fix(sync): restore worker incremental API DB resolution

.github/workflows/deploy.yaml

@@ -231,9 +231,10 @@ jobs:
         run: bun install --frozen-lockfile
 
       - name: Rebuild native modules
-        run: npm rebuild
+        run: npm rebuild --ignore-scripts
         env:
           HUSKY: "0"
+          HUSKY_SKIP_INSTALL: "1"
 
       - name: Build macOS distributables
         run: bun run make:macos
@@ -272,9 +273,10 @@ jobs:
         run: bun install --frozen-lockfile
 
       - name: Rebuild native modules
-        run: npm rebuild
+        run: npm rebuild --ignore-scripts
         env:
           HUSKY: "0"
+          HUSKY_SKIP_INSTALL: "1"
 
       - name: Build Windows distributables
         run: bun run make -- --platform win32

api/Dockerfile

@@ -90,6 +90,9 @@ COPY --from=build /app/dalpuri/generated/ ./dalpuri/generated/
 # Copy production node_modules (Prisma adapter needs native bindings)
 COPY --from=deps /app/node_modules/ ./node_modules/
 
+# Ensure pdfmake Roboto fonts are present at runtime for PDF generation.
+COPY --from=build /app/api/node_modules/pdfmake/build/fonts/ ./node_modules/pdfmake/build/fonts/
+
 ENV NODE_ENV=production
 
 # ---- Stage 4: API server runtime image ----

api/kubernetes/worker-deployment.yaml

@@ -20,6 +20,11 @@ spec:
           env:
             - name: MANAGER_SOCKET_URL
               value: "http://optima-api.optima.svc.cluster.local:8671"
+            - name: API_DATABASE_URL
+              valueFrom:
+                secretKeyRef:
+                  name: api-env-secret
+                  key: DATABASE_URL
           envFrom:
             - secretRef:
                 name: api-env-secret

api/src/modules/pdf-utils/generateQuote.ts

@@ -1,5 +1,5 @@
 import PdfPrinter from "pdfmake/src/Printer";
-import { readFileSync } from "node:fs";
+import { existsSync, readFileSync } from "node:fs";
 import { join } from "node:path";
 
 export interface QuoteLineItem {
@@ -110,7 +110,26 @@ const COMPANY = {
 
 const DEFAULT_LOGO_PATH = join(process.cwd(), "logo.png");
 
-const fontDir = join(process.cwd(), "node_modules/pdfmake/build/fonts/Roboto");
+function resolveRobotoFontDir(): string {
+  const candidates = [
+    join(process.cwd(), "node_modules/pdfmake/build/fonts/Roboto"),
+    join(import.meta.dir, "../../../node_modules/pdfmake/build/fonts/Roboto"),
+    join("/app/node_modules/pdfmake/build/fonts/Roboto"),
+    join("/app/api/node_modules/pdfmake/build/fonts/Roboto"),
+  ];
+
+  for (const dir of candidates) {
+    if (existsSync(join(dir, "Roboto-Medium.ttf"))) {
+      return dir;
+    }
+  }
+
+  throw new Error(
+    `[pdf] Could not locate pdfmake Roboto fonts. Checked: ${candidates.join(", ")}`
+  );
+}
+
+const fontDir = resolveRobotoFontDir();
 const fonts = {
   Roboto: {
     normal: join(fontDir, "Roboto-Regular.ttf"),

dalpuri/src/sync.ts

@@ -107,6 +107,20 @@ const resolveApiDatabaseUrl = (): string => {
   if (process.env.OPTIMA_API_DATABASE_URL)
     return process.env.OPTIMA_API_DATABASE_URL;
 
+  // Worker/runtime fallback:
+  // In Kubernetes we often provide CW via CW_DATABASE_URL and API Postgres via
+  // DATABASE_URL. Only use DATABASE_URL as API when we can safely infer that.
+  if (process.env.CW_DATABASE_URL && process.env.DATABASE_URL) {
+    return process.env.DATABASE_URL;
+  }
+
+  if (
+    process.env.DATABASE_URL &&
+    /^(postgres|postgresql):\/\//i.test(process.env.DATABASE_URL)
+  ) {
+    return process.env.DATABASE_URL;
+  }
+
   const candidates = [
     resolve(import.meta.dir, "../../api/.env"),
     resolve(process.cwd(), "../api/.env"),