fix(mac): use single-file EXE instead of BUNDLE for macOS build

PyInstaller's BUNDLE step claimed 'completed successfully' but produced
an empty directory (dist/PanelAgent with no .app structure) — a known
flakiness with BUNDLE on macOS-14 runners. Switching to the same single-
file EXE approach as Windows (exclude_binaries=False, no BUNDLE call)
produces a working dist/PanelAgent Unix executable directly.

UX trade-off: users run it from Terminal (or double-click in Finder,
which opens Terminal) rather than a dock-icon .app. Same launcher, same
~/.panelagent data dir. The release zips it as PanelAgent-mac-arm64.zip.

Workflow: look for dist/PanelAgent (file) not *.app (dir); smoke test
chmods +x before launching; zip uses ditto to preserve the exec bit.

Author: FlowCyt Dev

.github/workflows/build-desktop.yml

@@ -149,23 +149,20 @@ jobs:
           npm run build
           test -f out/index.html || { echo "next build did not produce out/index.html"; exit 1; }
 
-      - name: Build .app
+      - name: Build macOS binary
         run: |
           python -m PyInstaller panelagent-mac.spec --noconfirm --clean
           echo "=== dist/ contents ==="
           ls -la dist/
-          # Locate the produced .app (exact name may vary by PyInstaller version).
-          app_path=$(find dist -maxdepth 1 -name "*.app" -type d | head -1)
-          echo "Found app: ${app_path:-<none>}"
-          test -n "$app_path" || { echo "No .app produced under dist/"; exit 1; }
-          echo "APP_PATH=$app_path" >> "$GITHUB_ENV"
-          echo "APP_NAME=$(basename "$app_path")" >> "$GITHUB_ENV"
-
-      - name: Smoke test (launch app + poll health + dump log + kill)
+          test -f dist/PanelAgent || { echo "PyInstaller did not produce dist/PanelAgent"; exit 1; }
+          echo "APP_PATH=dist/PanelAgent" >> "$GITHUB_ENV"
+
+      - name: Smoke test (launch binary + poll health + dump log + kill)
         continue-on-error: true
         run: |
-          exe="${APP_PATH}/Contents/MacOS/${APP_NAME%.app}"
+          exe="${APP_PATH}"
           echo "Launching $exe..."
+          chmod +x "$exe"
           "$exe" &
           pid=$!
           ok=false
@@ -194,14 +191,15 @@ jobs:
             echo "::warning::Smoke test could not reach health endpoint within 120s. The .app will still be uploaded."
           fi
 
-      - name: Zip .app for upload
+      - name: Zip binary for upload
         run: |
           cd dist
-          # ditto preserves macOS metadata and permissions better than zip.
-          ditto -c -k --keepParent "${APP_NAME}" PanelAgent-mac-arm64.zip
+          # ditto preserves macOS permissions (executable bit) better than zip.
+          ditto -c -k --keepParent PanelAgent PanelAgent-mac-arm64.zip
           test -f PanelAgent-mac-arm64.zip
+          ls -la PanelAgent-mac-arm64.zip
 
-      - name: Upload .app zip to the release
+      - name: Upload macOS zip to the release
         uses: softprops/action-gh-release@v2
         with:
           tag_name: ${{ github.ref_name }}

panelagent-mac.spec

@@ -84,35 +84,25 @@ pyz = PYZ(a.pure, a.zipped_data, cipher=block_cipher)
 exe = EXE(
     pyz,
     a.scripts,
+    a.binaries,
+    a.zipfiles,
+    a.datas,
     [],
-    exclude_binaries=True,
     name="PanelAgent",
     debug=False,
     bootloader_ignore_signals=False,
     strip=False,
     upx=False,  # UPX is unreliable on macOS arm64
-    console=False,  # GUI app: no terminal window (logs go to ~/.panelagent/launcher.log)
+    console=True,  # macOS: run as a terminal app so users see startup output;
+                   # logs also go to ~/.panelagent/launcher.log
     disable_windowed_traceback=False,
     argv_emulation=False,
     target_arch="arm64",
 )
 
-app = BUNDLE(
-    exe,
-    a.binaries,
-    a.zipfiles,
-    a.datas,
-    name="PanelAgent",
-    info_plist={
-        "CFBundleDisplayName": "PanelAgent",
-        "CFBundleShortVersionString": "1.0.0",
-        "CFBundleVersion": "1",
-        "CFBundleIdentifier": "com.panelagent.app",
-        "NSHighResolutionCapable": True,
-        "LSMinimumSystemVersion": "12.0",
-        # Allow the bundled Python to run without a terminal; suppress the
-        # dock icon flicker on launch.
-        "LSUIElement": False,
-    },
-    # icon_filename="scripts/panelagent.icns",  # add an icns if available
-)
+# NOTE: A proper .app bundle (BUNDLE) is desirable for the dock-icon UX, but
+# PyInstaller's BUNDLE step produced an empty directory in CI (the .app
+# wasn't materialized). Falling back to a single-file Unix executable — same
+# launcher, same UX as the Windows exe. The release zips this as
+# PanelAgent-mac-arm64. Users run it from Terminal or via a wrapper.
+