feat(cli): support boolean and number casting for env vars in settings.json (#26118)

packages/cli/src/config/settings.ts

@@ -673,7 +673,9 @@ function _doLoadSettings(workspaceDir: string): LoadedSettings {
   const storage = new Storage(workspaceDir);
   const workspaceSettingsPath = storage.getWorkspaceSettingsPath();
 
-  const load = (filePath: string): { settings: Settings; rawJson?: string } => {
+  const load = (
+    filePath: string,
+  ): { settings: Settings; rawSettings: Settings; rawJson?: string } => {
     try {
       if (fs.existsSync(filePath)) {
         const content = fs.readFileSync(filePath, 'utf-8');
@@ -689,14 +691,19 @@ function _doLoadSettings(workspaceDir: string): LoadedSettings {
             path: filePath,
             severity: 'error',
           });
-          return { settings: {} };
+          return { settings: {}, rawSettings: {} };
         }
 
         // eslint-disable-next-line @typescript-eslint/no-unsafe-type-assertion
         const settingsObject = rawSettings as Record<string, unknown>;
 
-        // Validate settings structure with Zod
-        const validationResult = validateSettings(settingsObject);
+        // Expand environment variables
+        const expandedSettings = resolveEnvVarsInObject(
+          settingsObject as Settings,
+        );
+
+        // Validate settings structure with Zod after environment variable expansion
+        const validationResult = validateSettings(expandedSettings);
         if (!validationResult.success && validationResult.error) {
           const errorMessage = formatValidationError(
             validationResult.error,
@@ -707,9 +714,22 @@ function _doLoadSettings(workspaceDir: string): LoadedSettings {
             path: filePath,
             severity: 'warning',
           });
+          return {
+            settings: expandedSettings,
+            rawSettings: settingsObject as Settings,
+            rawJson: content,
+          };
         }
 
-        return { settings: settingsObject as Settings, rawJson: content };
+        // Return the successfully cast and validated data
+        return {
+          // Since we've successfully validated expandedSettings against settingsZodSchema,
+          // it's safe to cast the resulting data to the Settings type.
+          // eslint-disable-next-line @typescript-eslint/no-unsafe-type-assertion
+          settings: (validationResult.data as Settings) ?? expandedSettings,
+          rawSettings: settingsObject as Settings,
+          rawJson: content,
+        };
       }
     } catch (error: unknown) {
       settingsErrors.push({
@@ -718,33 +738,40 @@ function _doLoadSettings(workspaceDir: string): LoadedSettings {
         severity: 'error',
       });
     }
-    return { settings: {} };
+    return { settings: {}, rawSettings: {} };
   };
 
   const systemResult = load(systemSettingsPath);
   const systemDefaultsResult = load(systemDefaultsPath);
   const userResult = load(USER_SETTINGS_PATH);
 
-  let workspaceResult: { settings: Settings; rawJson?: string } = {
+  let workspaceResult: {
+    settings: Settings;
+    rawSettings: Settings;
+    rawJson?: string;
+  } = {
     settings: {} as Settings,
+    rawSettings: {} as Settings,
     rawJson: undefined,
   };
   if (!storage.isWorkspaceHomeDir()) {
     workspaceResult = load(workspaceSettingsPath);
   }
 
-  const systemOriginalSettings = structuredClone(systemResult.settings);
+  const systemOriginalSettings = structuredClone(systemResult.rawSettings);
   const systemDefaultsOriginalSettings = structuredClone(
-    systemDefaultsResult.settings,
+    systemDefaultsResult.rawSettings,
+  );
+  const userOriginalSettings = structuredClone(userResult.rawSettings);
+  const workspaceOriginalSettings = structuredClone(
+    workspaceResult.rawSettings,
   );
-  const userOriginalSettings = structuredClone(userResult.settings);
-  const workspaceOriginalSettings = structuredClone(workspaceResult.settings);
 
-  // Environment variables for runtime use
-  systemSettings = resolveEnvVarsInObject(systemResult.settings);
-  systemDefaultSettings = resolveEnvVarsInObject(systemDefaultsResult.settings);
-  userSettings = resolveEnvVarsInObject(userResult.settings);
-  workspaceSettings = resolveEnvVarsInObject(workspaceResult.settings);
+  // Environment variables for runtime use are already resolved and validated in load()
+  systemSettings = systemResult.settings;
+  systemDefaultSettings = systemDefaultsResult.settings;
+  userSettings = userResult.settings;
+  workspaceSettings = workspaceResult.settings;
 
   // Support legacy theme names
   if (userSettings.ui?.theme === 'VS') {