Serve lossless WOFF2 browser fonts outside blocking stylesheets

build.ts

@@ -12,7 +12,7 @@ const result = await Bun.build({
   minify: true,
   splitting: true,
   target: "bun",
-  external: ["@napi-rs/canvas"],
+  external: ["@napi-rs/canvas", "/fonts/browser/*"],
   sourcemap: "linked",
   define: {
     "process.env.NODE_ENV": JSON.stringify("production"),
@@ -31,3 +31,8 @@ await mkdir(path.join(outdir, "fonts"), { recursive: true });
 for (const file of ["InstrumentSerif-Regular.ttf", "NotoSans-Regular.ttf", "NotoSans-Medium.ttf", "NotoSans-SemiBold.ttf"]) {
   await copyFile(`src/assets/fonts/${file}`, path.join(outdir, "fonts", file));
 }
+
+await mkdir(path.join(outdir, "fonts/browser"), { recursive: true });
+for (const file of ["InstrumentSerif-Regular", "InstrumentSerif-Italic", "NotoSans-Regular", "NotoSans-Medium", "NotoSans-SemiBold"]) {
+  await copyFile(`src/assets/fonts/${file}.woff2`, path.join(outdir, `fonts/browser/${file}.woff2`));
+}

bunfig.toml

@@ -3,5 +3,5 @@
 env = false
 
 [serve.static]
-plugins = ["bun-plugin-tailwind"]
+plugins = ["bun-plugin-tailwind", "./scripts/browser-fonts-plugin.ts"]
 env = "BUN_PUBLIC_*"

scripts/browser-fonts-plugin.ts

@@ -0,0 +1,9 @@
+import type { BunPlugin } from "bun";
+
+/** Match the production bundler's external font URLs in the HTML dev server. */
+export default {
+  name: "external-browser-fonts",
+  setup(build) {
+    build.onResolve({ filter: /^\/fonts\/browser\// }, args => ({ path: args.path, external: true }));
+  },
+} satisfies BunPlugin;

scripts/dashboard-preview.ts

@@ -1,3 +1,4 @@
+import { browserFont } from "../src/browser-fonts";
 // Isolated browser QA server. Never opens or changes the user's database.
 import { sendDueReminders } from "../src/reminders/worker";
 import type { DiscordFetch } from "../src/sharing/routes";
@@ -55,6 +56,7 @@ const server = Bun.serve({
   hostname: "127.0.0.1",
   port,
   routes: {
+    "/fonts/browser/*": browserFont,
     "/__preview/reminder": () => new Response(reminderMessage ?? "No reminder sent"),
     "/__preview/shared-image": () => sharingPreview && sharedImage ? new Response(sharedImage) : new Response(null, { status: 404 }),
     "/__preview/login": () =>

src/assets/fonts/README.md

@@ -12,3 +12,24 @@ Downloaded September 7, 2026. The files are versioned in this repository and cop
 into the production image. Browser and native canvas renderers use the alias
 `Mina Sans`; no system sans-serif font is selected for card text. The native font
 loader fails startup if a required font cannot be registered.
+
+Browser WOFF2 copies are lossless conversions of these exact TTF files using
+FontTools with Brotli; no subsetting is applied. All glyphs and Unicode mappings
+are retained (3,748 glyphs for each Noto Sans weight, 377 for each Instrument
+Serif style). Native canvas keeps using the original TTFs. CSS uses separately
+cacheable `/fonts/browser/*.woff2` URLs so font bytes do not block CSS parsing.
+
+Regenerate with `uv run --with fonttools --with brotli python`:
+
+```python
+from pathlib import Path
+from fontTools.ttLib import TTFont
+for path in Path("src/assets/fonts").glob("*.ttf"):
+    font = TTFont(path)
+    cmap, glyphs = font.getBestCmap(), font.getGlyphOrder()
+    font.flavor = "woff2"
+    font.save(path.with_suffix(".woff2"))
+    restored = TTFont(path.with_suffix(".woff2"))
+    assert restored.getBestCmap() == cmap
+    assert restored.getGlyphOrder() == glyphs
+```

src/browser-fonts.test.ts

@@ -0,0 +1,14 @@
+import { expect, test } from "bun:test";
+import { browserFont } from "./browser-fonts";
+test("browser fonts are external WOFF2 files with conditional caching and a fixed allowlist", async () => {
+  const url = "http://localhost/fonts/browser/InstrumentSerif-Regular.woff2";
+  const response = browserFont(new Request(url));
+  expect(response.status).toBe(200);
+  expect(response.headers.get("Content-Type")).toBe("font/woff2");
+  const bytes = new Uint8Array(await response.arrayBuffer());
+  expect(new TextDecoder().decode(bytes.slice(0, 4))).toBe("wOF2");
+  expect(browserFont(new Request(url, { headers: { "If-None-Match": response.headers.get("ETag")! } })).status).toBe(304);
+  expect(browserFont(new Request("http://localhost/fonts/browser/.env")).status).toBe(404);
+  expect(browserFont(new Request("http://localhost/fonts/browser/%2e%2e%2f.env")).status).toBe(404);
+  expect(await browserFont(new Request(url, { method: "HEAD" })).text()).toBe("");
+});

src/browser-fonts.ts

@@ -0,0 +1,18 @@
+import path from "node:path";
+
+const names = ["InstrumentSerif-Regular", "InstrumentSerif-Italic", "NotoSans-Regular", "NotoSans-Medium", "NotoSans-SemiBold"];
+const directory = process.env.NODE_ENV === "production" ? "fonts/browser" : "src/assets/fonts";
+const fonts: Map<string, { file: ReturnType<typeof Bun.file>; etag: string }> = new Map(names.map(name => {
+  const file = Bun.file(path.resolve(directory, `${name}.woff2`));
+  return [`${name}.woff2`, { file, etag: `"${file.size.toString(16)}-${file.lastModified.toString(16)}"` }] as const;
+}));
+
+/** Explicit allowlist: font URLs never grant access to other filesystem paths. */
+export function browserFont(request: Request): Response {
+  const name = new URL(request.url).pathname.slice("/fonts/browser/".length);
+  const font = fonts.get(name);
+  if (!font || !["GET", "HEAD"].includes(request.method)) return new Response(null, { status: 404 });
+  const headers = { "Content-Type": "font/woff2", "Cache-Control": "public, max-age=3600", ETag: font.etag };
+  if (request.headers.get("If-None-Match") === font.etag) return new Response(null, { status: 304, headers });
+  return new Response(request.method === "HEAD" ? null : font.file, { headers });
+}

src/index.ts

@@ -1,3 +1,4 @@
+import { browserFont } from "./browser-fonts";
 import { startReminders } from "./reminders/worker";
 import { backupConfig, startBackups } from "./ops/backups";
 import { databasePath } from "./db/config";
@@ -28,6 +29,7 @@ const server = Bun.serve({
   hostname: process.env.HOST ?? "127.0.0.1",
   port: Number(process.env.PORT ?? 3000),
   routes: {
+    "/fonts/browser/*": browserFont,
     "/api": req => app.fetch(req),
     "/api/*": req => app.fetch(req),
     "/*": index,

styles/design-system.css

@@ -1,34 +1,34 @@
 @font-face {
   font-family: "Mina Sans";
-  src: url("../src/assets/fonts/NotoSans-Regular.ttf") format("truetype");
+  src: url("/fonts/browser/NotoSans-Regular.woff2") format("woff2");
   font-style: normal;
   font-weight: 400;
   font-display: swap;
 }
 @font-face {
   font-family: "Mina Sans";
-  src: url("../src/assets/fonts/NotoSans-Medium.ttf") format("truetype");
+  src: url("/fonts/browser/NotoSans-Medium.woff2") format("woff2");
   font-style: normal;
   font-weight: 500;
   font-display: swap;
 }
 @font-face {
   font-family: "Mina Sans";
-  src: url("../src/assets/fonts/NotoSans-SemiBold.ttf") format("truetype");
+  src: url("/fonts/browser/NotoSans-SemiBold.woff2") format("woff2");
   font-style: normal;
   font-weight: 600;
   font-display: swap;
 }
 @font-face {
   font-family: "Instrument Serif";
-  src: url("../src/assets/fonts/InstrumentSerif-Regular.ttf") format("truetype");
+  src: url("/fonts/browser/InstrumentSerif-Regular.woff2") format("woff2");
   font-weight: 400;
   font-style: normal;
   font-display: swap;
 }
 @font-face {
   font-family: "Instrument Serif";
-  src: url("../src/assets/fonts/InstrumentSerif-Italic.ttf") format("truetype");
+  src: url("/fonts/browser/InstrumentSerif-Italic.woff2") format("woff2");
   font-weight: 400;
   font-style: italic;
   font-display: swap;