fix(schema): avoid panics in manifest canonicalization

Make NormalizedManifest::canonical_json and compute_env_id fallible and propagate serialization errors through core engine code.

crates/karapace-core/src/engine.rs

@@ -112,10 +112,10 @@ impl Engine {
 
         // Use preliminary identity from manifest (not resolved yet).
         // This is sufficient for the Defined state; build will re-resolve.
-        let identity = compute_env_id(&normalized);
+        let identity = compute_env_id(&normalized)?;
 
         if !self.meta_store.exists(&identity.env_id) {
-            let manifest_json = normalized.canonical_json();
+            let manifest_json = normalized.canonical_json()?;
             let manifest_hash = self.obj_store.put(manifest_json.as_bytes())?;
 
             let now = chrono::Utc::now().to_rfc3339();
@@ -225,7 +225,7 @@ impl Engine {
         // Phase 1: Resolve dependencies through the backend.
         // This downloads the base image, computes its content digest,
         // and queries the package manager for exact versions.
-        let preliminary_id = compute_env_id(&normalized);
+        let preliminary_id = compute_env_id(&normalized)?;
         let preliminary_spec = RuntimeSpec {
             env_id: preliminary_id.env_id.to_string(),
             root_path: self
@@ -272,7 +272,8 @@ impl Engine {
         );
 
         // Phase 3: Build the environment, then capture real filesystem layers.
-        let manifest_hash = self.obj_store.put(normalized.canonical_json().as_bytes())?;
+        let manifest_json = normalized.canonical_json()?;
+        let manifest_hash = self.obj_store.put(manifest_json.as_bytes())?;
 
         let env_dir = self.layout.env_path(&identity.env_id);
 
@@ -639,7 +640,7 @@ impl Engine {
         if old_env_ids.is_empty() {
             let manifest = parse_manifest_file(manifest_path)?;
             let normalized = manifest.normalize()?;
-            let identity = compute_env_id(&normalized);
+            let identity = compute_env_id(&normalized)?;
             if self.meta_store.exists(&identity.env_id) {
                 old_env_ids.push(identity.env_id.to_string());
             }
@@ -953,7 +954,7 @@ impl Engine {
     ) -> Result<(ManifestV1, NormalizedManifest, EnvIdentity), CoreError> {
         let manifest = parse_manifest_file(manifest_path)?;
         let normalized = manifest.normalize()?;
-        let identity = compute_env_id(&normalized);
+        let identity = compute_env_id(&normalized)?;
         Ok((manifest, normalized, identity))
     }
 }

crates/karapace-schema/src/identity.rs

@@ -22,10 +22,10 @@ pub struct EnvIdentity {
 /// - Internal lookup during rebuild (to find old environments)
 ///
 /// After `build`, the env_id stored in metadata comes from the lock file.
-pub fn compute_env_id(normalized: &NormalizedManifest) -> EnvIdentity {
+pub fn compute_env_id(normalized: &NormalizedManifest) -> Result<EnvIdentity, serde_json::Error> {
     let mut hasher = blake3::Hasher::new();
 
-    hasher.update(normalized.canonical_json().as_bytes());
+    hasher.update(normalized.canonical_json()?.as_bytes());
 
     let base_digest = blake3::hash(normalized.base_image.as_bytes())
         .to_hex()
@@ -71,10 +71,10 @@ pub fn compute_env_id(normalized: &NormalizedManifest) -> EnvIdentity {
     let hex = hasher.finalize().to_hex().to_string();
     let short = hex[..12].to_owned();
 
-    EnvIdentity {
+    Ok(EnvIdentity {
         env_id: EnvId::new(hex),
         short_id: ShortId::new(short),
-    }
+    })
 }
 
 #[cfg(test)]
@@ -110,7 +110,7 @@ packages = ["clang", "git"]
         .normalize()
         .unwrap();
 
-        assert_eq!(compute_env_id(&a), compute_env_id(&b));
+        assert_eq!(compute_env_id(&a).unwrap(), compute_env_id(&b).unwrap());
     }
 
     #[test]
@@ -141,7 +141,7 @@ packages = ["git", "cmake"]
         .normalize()
         .unwrap();
 
-        assert_ne!(compute_env_id(&a), compute_env_id(&b));
+        assert_ne!(compute_env_id(&a).unwrap(), compute_env_id(&b).unwrap());
     }
 
     #[test]
@@ -172,7 +172,7 @@ backend = "oci"
         .normalize()
         .unwrap();
 
-        assert_ne!(compute_env_id(&a), compute_env_id(&b));
+        assert_ne!(compute_env_id(&a).unwrap(), compute_env_id(&b).unwrap());
     }
 
     #[test]
@@ -188,7 +188,7 @@ image = "rolling"
         .normalize()
         .unwrap();
 
-        let id = compute_env_id(&n);
+        let id = compute_env_id(&n).unwrap();
         assert_eq!(id.short_id.as_str().len(), 12);
         assert!(id.env_id.as_str().starts_with(id.short_id.as_str()));
     }

crates/karapace-schema/src/normalize.rs

@@ -74,8 +74,8 @@ impl ManifestV1 {
 }
 
 impl NormalizedManifest {
-    pub fn canonical_json(&self) -> String {
-        serde_json::to_string(self).expect("normalized manifest serialization is infallible")
+    pub fn canonical_json(&self) -> Result<String, serde_json::Error> {
+        serde_json::to_string(self)
     }
 }
 
@@ -175,7 +175,7 @@ packages = ["clang", "git"]
         .normalize()
         .unwrap();
 
-        assert_eq!(a.canonical_json(), b.canonical_json());
+        assert_eq!(a.canonical_json().unwrap(), b.canonical_json().unwrap());
     }
 
     #[test]