manager = new ModelManager(dir)
+
+      await expect(manager.downloadModel(manifest.id)).rejects.toThrow('network down')
+
+      expect(request.off).toHaveBeenCalledWith('error', expect.any(Function))
+      expect(errorHandlers).toHaveLength(0)
+    } finally {
+      rmSync(dir, { recursive: true, force: true })
+    }
+  })
+})
diff --git a/src/main/speech/model-manager.ts b/src/main/speech/model-manager.ts
index 1b25fd63a..8eb35844e 100644
--- a/src/main/speech/model-manager.ts
+++ b/src/main/speech/model-manager.ts
@@ -179,6 +179,11 @@ export class ModelManager {
         this.updateState(modelId, 'error', undefined, String(err))
       }
       this.cleanup(modelId, archivePath)
+      if (!aborted) {
+        // Why: the settings UI awaits this promise to show download failures;
+        // cancellation stays quiet, but real failures must reach the caller.
+        throw err
+      }
     } finally {
       this.activeDownloads.delete(modelId)
       try {