Bundle audit: remove dead WASM deps, add analyzer, document composition

.gitignore

@@ -26,3 +26,6 @@ yarn-error.log*
 
 # Sourcemaps from pre-built utility bundles (issue #57): don't recommit them
 static/utility-apps/**/*.map
+
+# Generated by ANALYZE=1 builds
+bundle-report.html

dev-plans/bundle-audit-2026-07.md

@@ -0,0 +1,60 @@
+# Bundle Audit — July 2026 (issue #99)
+
+Run `ANALYZE=1 npm run build` to regenerate the interactive report at
+`build/bundle-report.html` (webpack-bundle-analyzer, client bundle only).
+
+## Headline result
+
+The micro-app migrations (#93/#94/#95) already achieved the audit's main goal:
+**no WASM, 3D, or document library ships on the critical path.** Every page
+loads the same two files first:
+
+| File | Parsed size | Contents |
+|---|---|---|
+| `main.<hash>.js` | 633 KB | react-dom (174 KB), prism-react-renderer + prismjs (109 KB), Docusaurus theme/runtime (~140 KB), lunr + language stemmers (71 KB, offline search), mark.js (17 KB), site code incl. the `en` dictionary (33 KB) |
+| `runtime~main.<hash>.js` | 9 KB | webpack runtime |
+
+Everything in `main` is framework or deliberately-global functionality
+(search, syntax highlighting, theme). There is no obvious low-effort cut left:
+the next meaningful step would be swapping search or highlighting strategies,
+which trades UX for bytes.
+
+## Heavy libraries — all verified lazy
+
+| Chunk | Size | Contents | Loaded on |
+|---|---|---|---|
+| `7084.*` | 3.0 MB | rapier physics (2.2 MB) + three.js (698 KB) + react-three-fiber | Eco Sort game page only |
+| `5741.*` | 743 KB | @mdx-js/mdx compiler + acorn + framer-motion | MDX post editor only |
+| `3512.*` | 391 KB | jspdf | PDF-export tools only |
+| `5527.*` | 262 KB | emoji-picker-react | comment editor interaction |
+| locale chunks | ~15 KB each | `ru/ua/de/es/et` dictionaries | on language switch (only `en` is in `main`) |
+
+Supabase is dynamically imported by the lazy client facade
+(`src/lib/supabaseClient.ts`) and does not appear in `main`.
+
+## Changes made in this audit
+
+1. **Removed dead dependencies `replicad` and `replicad-opencascadejs`** —
+   zero imports remained in `src/` after the CAD tools moved to standalone
+   apps. Shrinks installs/CI by ~15 MB (the OpenCascade WASM binary alone is
+   ~11 MB in node_modules); runtime bundles were never affected because
+   webpack only bundles imported modules.
+2. **Removed the replicad WASM webpack config** (`asyncWebAssembly`,
+   `__filename` mocks, `fs/path/crypto` fallbacks) — nothing in the site
+   bundle imports WASM anymore. Verified by a clean production build.
+3. **Committed the analyzer tooling** (`ANALYZE=1` flag in the webpack
+   plugin) so future audits are a one-liner.
+
+## Acceptance criteria mapping
+
+- *Bundle analysis report committed or documented* — this file + reproducible
+  `ANALYZE=1` build.
+- *No WASM/3D library loaded on the landing or docs pages* — verified: the
+  only render-path JS is `main` + `runtime` (table above); three/rapier live
+  exclusively in the Eco Sort chunk.
+- *Measurable reduction in first-load JS for non-tool pages* — the big
+  reduction was delivered by the migrations this audit verified (the last
+  in-bundle CAD tool previously pulled replicad/OpenCascade context into
+  shared chunks); this pass removes the leftover dependency and config debt
+  and establishes the measurement baseline (642 KB total first-load) to hold
+  the line against regressions.

docusaurus.config.ts

@@ -4,6 +4,7 @@ dotenv.config({path: './.env.local'});
 import {themes as prismThemes} from 'prism-react-renderer';
 import type {Config} from '@docusaurus/types';
 import type * as Preset from '@docusaurus/preset-classic';
+import {BundleAnalyzerPlugin} from 'webpack-bundle-analyzer';
 
 const config: Config = {
   title: 'CAD AutoScript',
@@ -49,29 +50,26 @@ const config: Config = {
   },
   clientModules: ['./src/clientModules/errorReporting.ts'],
   plugins: [
-    async function myPlugin(_context, _options) {
+    async function siteWebpackPlugin(_context, _options) {
       return {
-        name: 'docusaurus-replicad-config',
-        configureWebpack(_config, _isServer) {
+        name: 'site-webpack-config',
+        configureWebpack(_config, isServer) {
+          // ANALYZE=1 npm run build → writes build/bundle-report.html (client bundle).
+          // The replicad/OpenCascade WASM webpack config that used to live here
+          // was removed with the last in-bundle CAD tool (issues #93/#94/#99):
+          // every WASM consumer now runs as a standalone utility app.
+          const analyzerPlugins =
+            process.env.ANALYZE && !isServer
+              ? [
+                  new BundleAnalyzerPlugin({
+                    analyzerMode: 'static',
+                    reportFilename: '../bundle-report.html',
+                    openAnalyzer: false,
+                  }),
+                ]
+              : [];
           return {
-            // replicad-opencascadejs requires async-WebAssembly streaming.
-            experiments: {
-              asyncWebAssembly: true,
-            },
-            // Vendor wasm bindings reference __filename / __dirname. webpack 5
-            // defaults to 'warn-mock', which mocks them AND emits a warning per
-            // locale build. 'mock' keeps the same runtime behaviour silently.
-            node: {
-              __filename: 'mock',
-              __dirname: 'mock',
-            },
-            resolve: {
-              fallback: {
-                crypto: false,
-                fs: false,
-                path: false,
-              },
-            },
+            plugins: analyzerPlugins,
           };
         },
       };

package.json

@@ -60,8 +60,6 @@
     "remark-frontmatter": "^5.0.0",
     "remark-gfm": "^4.0.1",
     "remark-mdx-frontmatter": "^5.2.0",
-    "replicad": "^0.20.5",
-    "replicad-opencascadejs": "^0.20.2",
     "three": "^0.182.0",
     "three-stdlib": "2.36.1",
     "uuid": "^13.0.1",
@@ -86,7 +84,8 @@
     "sharp": "^0.34.5",
     "tailwindcss": "^4.2.1",
     "typescript": "~5.6.2",
-    "typescript-eslint": "^8.64.0"
+    "typescript-eslint": "^8.64.0",
+    "webpack-bundle-analyzer": "^5.3.1"
   },
   "browserslist": {
     "production": [