From 3c796da649f4108f64ef27f75061f14a76cd0682 Mon Sep 17 00:00:00 2001
From: marcuspaico <marcus@thepai.co>
Date: Mon, 17 Aug 2026 14:07:50 -0700
Subject: [PATCH] feat(crypto): boot-generated key + AES-256-GCM sealed values

---
 server/src/lib/crypto.ts   | 31 +++++++++++++++++++++++++++++++
 server/test/crypto.test.ts | 35 +++++++++++++++++++++++++++++++++++
 2 files changed, 66 insertions(+)
 create mode 100644 server/src/lib/crypto.ts
 create mode 100644 server/test/crypto.test.ts

diff --git a/server/src/lib/crypto.ts b/server/src/lib/crypto.ts
new file mode 100644
index 0000000..46fa137
--- /dev/null
+++ b/server/src/lib/crypto.ts
@@ -0,0 +1,31 @@
+import { createCipheriv, createDecipheriv, randomBytes } from "node:crypto";
+import { existsSync, mkdirSync, readFileSync, writeFileSync } from "node:fs";
+import { join } from "node:path";
+
+export function loadOrCreateKey(dataDir: string): Buffer {
+  mkdirSync(dataDir, { recursive: true });
+  const path = join(dataDir, "secret.key");
+  if (!existsSync(path)) writeFileSync(path, randomBytes(32), { mode: 0o600 });
+  const key = readFileSync(path);
+  if (key.length !== 32) throw new Error(`secret.key must be 32 bytes, got ${key.length}`);
+  return key;
+}
+
+export function encrypt(key: Buffer, plaintext: string): string {
+  const iv = randomBytes(12);
+  const cipher = createCipheriv("aes-256-gcm", key, iv);
+  const ct = Buffer.concat([cipher.update(plaintext, "utf8"), cipher.final()]);
+  return "enc:" + Buffer.concat([iv, cipher.getAuthTag(), ct]).toString("base64");
+}
+
+export function decrypt(key: Buffer, sealed: string): string {
+  if (!sealed.startsWith("enc:")) throw new Error("not an encrypted value");
+  const buf = Buffer.from(sealed.slice(4), "base64");
+  const decipher = createDecipheriv("aes-256-gcm", key, buf.subarray(0, 12));
+  decipher.setAuthTag(buf.subarray(12, 28));
+  return Buffer.concat([decipher.update(buf.subarray(28)), decipher.final()]).toString("utf8");
+}
+
+export function mask(secret: string): string {
+  return secret.length >= 5 ? "…" + secret.slice(-4) : "…";
+}
diff --git a/server/test/crypto.test.ts b/server/test/crypto.test.ts
new file mode 100644
index 0000000..4873feb
--- /dev/null
+++ b/server/test/crypto.test.ts
@@ -0,0 +1,35 @@
+import { describe, expect, test } from "bun:test";
+import { mkdtempSync } from "node:fs";
+import { tmpdir } from "node:os";
+import { join } from "node:path";
+import { decrypt, encrypt, loadOrCreateKey, mask } from "../src/lib/crypto";
+
+describe("crypto", () => {
+  test("key is created once and reused", () => {
+    const dir = mkdtempSync(join(tmpdir(), "helios-"));
+    const a = loadOrCreateKey(dir);
+    const b = loadOrCreateKey(dir);
+    expect(a.length).toBe(32);
+    expect(a.equals(b)).toBe(true);
+  });
+
+  test("encrypt/decrypt round-trip; ciphertexts differ per call", () => {
+    const key = loadOrCreateKey(mkdtempSync(join(tmpdir(), "helios-")));
+    const sealed = encrypt(key, "sk-or-v1-secret");
+    expect(sealed.startsWith("enc:")).toBe(true);
+    expect(decrypt(key, sealed)).toBe("sk-or-v1-secret");
+    expect(encrypt(key, "sk-or-v1-secret")).not.toBe(sealed);
+  });
+
+  test("tampering fails closed", () => {
+    const key = loadOrCreateKey(mkdtempSync(join(tmpdir(), "helios-")));
+    const sealed = encrypt(key, "x");
+    const bad = sealed.slice(0, -2) + (sealed.endsWith("A") ? "BB" : "AA");
+    expect(() => decrypt(key, bad)).toThrow();
+  });
+
+  test("mask keeps only tail", () => {
+    expect(mask("sk-or-v1-abcdef")).toBe("…cdef");
+    expect(mask("abc")).toBe("…");
+  });
+});