fix(docs): start dev server without Kumo build

[nandanmen]

Summary

• defer loading the built theme-generator config until the production virtual module is requested
• let Astro load the docs Vite plugin before @cloudflare/kumo has a dist directory
• alias the separate Kumo code entry points to source during development so dependency optimization also works on a clean checkout

Testing

• vp lint src/lib/vite-plugin-kumo-colors.ts src/lib/vite-plugin-kumo-hmr.ts

• started Astro dev with packages/kumo/dist absent

• verified GET / returned HTTP 200 without unresolved-import errors

• Reviews

• bonk has reviewed the change

• automated review not possible because: no automated reviewer was available before opening this PR

• Tests

• Tests included/updated

• Automated tests not possible - manual testing has been completed as follows: started Astro dev without Kumo build output and verified the home page returned HTTP 200

• Additional testing not necessary because: not applicable

[pkg-pr-new]

npm i https://pkg.pr.new/@cloudflare/kumo@804

commit: c9c6256

[ask-bonk]

LGTM!

Review notes

• Confirmed the review target is PR fix(docs): start dev server without Kumo build #804. I’m inspecting the package guidance, full changed modules, PR diff, and existing review feedback before assessing the clean-checkout dev-server behavior.
• The diff contains the intended lazy production import and two new code-entry aliases. Existing PR reviews and inline comments are empty. I’m now checking all docs-side Kumo import paths and the package export/source layout to identify aliases that would still require dist on a clean checkout.
• Package exports and source entry points match the new aliases, and the docs config installs the resolver before Tailwind. The registry plugin already reads source-side registry files. The environment lacks both pnpm and shell rg, so I cannot run the proposed lint command or start Astro here; I’m completing static resolution checks instead.
• Static resolution checks are complete: all runtime docs imports use aliases already handled by the plugin, with the newly added @cloudflare/kumo/code entry point covering the clean-checkout dependency optimization path. The PR changes only the two declared modules, git diff --check passed, and no published feedback duplicates a finding.

github run

[github-actions]

📐 Bundle Size

Consumer fixtures bundled against packages/kumo/dist (peers external, minified ESM).

Fixture	Raw	Gzip	Brotli
Button (root)	174.6 KB	49.9 KB	43.1 KB
Button (components/button)	174.5 KB	49.9 KB	43.1 KB
Button + Dialog + Select (root)	299.5 KB	85.8 KB	71.9 KB
Button + Dialog + Select (component subpaths)	299.5 KB	85.9 KB	71.9 KB
Chart (root)	247.0 KB	71.1 KB	60.9 KB
Chart (components/chart)	246.9 KB	71.1 KB	60.9 KB
Badge (components/badge)	44.7 KB	11.7 KB	10.0 KB
Flow (components/flow)	208.9 KB	58.3 KB	50.5 KB
Button (primitives/button)	12.2 KB	4.4 KB	3.9 KB
Primitives barrel	635.8 KB	176.9 KB	139.3 KB
Code highlighting (code)	2.08 MB	467.9 KB	349.1 KB

npm tarball: 540 files, 1.49 MB packed, 6.91 MB unpacked.

⚠️ 23 flagged files in tarball (tests / raw scripts)

• dist/blocks-source/resource-list/resource-list.test.tsx
• scripts/component-registry/cache.ts
• scripts/component-registry/discovery.ts
• scripts/component-registry/example-cleanup.ts
• scripts/component-registry/index.test.ts
• scripts/component-registry/index.ts
• scripts/component-registry/markdown-generator.ts
• scripts/component-registry/metadata.ts
• scripts/component-registry/props-filter.ts
• scripts/component-registry/schema-generator.ts
• scripts/component-registry/sub-components.ts
• scripts/component-registry/types.ts
• scripts/component-registry/utils.ts
• scripts/component-registry/variant-parser.ts
• scripts/css-build.ts
• scripts/generate-globe-land-mask.mjs
• scripts/generate-primitives.ts
• scripts/theme-generator/config.ts
• scripts/theme-generator/generate-css.test.ts
• scripts/theme-generator/generate-css.ts
• scripts/theme-generator/index.ts
• scripts/theme-generator/migrate.ts
• scripts/theme-generator/types.ts

Report-only: no size thresholds are enforced yet.

Commit: c9c6256b

[github-actions]

Visual contracts

Linux Chromium references exercised by the PR's visual-contracts job.

1 curated contract

truncating text trigger

[cloudflare-workers-and-pages]

🚀 Deploying Preview to Cloudflare 🚀

Preview URL: https://nanda-fix-theme-config-dev-import-kumo-docs.design-engineering.workers.dev (commit c9c6256)

This URL reflects your latest Preview deployment

Preview Deployments by commit

Status	Deployment URL	Commit	Updated (UTC)	See this deployment's details
Build: Success ✅ Deployment: Success ✅ View logs ↗	https://adb53844-kumo-docs.design-engineering.workers.dev	c9c6256	2026-09-15T19:15:09.288Z	Visit the dashboard ↗
Build: Failed ❌ View logs ↗		aa7bdba	2026-09-15T18:25:29.739Z	View logs ↗

[github-actions]

Visual Regression Report — 2 changed, 0 unchanged

2 screenshot(s) with visual changes:

Dialog (Open)

22,838,414 px (93.68%) changed

Before	After	Diff

Select (Open)

29,360,728 px (94.6%) changed

Before	After	Diff

---

Generated by Kumo Visual Regression