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# Root cause of the wheel-build cascade We have shipped 5 release-pipeline hot-fixes in 12 hours, each addressing a different symptom of the same architectural problem: 1. PR #363 — npm artifact downloads + tried `yum openssl-devel` 2. PR #367 — vendored OpenSSL in `headroom-proxy` + dropped Intel mac 3. PR #369 — Debian-cross perl install (`perl` not `libipc-cmd-perl`) 4. PR #370 — moved `openssl/vendored` from headroom-proxy to headroom-py 5. (this PR) — ELIMINATE OpenSSL entirely Each fix exposed a different missing system package or feature flag in a different build surface (manylinux x86_64 vs aarch64-cross-Debian vs macOS Intel vs e2e/wrap Dockerfile vs e2e/init Dockerfile vs main Dockerfile vs devcontainer). We were playing whack-a-mole because every Cargo dep change to the OpenSSL surface required matching system-package updates in 6+ different Dockerfiles and workflows, and the PR-level CI didn't exercise all of them. # Why this PR is the structural fix `fastembed` exposes clean rustls feature flags: - `hf-hub-rustls-tls` (replaces default `hf-hub-native-tls`) - `ort-download-binaries-rustls-tls` (replaces default `…native-tls`) By disabling fastembed's default features and enabling the rustls variants explicitly, we remove `native-tls` (and therefore `openssl-sys`, `openssl`, `openssl-src`, perl modules, OpenSSL build-time deps, vendored OpenSSL ~30s build cost) from the entire workspace dep tree. Verified locally: $ cargo tree -p headroom-py -i openssl-sys error: package ID specification `openssl-sys` did not match any packages $ cargo tree -p headroom-py -i native-tls error: package ID specification `native-tls` did not match any packages $ cargo build --release -p headroom-py Finished `release` profile [optimized] target(s) in 25.57s (Down from 1m+ with vendored OpenSSL.) # Cleanups enabled by this change - crates/headroom-py/Cargo.toml — dropped the `openssl/vendored` workaround from PR #370. - crates/headroom-proxy/Cargo.toml — same dep removed. - e2e/wrap/Dockerfile — dropped `yum install openssl-devel pkgconfig perl-IPC-Cmd`. Comment retained explaining why. - e2e/init/Dockerfile — same. - Dockerfile (main) — dropped `pkg-config libssl-dev` from apt-get. - .devcontainer/Dockerfile — dropped `pkg-config libssl-dev`. - .github/workflows/release.yml — removed the entire before-script-linux block (perl install probe + multi-package-manager dispatch + fail-loud assertion). No longer needed. # Regression gate Three new structural tests in tests/test_release_workflows.py: - test_no_openssl_sys_in_wheel_build_tree — runs `cargo tree -p <crate> -i openssl-sys` for headroom-py / headroom-proxy / headroom-core. If openssl-sys reappears (a future native-tls enabler creeping in via a new dep), this fails AT PR TIME with an actionable message. - test_no_native_tls_in_wheel_build_tree — same shape, native-tls is the proximate cause. - test_fastembed_uses_rustls_features — checks the Cargo.toml so a future "let me bump fastembed and forget the features" doesn't silently re-introduce OpenSSL. Plus two cleanup gates: - test_dockerfiles_no_longer_install_openssl_devel - test_release_yml_does_not_install_openssl_or_perl_for_wheels All 13 release-workflow tests pass. `make ci-precheck` PASSED. # What this teaches us about rollouts (per user's ultrathink ask) The 5-fix cascade exposed three meta-problems: 1. PR checks don't block merges. PR #370 had docker-init-e2e, docker-wrap-e2e, docker-native-e2e all FAILED yet got merged. Branch protection should require these checks. Operator action needed (cannot fix in code). 2. Local validation is misleading. `cargo build -p headroom-py` from the workspace root used the workspace lockfile and looked green; CI did fresh resolution against headroom-py's manifest alone where the feature wasn't enabled. Lesson: verify structural invariants with `cargo tree -e features` before trusting that a build "works." 3. 6+ build surfaces with independent system-dep state. Every Cargo change required matching updates in 6 places. The structural answer (this PR) is to NOT depend on system OpenSSL at all. Where structural fixes are not possible, the answer is a single shared scripts/install-rust-build-deps.sh — but with this PR there's nothing left to install. |
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