From 1863c613f85082bf7676f99f4a37d5dd1799c9ed Mon Sep 17 00:00:00 2001
From: musingfox <nick12703990@gmail.com>
Date: Sun, 12 Jul 2026 22:03:04 +0800
Subject: [PATCH] fix(tts): honor volume for macOS say via afplay
MIME-Version: 1.0
Content-Type: text/plain; charset=UTF-8
Content-Transfer-Encoding: 8bit

macOS `say` has no volume flag, so the configured volume (e.g.
notification_volume) was silently ignored — notifications always played at
system volume, which is uncontrollable on output devices reporting no
software volume (missing value). Render to a temp AIFF and play through
afplay -v {volume/100} instead, routing macOS TTS through the same afplay
choke point as every other provider (also drives the avatar mouth-flap).

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
---
 src/tts/macos.rs | 46 ++++++++++++++++++++++++++++++++++++++++++----
 1 file changed, 42 insertions(+), 4 deletions(-)

diff --git a/src/tts/macos.rs b/src/tts/macos.rs
index b6e90f3..724a984 100644
--- a/src/tts/macos.rs
+++ b/src/tts/macos.rs
@@ -1,16 +1,25 @@
 // macOS say command TTS provider
 
+use std::sync::atomic::{AtomicU64, Ordering};
+
 use async_trait::async_trait;
 use tokio::process::Command;
 
 use super::TtsProvider;
 use crate::error::{Result, VoiceError};
 
+// Per-call counter so the temp path is unique even for concurrent calls that
+// share a PID — same collision-safety scheme as audio/normalize.rs.
+static CALL_SEQ: AtomicU64 = AtomicU64::new(0);
+
 /// macOS TTS provider using the built-in `say` command
 pub struct MacOsTtsProvider {
     voice_name: Option<String>,
     rate: u32,
-    #[allow(dead_code)] // macOS say doesn't support volume control
+    // `say` itself has no volume flag, so we render to a file and let afplay
+    // apply `-v {volume/100}` on playback. This also routes macOS TTS through
+    // the same afplay choke point as every other provider (honors the volume
+    // knob on output devices with no software system volume, drives the avatar).
     volume: u32,
 }
 
@@ -42,12 +51,24 @@ impl TtsProvider for MacOsTtsProvider {
         }
 
         tracing::info!(
-            "Speaking with macOS say: voice={:?}, rate={}",
+            "Speaking with macOS say: voice={:?}, rate={}, volume={}",
             self.voice_name,
-            self.rate
+            self.rate,
+            self.volume
         );
 
+        // Render to a temp AIFF, then play via afplay so the volume knob applies.
+        // Qualify by PID + per-call counter so concurrent invocations (rapid
+        // `sumvox say` calls that don't hold the hook queue lock, or across
+        // processes) never clobber each other's file.
+        let aiff_path = std::env::temp_dir().join(format!(
+            "sumvox_macos_{}_{}.aiff",
+            std::process::id(),
+            CALL_SEQ.fetch_add(1, Ordering::Relaxed)
+        ));
+
         let mut cmd = Command::new("say");
+        cmd.arg("-o").arg(&aiff_path);
 
         // Only add -v argument if voice is specified and not empty
         if let Some(ref voice) = self.voice_name {
@@ -58,17 +79,24 @@ impl TtsProvider for MacOsTtsProvider {
 
         cmd.arg("-r").arg(self.rate.to_string()).arg(text);
 
-        // Blocking: wait for completion
+        // Blocking: wait for synthesis to finish
         let output = cmd
             .output()
             .await
             .map_err(|e| VoiceError::Voice(format!("Say command failed: {}", e)))?;
 
         if !output.status.success() {
+            // `say` may have left a partial file behind before failing.
+            let _ = std::fs::remove_file(&aiff_path);
             let stderr = String::from_utf8_lossy(&output.stderr);
             return Err(VoiceError::Voice(format!("Say command failed: {}", stderr)));
         }
 
+        // Play with afplay -v; clean up on every path (including playback error).
+        let result = crate::audio::afplay::run_afplay(&aiff_path, self.volume);
+        let _ = std::fs::remove_file(&aiff_path);
+        result?;
+
         tracing::debug!("Voice playback completed (blocking)");
 
         Ok(true)
@@ -120,4 +148,14 @@ mod tests {
         let result = provider.speak("   ").await.unwrap();
         assert!(!result);
     }
+
+    // Exercises the full render-to-file + afplay path at a low volume; fails if
+    // `say -o` or the afplay handoff breaks. Uses volume 1 to stay near-silent.
+    #[cfg(target_os = "macos")]
+    #[tokio::test]
+    async fn test_speak_renders_and_plays() {
+        let provider = MacOsTtsProvider::new(None, 300, 1);
+        let result = provider.speak("test").await.unwrap();
+        assert!(result);
+    }
 }