Harden dev menu rebuild and extension startup paths

src/main/main.ts

@@ -93,12 +93,15 @@ const installExtensions = async () => {
   const forceDownload = !!process.env.UPGRADE_EXTENSIONS
   const extensions = ['REACT_DEVELOPER_TOOLS']
 
-  return installer
-    .default(
+  try {
+    return await installer.default(
       extensions.map((name) => installer[name as keyof typeof Installer]),
       forceDownload,
     )
-    .catch((err: unknown) => logger.error(getErrorMessage(err)))
+  } catch (error) {
+    logger.warn(`Skipping development extension installation: ${getErrorMessage(error)}`)
+    return []
+  }
 }
 
 const createMainWindow = async () => {

src/main/menu.ts

@@ -19,6 +19,24 @@ interface DarwinMenuItemConstructorOptions extends MenuItemConstructorOptions {
 export default class MenuBuilder {
   private mainWindow: BrowserWindow
   private projectService: ProjectService
+  private readonly handleDevelopmentContextMenu = (
+    _: Electron.Event,
+    props: Electron.ContextMenuParams,
+  ): void => {
+    if (!this.hasLiveWindow()) return
+
+    const { x, y } = props
+
+    Menu.buildFromTemplate([
+      {
+        label: 'Inspect element',
+        click: () => {
+          if (!this.hasLiveWindow()) return
+          this.mainWindow.webContents.inspectElement(x, y)
+        },
+      },
+    ]).popup({ window: this.mainWindow })
+  }
 
   developOptions: MenuItemConstructorOptions[] = [
     { type: 'separator' },
@@ -32,7 +50,19 @@ export default class MenuBuilder {
     this.projectService = new ProjectService(mainWindow)
   }
 
+  private hasLiveWindow(): boolean {
+    return !this.mainWindow.isDestroyed()
+  }
+
+  private getFallbackMenu(): Menu {
+    return Menu.getApplicationMenu() ?? Menu.buildFromTemplate([])
+  }
+
   async buildMenu(): Promise<Menu> {
+    if (!this.hasLiveWindow()) {
+      return this.getFallbackMenu()
+    }
+
     if (process.env.NODE_ENV === 'development' || process.env.DEBUG_PROD === 'true') {
       this.setupDevelopmentEnvironment()
     }
@@ -129,26 +159,22 @@ export default class MenuBuilder {
    */
 
   setupDevelopmentEnvironment(): void {
-    this.mainWindow.webContents.on('context-menu', (_, props) => {
-      const { x, y } = props
+    if (!this.hasLiveWindow()) return
 
-      Menu.buildFromTemplate([
-        {
-          label: 'Inspect element',
-          click: () => {
-            this.mainWindow.webContents.inspectElement(x, y)
-          },
-        },
-      ]).popup({ window: this.mainWindow })
-    })
+    this.mainWindow.webContents.removeListener('context-menu', this.handleDevelopmentContextMenu)
+    this.mainWindow.webContents.on('context-menu', this.handleDevelopmentContextMenu)
   }
 
   updateAppTheme() {
     const newTheme = nativeTheme.shouldUseDarkColors ? 'light' : 'dark'
     nativeTheme.themeSource = newTheme
     store.set('theme', newTheme)
-    this.mainWindow.webContents.send('system:update-theme')
-    void this.buildMenu()
+    if (this.hasLiveWindow()) {
+      this.mainWindow.webContents.send('system:update-theme')
+    }
+    void this.buildMenu().catch((error) => {
+      console.error('Error rebuilding application menu:', error)
+    })
   }
 
   /**

src/main/modules/ipc/main.ts

@@ -952,7 +952,11 @@ class MainProcessBridge implements MainIpcModule {
     this.simulatorModule.stop()
     this.mainWindow?.webContents.reload()
   }
-  handleWindowRebuildMenu = () => void this.menuBuilder.buildMenu()
+  handleWindowRebuildMenu = () => {
+    void this.menuBuilder.buildMenu().catch((error) => {
+      console.error('Error rebuilding application menu:', error)
+    })
+  }
 
   // Hardware handlers
   handleHardwareGetAvailableCommunicationPorts = async () => this.hardwareModule.getAvailableSerialPorts()