fix(ci): serialize the heavy 3D-viewer e2e specs (dedicated chromium-ci-3d project)

The three heavy 3D-viewer specs (3d-viewer, 3d-viewer-deadlock, 3d-viewer-models)
crashed on CI (run 28604015154): "Target crashed", "browser has been closed", and a
black frozen canvas. Each boots the 3D-enabled pcbnew build, which pre-warms
~hardwareConcurrency*2+8 (~68 on the 30-core VM) Web Workers AND runs a multi-threaded
CPU raytracer over SwiftShader software-WebGL. Under fullyParallel the three spec FILES
run in separate browser processes concurrently, and the simultaneous raytrace tabs
exhaust the shared GPU process's ~16 live-WebGL-context limit / renderer memory. The
pool pre-warm (the deadlock fix, 7630c7e) is correct and present in the tested binary;
per-file isolation prevented in-process Worker accumulation but NOT this cross-process
concurrency — the gap these specs' first CI exposure hit.

Fix (test-orchestration only; no wasm/submodule changes):
- Route the three specs to a dedicated `chromium-ci-3d` Playwright project (own
  outputDir=pw-artifacts/kicad-3d so its failure traces survive the later perf run's
  wipe; the existing tests/pw-artifacts/** upload already captures it).
- test:kicad:ci runs it as a SECOND `playwright test` pass with --workers=1, so at most
  one raytrace tab is alive at a time (the environment in which a single 3D load is
  reliably green — docs/features/3d-raytracer/README.md §7). An exit-code-aggregating
  sequencer runs both phases and fails if either fails (no silent skip of the 3D pass).
- Cap phase-1 CI workers to 12 as headroom under the WebGL-context cap.
- Log a resource-diagnostic snapshot (hardwareConcurrency, pthread pool, GL-canvas
  count, wasm/JS heap) before each 3D interaction so any recurrence is attributable.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

tests/kicad/3d-viewer-deadlock.spec.ts

@@ -1,6 +1,6 @@
 import { test, expect } from './fixtures';
 import { waitForPcbnew } from './utils/pcbnew-ready';
-import { countGlCanvases, loadBoard, openThreeDViewer } from './utils/threed-viewer';
+import { countGlCanvases, loadBoard, logThreeDDiag, openThreeDViewer } from './utils/threed-viewer';
 
 /**
  * Regression for the camera-move-on-canvas raytrace DEADLOCK.
@@ -58,6 +58,7 @@ test.describe('3D viewer camera-move deadlock', () => {
 
         // Let the INITIAL raytrace settle through the safe per-frame pump (Workers boot here).
         await page.waitForTimeout(5000);
+        await logThreeDDiag(page, 'deadlock: after open+settle');
 
         // Read the newest glcanvas-* (the 3D viewer) client rect in viewport coords.
         const canvasRect = () => page.evaluate(() => {
@@ -181,6 +182,7 @@ test.describe('3D viewer camera-move deadlock', () => {
         await page.screenshot({ path: 'test-results/3d-viewer-deadlock.png', scale: 'device' });
 
         // Sanity: the board still renders (not blank / crashed) after both moves.
+        await logThreeDDiag(page, 'deadlock: after moves');
         const after = await sampleCanvas();
         console.log(`[TEST] 3D render after interaction: ${after.distinctColors} distinct colours`);
         expect(after.distinctColors,

tests/kicad/3d-viewer-models.spec.ts

@@ -4,6 +4,7 @@ import { clickMenuBarItem, clickMenuItem } from '../e2e/utils/element-tracker';
 import { injectFromSubmodule } from './utils/fs-inject';
 import { waitForBoardLoaded } from './utils/board-ready';
 import { waitForPcbnew } from './utils/pcbnew-ready';
+import { logThreeDDiag } from './utils/threed-viewer';
 
 /**
  * 3D viewer COMPONENT MODELS e2e (docs/features/3d-models): load pic_programmer,
@@ -193,6 +194,7 @@ test.describe('3D viewer component models', () => {
 
         // Scene build + progressive raytrace passes.
         await page.waitForTimeout(8000);
+        await logThreeDDiag(page, 'models: before screenshot');
         await page.screenshot({ path: `test-results/3d-viewer-models-${DEMO.name}.png`, scale: 'css' });
 
         // --- bridge assertions -------------------------------------------------

tests/kicad/3d-viewer.spec.ts

@@ -1,6 +1,6 @@
 import { test, expect } from './fixtures';
 import { waitForPcbnew } from './utils/pcbnew-ready';
-import { DEMO, loadBoard, countGlCanvases, openThreeDViewer } from './utils/threed-viewer';
+import { DEMO, loadBoard, countGlCanvases, logThreeDDiag, openThreeDViewer } from './utils/threed-viewer';
 
 /**
  * 3D viewer e2e: load a real board in pcbnew, open the native 3D viewer
@@ -318,6 +318,7 @@ test.describe('3D viewer from pcbnew', () => {
         const beforeFrame = await frameWidth(winId as string);
         const beforeGl = await glWidth();
         expect(beforeFrame, 'frame should have a width').toBeGreaterThan(0);
+        await logThreeDDiag(page, 'resize: before edge drag');
 
         // Drag the right edge inward (left) to shrink the frame width.
         const edge = page.locator(`#${winId} .window-resize-e`);

tests/kicad/utils/threed-viewer.ts

@@ -63,6 +63,37 @@ export function countGlCanvases(page: Page): Promise<number> {
     return page.evaluate(() => document.querySelectorAll('canvas[id^="glcanvas-"]').length);
 }
 
+// Resource-diagnostic snapshot for the heavy 3D-viewer specs. On CI these can kill the tab
+// (renderer OOM, a lost WebGL context when the shared GPU process passes its ~16-context cap,
+// or a raytracer pthread deadlock) and the failure surfaces identically ("Target crashed" /
+// black canvas). Logging hardwareConcurrency, the emscripten pthread-pool ledger, the live
+// GL-canvas count, and the wasm/JS heap sizes right before an interaction makes any recurrence
+// attributable (GL-context exhaustion vs heap-OOM vs deadlock) — and confirms, on the real CI
+// VM, what navigator.hardwareConcurrency actually is (the whole 2N+8 pool sizing depends on it).
+// Best-effort: never throws, so it can't itself fail a spec.
+export async function logThreeDDiag(page: Page, label: string): Promise<void> {
+    const snap = await page.evaluate(() => {
+        const w = window as unknown as { Module?: Record<string, unknown> };
+        const M = (w.Module ?? {}) as Record<string, unknown>;
+        const P = (M.PThread ?? {}) as { unusedWorkers?: unknown[]; runningWorkers?: unknown[] };
+        const heap = M.HEAPU8 as { length?: number } | undefined;
+        const perf = (performance as unknown as { memory?: Record<string, number> }).memory ?? {};
+        const mb = (b?: number) => (typeof b === 'number' ? Math.round(b / 1048576) : null);
+        return {
+            hardwareConcurrency: navigator.hardwareConcurrency,
+            // emscripten pool ledger: pre-warmed-but-idle + currently-running Workers.
+            pthreadUnused: Array.isArray(P.unusedWorkers) ? P.unusedWorkers.length : null,
+            pthreadRunning: Array.isArray(P.runningWorkers) ? P.runningWorkers.length : null,
+            glCanvases: document.querySelectorAll('canvas[id^="glcanvas-"]').length,
+            canvases: document.querySelectorAll('canvas').length,
+            wasmHeapMB: mb(heap?.length),
+            jsHeapUsedMB: mb(perf.usedJSHeapSize),
+            jsHeapLimitMB: mb(perf.jsHeapSizeLimit),
+        };
+    }).catch((e: unknown) => ({ error: String(e) }));
+    console.log(`[DIAG ${label}] ${JSON.stringify(snap)}`);
+}
+
 // Open the 3D viewer (View → 3D Viewer, with an Alt+3 fallback) and wait for the
 // secondary frame + its NEW `glcanvas-*` to appear. The main pcbnew board view is
 // itself a wxGLCanvas, so the viewer is detected by the GL-canvas COUNT increasing.

tests/package.json

@@ -16,7 +16,7 @@
     "test:kicad:firefox": "npm run setup:kicad && playwright test --config=playwright-kicad.config.ts --project=firefox",
     "test:kicad:chrome": "npm run setup:kicad && playwright test --config=playwright-kicad.config.ts --project=chromium --headed",
     "test:kicad": "npm run test:kicad:firefox",
-    "test:kicad:ci": "npm run setup:kicad && playwright test --config=playwright-kicad.config.ts --project=firefox --project=chromium-ci",
+    "test:kicad:ci": "npm run setup:kicad && sh -c 'playwright test --config=playwright-kicad.config.ts --project=firefox --project=chromium-ci; a=$?; playwright test --config=playwright-kicad.config.ts --project=chromium-ci-3d --workers=1; b=$?; exit $((a||b))'",
     "test:kicad:headed": "npm run test:kicad:chrome",
     "test:perf": "npm run setup:kicad && playwright test --config=playwright-kicad.config.ts --project=perf --workers=1",
     "test:pcbnew:firefox": "npm run setup:kicad && playwright test --config=playwright-kicad.config.ts --project=firefox kicad/pcbnew.spec.ts",

tests/playwright-kicad.config.ts

@@ -118,6 +118,24 @@ const BIG_MODULE_SPECS = [
   "**/occ-probe.spec.ts",
 ];
 
+// The heavy 3D-viewer specs each boot the 3D-enabled pcbnew build, which pre-warms
+// ~hardwareConcurrency*2+8 Web Workers AND runs a multi-threaded CPU raytracer over
+// SwiftShader software-WebGL. Under fullyParallel these separate spec FILES land in
+// separate browser processes CONCURRENTLY, and the simultaneous raytrace tabs exhaust
+// Workers / wasm heap / the shared GPU process's ~16 live-WebGL-context limit → the tab
+// crashes ("Target crashed" / "browser has been closed" / a black frozen canvas). Per-file
+// isolation (own worker) prevents in-process Worker accumulation but NOT this cross-process
+// concurrency. They STAY in BIG_MODULE_SPECS (so firefox keeps ignoring them — the ~190 MB
+// module OOMs SpiderMonkey/x86), but on CI they run in the dedicated 'chromium-ci-3d' project,
+// which test:kicad:ci invokes with --workers=1 so at most ONE raytrace tab is alive at a time.
+// (footprint-3d-preview.spec.ts is a placeholder glob — no such file exists yet — harmless.)
+const THREE_D_HEAVY_SPECS = [
+  "**/3d-viewer.spec.ts",
+  "**/3d-viewer-deadlock.spec.ts",
+  "**/3d-viewer-models.spec.ts",
+  "**/footprint-3d-preview.spec.ts",
+];
+
 // Runtime-perf specs run ONLY on the Chromium 'perf' project below: they need
 // CDP CPU throttling (Chromium-only) and pcbnew needs V8. Excluded from the
 // firefox/chromium projects so they don't double-run there.
@@ -137,10 +155,13 @@ export default defineConfig({
   // as playwright.config.ts): the load-pcb post-load clipboard crash that can
   // close the page on Firefox, and the calculator first-run-wizard timing race.
   retries: process.env.CI ? 2 : 1,
-  // Run parallel workers on CI too (Playwright default ≈ 50% of cores), same as
+  // Run parallel workers on CI too, same as local — the serial CI run was the dominant
-  // local — the serial CI run was the dominant wall-clock cost. Cap (e.g. '50%'
+  // wall-clock cost. Capped to a fixed 12 on CI (down from Playwright's default ≈ 50% of
-  // or a fixed count) if contention OOMs/flakes; retries:2 covers transient.
+  // cores = ~15 on the 30-core VM) as defense-in-depth for the ~16 live-WebGL-context limit
-  workers: undefined,
+  // in Chromium's shared GPU process: ~15 GAL-canvas tabs already brush that cap. The heavy
+  // 3D-viewer specs (a *second* WebGL context each) no longer run here — they're isolated to
+  // the serial 'chromium-ci-3d' project — so 12 is only headroom, not the primary fix.
+  workers: process.env.CI ? 12 : undefined,
   reporter: "html",
   timeout: 180000, // KiCad WASM needs more time to load (3 minutes)
 
@@ -210,7 +231,29 @@ export default defineConfig({
       // --enable-unsafe-swiftshader: newer Chromium refuses software WebGL in
       // headless without it.
       name: "chromium-ci",
-      testMatch: BIG_MODULE_SPECS,
+      // Every big-module spec EXCEPT the heavy 3D-viewer ones — those move to the
+      // serial 'chromium-ci-3d' project below so they never raytrace concurrently.
+      testMatch: BIG_MODULE_SPECS.filter((s) => !THREE_D_HEAVY_SPECS.includes(s)),
+      use: {
+        ...devices["Desktop Chrome"],
+        viewport: { width: 1280, height: 720 },
+        launchOptions: {
+          args: ["--enable-unsafe-swiftshader"],
+        },
+      },
+    },
+    {
+      // CI-only serial carrier for the heavy 3D-viewer specs (see THREE_D_HEAVY_SPECS).
+      // Same runtime as chromium-ci; test:kicad:ci invokes this project in a SEPARATE
+      // `playwright test` pass with --workers=1, so at most one raytrace tab is alive at a
+      // time (the environment in which a single 3D load is reliably green — see
+      // docs/features/3d-raytracer/README.md §6-§7). Own outputDir so its start-of-run
+      // cleanup doesn't wipe chromium-ci's retained traces, and so its own failure traces
+      // survive the later `test:perf` run's pw-artifacts/kicad wipe; the CI upload glob
+      // tests/pw-artifacts/** already captures it, so no workflow change is needed.
+      name: "chromium-ci-3d",
+      testMatch: THREE_D_HEAVY_SPECS,
+      outputDir: process.env.CI ? "pw-artifacts/kicad-3d" : "test-results",
       use: {
         ...devices["Desktop Chrome"],
         viewport: { width: 1280, height: 720 },