fix: resolve analytics data gaps and resize validation failures

- Fix resize 20% failure rate: add Zod refine requiring at least one
  dimension, enforce integer/max constraints, clamp percentage scaling
  to minimum 1px, and guard against missing metadata in withoutEnlargement
- Fix PostHog init race condition: move consent check before async import
  so frontend events (search, pageview) are no longer silently dropped
- Fix identify() passing nested $set/$set_once wrappers instead of flat
  properties, so version person property now appears on PostHog profiles
- Add error_code and error_message to failed tool_used analytics events
  for debugging tool failures from PostHog

apps/api/src/routes/tool-factory.ts

@@ -436,6 +436,8 @@ export function createToolRoute<T>(app: FastifyInstance, config: ToolRouteConfig
           duration_ms: Date.now() - startTime,
           category: TOOLS.find((t) => t.id === config.toolId)?.category ?? "unknown",
           is_ai_tool: getBundleForTool(config.toolId) !== null,
+          error_code: err instanceof Error ? err.constructor.name : "UnknownError",
+          error_message: message.slice(0, 200),
         });
         return reply.status(422).send({
           error: "Processing failed",

apps/api/src/routes/tools/resize.ts

@@ -5,13 +5,19 @@ import { z } from "zod";
 import { resolveOutputFormat } from "../../lib/output-format.js";
 import { createToolRoute } from "../tool-factory.js";
 
-const settingsSchema = z.object({
-  width: z.number().positive().optional(),
-  height: z.number().positive().optional(),
-  fit: z.enum(["contain", "cover", "fill", "inside", "outside"]).default("contain"),
-  withoutEnlargement: z.boolean().default(false),
-  percentage: z.number().positive().optional(),
-});
+const MAX_DIMENSION = 16383;
+
+const settingsSchema = z
+  .object({
+    width: z.number().int().positive().max(MAX_DIMENSION).optional(),
+    height: z.number().int().positive().max(MAX_DIMENSION).optional(),
+    fit: z.enum(["contain", "cover", "fill", "inside", "outside"]).default("contain"),
+    withoutEnlargement: z.boolean().default(false),
+    percentage: z.number().positive().optional(),
+  })
+  .refine((s) => s.width !== undefined || s.height !== undefined || s.percentage !== undefined, {
+    message: "At least one of width, height, or percentage is required",
+  });
 
 export function registerResize(app: FastifyInstance) {
   createToolRoute(app, {

apps/web/src/App.tsx

@@ -5,7 +5,7 @@ import { Toaster } from "sonner";
 import { ConnectionMonitor } from "./components/common/connection-monitor";
 import { KeyboardShortcutProvider } from "./components/common/keyboard-shortcut-provider";
 import { useAuth } from "./hooks/use-auth";
-import { identify, initAnalytics } from "./lib/analytics";
+import { identify, initAnalytics, setAnalyticsConsent } from "./lib/analytics";
 import { useAnalyticsStore } from "./stores/analytics-store";
 
 // Lazy-load all pages so each page's JS (and its icons/deps) is only
@@ -190,11 +190,13 @@ export function App() {
     )
       return;
     void (async () => {
+      setAnalyticsConsent(true);
       await initAnalytics(analyticsConfig);
-      identify(analyticsConfig.instanceId, {
-        $set: { version: APP_VERSION },
-        $set_once: { instance_id: analyticsConfig.instanceId },
-      });
+      identify(
+        analyticsConfig.instanceId,
+        { version: APP_VERSION },
+        { instance_id: analyticsConfig.instanceId },
+      );
     })();
   }, [analyticsConfigLoaded, analyticsConfig, analyticsConsent.analyticsEnabled]);
 

apps/web/src/lib/analytics.ts

@@ -15,13 +15,10 @@ function scrubString(str: string): string {
 }
 
 export async function initAnalytics(config: AnalyticsConfig): Promise<void> {
-  if (initialized || !config.enabled) return;
+  if (initialized || !config.enabled || !consentGranted) return;
 
   try {
     const posthogJs = (await import("posthog-js")).default;
-    if (!consentGranted) {
-      return;
-    }
     posthog =
       posthogJs.init(config.posthogApiKey, {
         api_host: config.posthogHost,
@@ -45,9 +42,6 @@ export async function initAnalytics(config: AnalyticsConfig): Promise<void> {
   try {
     if (config.sentryDsn) {
       const Sentry = await import("@sentry/react");
-      if (!consentGranted) {
-        return;
-      }
       Sentry.init({
         dsn: config.sentryDsn,
         sendDefaultPii: false,
@@ -110,10 +104,14 @@ export function setAnalyticsConsent(enabled: boolean): void {
   }
 }
 
-export function identify(instanceId: string, properties: Record<string, unknown>): void {
+export function identify(
+  instanceId: string,
+  properties: Record<string, unknown>,
+  propertiesSetOnce?: Record<string, unknown>,
+): void {
   if (!posthog || !consentGranted) return;
   try {
-    posthog.identify(instanceId, properties);
+    posthog.identify(instanceId, properties, propertiesSetOnce);
   } catch {
     // never throw
   }

packages/image-engine/src/operations/resize.ts

@@ -8,10 +8,11 @@ export async function resize(image: Sharp, options: ResizeOptions): Promise<Shar
       throw new Error("Resize percentage must be greater than 0");
     }
     const metadata = await image.metadata();
-    const currentWidth = metadata.width ?? 0;
-    const currentHeight = metadata.height ?? 0;
-    width = Math.round(currentWidth * (percentage / 100));
-    height = Math.round(currentHeight * (percentage / 100));
+    if (!metadata.width || !metadata.height) {
+      throw new Error("Cannot determine image dimensions for percentage resize");
+    }
+    width = Math.max(1, Math.round(metadata.width * (percentage / 100)));
+    height = Math.max(1, Math.round(metadata.height * (percentage / 100)));
   }
 
   if (width !== undefined && width <= 0) {
@@ -26,10 +27,11 @@ export async function resize(image: Sharp, options: ResizeOptions): Promise<Shar
 
   if (withoutEnlargement) {
     const meta = await image.metadata();
-    const curW = meta.width ?? 0;
-    const curH = meta.height ?? 0;
-    if (width !== undefined && width > curW) width = curW;
-    if (height !== undefined && height > curH) height = curH;
+    if (!meta.width || !meta.height) {
+      throw new Error("Cannot determine image dimensions for resize clamping");
+    }
+    if (width !== undefined && width > meta.width) width = meta.width;
+    if (height !== undefined && height > meta.height) height = meta.height;
   }
 
   return image.resize({

packages/shared/src/analytics/events.ts

@@ -14,6 +14,8 @@ export interface ToolUsedProperties {
   category: string;
   is_ai_tool: boolean;
   params?: Record<string, string | number | boolean>;
+  error_code?: string;
+  error_message?: string;
 }
 
 export interface SearchProperties {

tests/integration/api.test.ts

@@ -851,7 +851,7 @@ describe("Tool processing", () => {
       expect(JSON.parse(res.body).error).toMatch(/json/i);
     });
 
-    it("returns 422 with empty settings (no dimensions given)", async () => {
+    it("returns 400 with empty settings (no dimensions given)", async () => {
       const { body: payload, contentType } = createMultipartPayload([
         { name: "file", filename: "defaults.png", contentType: "image/png", content: PNG_200x150 },
         { name: "settings", content: "{}" },
@@ -866,9 +866,7 @@ describe("Tool processing", () => {
         },
         payload,
       });
-      // All resize fields are optional at the Zod level, but Sharp needs at
-      // least width or height — so processing fails with 422
-      expect(res.statusCode).toBe(422);
+      expect(res.statusCode).toBe(400);
     });
 
     it("download URL from resize result is accessible", async () => {

tests/unit/image-engine/operations.test.ts

@@ -229,13 +229,12 @@ describe("resize", () => {
     expect(meta.width).toBeGreaterThanOrEqual(0);
   });
 
-  it("percentage=1 on 1x1 yields width rounded to 0 and triggers error", async () => {
-    // 1 * 1/100 = 0.01 -> Math.round -> 0
-    // Then the check width <= 0 should throw
+  it("percentage=1 on 1x1 clamps to 1px minimum", async () => {
     const img = sharp(png1x1);
-    await expect(resize(img, { percentage: 1 })).rejects.toThrow(
-      "Resize width must be greater than 0",
-    );
+    const result = await resize(img, { percentage: 1 });
+    const meta = await result.toBuffer().then((b) => sharp(b).metadata());
+    expect(meta.width).toBe(1);
+    expect(meta.height).toBe(1);
   });
 });
 

tests/unit/web/analytics.test.ts

@@ -319,7 +319,7 @@ describe("analytics lib", () => {
       setAnalyticsConsent(true);
       await initAnalytics(enabledConfig);
       identify("inst-1", { version: "1.0" });
-      expect(mockIdentify).toHaveBeenCalledWith("inst-1", { version: "1.0" });
+      expect(mockIdentify).toHaveBeenCalledWith("inst-1", { version: "1.0" }, undefined);
     });
 
     it("does not throw before initialization", () => {
@@ -382,7 +382,7 @@ describe("analytics lib", () => {
       track("phase1_event");
       expect(mockCapture).toHaveBeenCalledWith("phase1_event", undefined);
       identify("inst-1", { phase: 1 });
-      expect(mockIdentify).toHaveBeenCalledWith("inst-1", { phase: 1 });
+      expect(mockIdentify).toHaveBeenCalledWith("inst-1", { phase: 1 }, undefined);
 
       // Phase 2: Revoke consent mid-session
       setAnalyticsConsent(false);