packages/iios-service/package.json

@@ -28,6 +28,7 @@
     "ioredis": "^5.11.1",
     "jsonwebtoken": "^9.0.3",
     "jwks-rsa": "^4.1.0",
+    "nodemailer": "^9.0.3",
     "prisma": "^6.2.1",
     "reflect-metadata": "^0.2.2",
     "rxjs": "^7.8.2",
@@ -41,6 +42,7 @@
     "@types/express": "^5.0.6",
     "@types/jsonwebtoken": "^9.0.10",
     "@types/node": "^26.0.1",
+    "@types/nodemailer": "^8.0.1",
     "@types/web-push": "^3.6.4",
     "socket.io-client": "^4.8.3",
     "typescript": "^5.7.3"

packages/iios-service/src/capability/capability.registry.spec.ts

@@ -0,0 +1,34 @@
+import { describe, it, expect, afterEach } from 'vitest';
+import { CapabilityProviderRegistry } from './capability.registry';
+
+// The registry reads env in its constructor, so each case sets env → constructs a fresh registry →
+// asserts → restores env.
+const SMTP_KEYS = ['IIOS_SMTP_HOST', 'IIOS_SMTP_USER', 'IIOS_SMTP_PASS', 'IIOS_PROVIDER_URL_EMAIL'];
+const saved: Record<string, string | undefined> = {};
+function set(env: Record<string, string | undefined>) {
+  for (const k of SMTP_KEYS) { saved[k] = process.env[k]; delete process.env[k]; }
+  for (const [k, v] of Object.entries(env)) if (v != null) process.env[k] = v;
+}
+afterEach(() => { for (const k of SMTP_KEYS) { if (saved[k] == null) delete process.env[k]; else process.env[k] = saved[k]; } });
+
+describe('CapabilityProviderRegistry — EMAIL precedence (SMTP > HTTP > sandbox)', () => {
+  it('binds SMTP for EMAIL when the SMTP env trio is set', () => {
+    set({ IIOS_SMTP_HOST: 'smtp.test', IIOS_SMTP_USER: 'accounts@x', IIOS_SMTP_PASS: 'p' });
+    expect(new CapabilityProviderRegistry().forChannel('EMAIL').name).toBe('smtp');
+  });
+
+  it('binds the HTTP EmailProvider when only IIOS_PROVIDER_URL_EMAIL is set', () => {
+    set({ IIOS_PROVIDER_URL_EMAIL: 'https://relay.test/send' });
+    expect(new CapabilityProviderRegistry().forChannel('EMAIL').name).toBe('email-http');
+  });
+
+  it('SMTP wins over the HTTP relay when both are set', () => {
+    set({ IIOS_SMTP_HOST: 'smtp.test', IIOS_SMTP_USER: 'accounts@x', IIOS_SMTP_PASS: 'p', IIOS_PROVIDER_URL_EMAIL: 'https://relay.test/send' });
+    expect(new CapabilityProviderRegistry().forChannel('EMAIL').name).toBe('smtp');
+  });
+
+  it('falls back to the sandbox when neither is configured', () => {
+    set({});
+    expect(new CapabilityProviderRegistry().forChannel('EMAIL').name).toBe('sandbox');
+  });
+});

packages/iios-service/src/capability/capability.registry.ts

@@ -3,6 +3,7 @@ import type { CapabilityProvider } from '@insignia/iios-contracts';
 import { SandboxProvider } from './sandbox.provider';
 import { HttpProvider } from './http.provider';
 import { EmailProvider } from './email.provider';
+import { SmtpProvider, smtpFallbackFromEnv, smtpIdentityFromEnv } from './smtp.provider';
 
 const DEFAULT_CHANNELS = ['WEBHOOK', 'EMAIL', 'SMS', 'WHATSAPP', 'PORTAL'];
 
@@ -11,6 +12,9 @@ const DEFAULT_CHANNELS = ['WEBHOOK', 'EMAIL', 'SMS', 'WHATSAPP', 'PORTAL'];
  * default; if `IIOS_PROVIDER_URL_<CHANNELTYPE>` is set, a real HttpProvider
  * overrides the sandbox for that channel (the "flip the binding" swap). Unknown
  * channels fail closed — no silent egress path.
+ *
+ * Precedence is registration ORDER (register() does Map.set → last wins). For EMAIL:
+ * sandbox → HTTP EmailProvider (if URL set) → SMTP (if SMTP env set), so SMTP > HTTP > sandbox.
  */
 @Injectable()
 export class CapabilityProviderRegistry {
@@ -24,6 +28,9 @@ export class CapabilityProviderRegistry {
       // EMAIL gets an email-shaped envelope provider; other channels use the generic HTTP one.
       this.register(ch === 'EMAIL' ? new EmailProvider(url) : new HttpProvider(ch, url));
     }
+    // Real SMTP for EMAIL wins over the HTTP relay when configured (registered last).
+    const smtp = smtpIdentityFromEnv();
+    if (smtp) this.register(new SmtpProvider(smtp, smtpFallbackFromEnv() ?? undefined));
   }
 
   register(provider: CapabilityProvider): void {

packages/iios-service/src/capability/smtp.provider.spec.ts

@@ -0,0 +1,90 @@
+import { describe, it, expect } from 'vitest';
+import { SmtpProvider, smtpIdentityFromEnv, smtpFallbackFromEnv, type MailTransport, type SmtpIdentity } from './smtp.provider';
+import type { CapabilityRequest } from '@insignia/iios-contracts';
+
+const ID: SmtpIdentity = { host: 'smtp.test', port: 587, secure: false, user: 'accounts@lynkeduppro.com', pass: 'p', from: 'accounts@lynkeduppro.com' };
+const FB: SmtpIdentity = { ...ID, user: 'ceo@lynkeduppro.com', from: 'Justin <ceo@lynkeduppro.com>' };
+
+const req = (payload: Record<string, unknown>): CapabilityRequest => ({
+  capability: 'channel.send', channelType: 'EMAIL', target: 'dana@acme.com', payload, idempotencyKey: 'k1',
+});
+
+/** A recording transport; optionally throws a given error on send. */
+function stub(opts: { throwErr?: unknown; messageId?: string } = {}) {
+  const calls: Array<{ id: SmtpIdentity; mail: Parameters<MailTransport['sendMail']>[0] }> = [];
+  const make = (id: SmtpIdentity): MailTransport => ({
+    async sendMail(mail) {
+      calls.push({ id, mail });
+      if (opts.throwErr) throw opts.throwErr;
+      return { messageId: opts.messageId ?? '<generated@smtp.test>' };
+    },
+  });
+  return { make, calls };
+}
+
+describe('smtpIdentityFromEnv', () => {
+  const base = { IIOS_SMTP_HOST: 'smtp.test', IIOS_SMTP_USER: 'accounts@x', IIOS_SMTP_PASS: 'p' };
+
+  it('builds the identity from a complete env trio (defaults port 587, secure false)', () => {
+    const id = smtpIdentityFromEnv({ ...base } as NodeJS.ProcessEnv);
+    expect(id).toMatchObject({ host: 'smtp.test', port: 587, secure: false, user: 'accounts@x', from: 'accounts@x' });
+  });
+
+  it('returns null when the trio is incomplete', () => {
+    expect(smtpIdentityFromEnv({ IIOS_SMTP_HOST: 'smtp.test', IIOS_SMTP_USER: 'a@x' } as NodeJS.ProcessEnv)).toBeNull();
+  });
+
+  it('reads the fallback identity, reusing the primary host', () => {
+    const fb = smtpFallbackFromEnv({ ...base, IIOS_SMTP_FALLBACK_USER: 'ceo@x', IIOS_SMTP_FALLBACK_PASS: 'q', IIOS_SMTP_FALLBACK_FROM: 'CEO <ceo@x>' } as NodeJS.ProcessEnv);
+    expect(fb).toMatchObject({ host: 'smtp.test', user: 'ceo@x', from: 'CEO <ceo@x>' });
+  });
+
+  it('returns null fallback when not configured', () => {
+    expect(smtpFallbackFromEnv({ ...base } as NodeJS.ProcessEnv)).toBeNull();
+  });
+});
+
+describe('SmtpProvider.send — envelope', () => {
+  it('maps target + payload into the mail and returns the messageId as providerRef', async () => {
+    const t = stub({ messageId: '<abc@smtp.test>' });
+    const res = await new SmtpProvider(ID, undefined, t.make).send(req({ subject: 'Hi Dana', html: '<p>x</p>', text: 'x' }));
+    expect(res).toMatchObject({ outcome: 'SENT', providerRef: '<abc@smtp.test>' });
+    expect(t.calls[0].mail).toMatchObject({ from: 'accounts@lynkeduppro.com', to: 'dana@acme.com', subject: 'Hi Dana', html: '<p>x</p>', text: 'x' });
+  });
+
+  it('sets In-Reply-To + References headers for a reply', async () => {
+    const t = stub();
+    await new SmtpProvider(ID, undefined, t.make).send(req({ subject: 're', inReplyTo: '<parent@smtp.test>' }));
+    expect(t.calls[0].mail).toMatchObject({ inReplyTo: '<parent@smtp.test>', references: '<parent@smtp.test>' });
+  });
+});
+
+describe('SmtpProvider.send — failure + fallback', () => {
+  it('retries via the fallback identity on a pre-acceptance failure (SENT via fallback)', async () => {
+    // primary throws ECONNREFUSED (server never accepted) → fallback used.
+    const primaryThrows = { make: (id: SmtpIdentity): MailTransport => ({
+      async sendMail(mail) {
+        if (id.user === ID.user) throw Object.assign(new Error('refused'), { code: 'ECONNREFUSED' });
+        return { messageId: '<viaFallback@smtp.test>' };
+      },
+    }) };
+    const res = await new SmtpProvider(ID, FB, primaryThrows.make).send(req({ subject: 'x' }));
+    expect(res.outcome).toBe('SENT');
+    expect(res.providerRef).toBe('fallback:<viaFallback@smtp.test>');
+  });
+
+  it('does NOT retry a post-acceptance failure (avoids double delivery) → FAILED', async () => {
+    // responseCode present = the server already spoke; retrying could double-send.
+    const t = stub({ throwErr: Object.assign(new Error('rejected after data'), { responseCode: 550 }) });
+    const res = await new SmtpProvider(ID, FB, t.make).send(req({ subject: 'x' }));
+    expect(res.outcome).toBe('FAILED');
+    expect(t.calls).toHaveLength(1); // primary only — no fallback attempt
+  });
+
+  it('with no fallback, a failure is FAILED and never throws', async () => {
+    const t = stub({ throwErr: Object.assign(new Error('boom'), { code: 'ETIMEDOUT' }) });
+    const res = await new SmtpProvider(ID, undefined, t.make).send(req({ subject: 'x' }));
+    expect(res.outcome).toBe('FAILED');
+    expect(res.errorCode).toBe('ETIMEDOUT');
+  });
+});

packages/iios-service/src/capability/smtp.provider.ts

@@ -0,0 +1,145 @@
+import { randomUUID } from 'node:crypto';
+import { createTransport } from 'nodemailer';
+import type { CapabilityProvider, CapabilityRequest, ProviderResult } from '@insignia/iios-contracts';
+
+/** One SMTP sending identity (a mailbox + how to reach its server). */
+export interface SmtpIdentity {
+  host: string;
+  port: number;
+  secure: boolean;
+  user: string;
+  pass: string;
+  from: string;
+}
+
+/** The subset of a mail transport this provider needs — lets tests inject a stub (no live server). */
+export interface MailTransport {
+  sendMail(mail: {
+    from: string;
+    to: string;
+    subject?: string;
+    text?: string;
+    html?: string;
+    inReplyTo?: string;
+    references?: string;
+  }): Promise<{ messageId: string; accepted?: unknown[] }>;
+}
+
+const bool = (v: string | undefined): boolean => v === 'true' || v === '1';
+
+/** Build the primary SMTP identity from env, or null if the required trio is incomplete. */
+export function smtpIdentityFromEnv(env: NodeJS.ProcessEnv = process.env): SmtpIdentity | null {
+  return identityFrom(env, '');
+}
+
+/** Build the optional fallback identity (accounts@ → ceo@), or null if not configured. */
+export function smtpFallbackFromEnv(env: NodeJS.ProcessEnv = process.env): SmtpIdentity | null {
+  const fb = identityFrom(env, 'FALLBACK_');
+  if (fb) return fb;
+  // Fallback may reuse the primary host/port and only override the mailbox identity.
+  const host = env.IIOS_SMTP_HOST;
+  const user = env.IIOS_SMTP_FALLBACK_USER;
+  const pass = env.IIOS_SMTP_FALLBACK_PASS;
+  if (!host || !user || !pass) return null;
+  return {
+    host,
+    port: Number(env.IIOS_SMTP_PORT ?? 587),
+    secure: bool(env.IIOS_SMTP_SECURE),
+    user,
+    pass,
+    from: env.IIOS_SMTP_FALLBACK_FROM ?? user,
+  };
+}
+
+function identityFrom(env: NodeJS.ProcessEnv, prefix: string): SmtpIdentity | null {
+  const host = env[`IIOS_SMTP_${prefix}HOST`] ?? (prefix ? undefined : env.IIOS_SMTP_HOST);
+  const user = env[`IIOS_SMTP_${prefix}USER`];
+  const pass = env[`IIOS_SMTP_${prefix}PASS`];
+  if (!host || !user || !pass) return null;
+  return {
+    host,
+    port: Number(env[`IIOS_SMTP_${prefix}PORT`] ?? env.IIOS_SMTP_PORT ?? 587),
+    secure: bool(env[`IIOS_SMTP_${prefix}SECURE`] ?? env.IIOS_SMTP_SECURE),
+    user,
+    pass,
+    from: env[`IIOS_SMTP_${prefix}FROM`] ?? user,
+  };
+}
+
+interface EmailPayload {
+  subject?: string;
+  text?: string;
+  html?: string;
+  inReplyTo?: string;
+}
+
+/**
+ * SMTP egress provider (nodemailer). Bound for EMAIL when the SMTP env trio is set (else the sandbox
+ * stays). A transport failure surfaces as FAILED, never thrown. On a PRE-acceptance failure it retries
+ * once via the fallback identity (accounts@ → ceo@); a post-acceptance failure is NOT retried, so a
+ * message the server already accepted can't be double-delivered.
+ */
+export class SmtpProvider implements CapabilityProvider {
+  readonly name = 'smtp';
+  readonly channelTypes = ['EMAIL'];
+  readonly capabilities = { canSend: true };
+
+  private readonly makeTransport: (id: SmtpIdentity) => MailTransport;
+
+  constructor(
+    private readonly primary: SmtpIdentity,
+    private readonly fallback?: SmtpIdentity,
+    makeTransport?: (id: SmtpIdentity) => MailTransport,
+  ) {
+    this.makeTransport = makeTransport ?? defaultTransport;
+  }
+
+  async send(req: CapabilityRequest): Promise<ProviderResult> {
+    const started = Date.now();
+    const p = (req.payload ?? {}) as EmailPayload;
+
+    const attempt = async (id: SmtpIdentity): Promise<{ messageId: string }> =>
+      this.makeTransport(id).sendMail({
+        from: id.from,
+        to: req.target,
+        subject: p.subject ?? '(no subject)',
+        text: p.text,
+        html: p.html,
+        ...(p.inReplyTo ? { inReplyTo: p.inReplyTo, references: p.inReplyTo } : {}),
+      });
+
+    try {
+      const info = await attempt(this.primary);
+      return { providerRef: info.messageId, outcome: 'SENT', latencyMs: Date.now() - started };
+    } catch (err) {
+      // Retry via the fallback identity ONLY if the primary never got the message accepted.
+      if (this.fallback && isPreAcceptanceFailure(err)) {
+        try {
+          const info = await attempt(this.fallback);
+          return { providerRef: `fallback:${info.messageId}`, outcome: 'SENT', latencyMs: Date.now() - started };
+        } catch (err2) {
+          return { providerRef: `smtp-error-${randomUUID().slice(0, 8)}`, outcome: 'FAILED', errorCode: codeOf(err2), latencyMs: Date.now() - started };
+        }
+      }
+      return { providerRef: `smtp-error-${randomUUID().slice(0, 8)}`, outcome: 'FAILED', errorCode: codeOf(err), latencyMs: Date.now() - started };
+    }
+  }
+}
+
+/** True for connect/auth/timeout errors (server never accepted); false once the server responded 2xx. */
+function isPreAcceptanceFailure(err: unknown): boolean {
+  const e = err as { code?: string; responseCode?: number };
+  const preCodes = ['ECONNECTION', 'ETIMEDOUT', 'ECONNREFUSED', 'EDNS', 'EAUTH', 'ESOCKET', 'EENVELOPE'];
+  if (e.code && preCodes.includes(e.code)) return true;
+  // A responseCode present means the server spoke — treat 5xx after acceptance as terminal (no retry).
+  return e.responseCode == null && e.code == null;
+}
+
+function codeOf(err: unknown): string {
+  const e = err as { code?: string; message?: string };
+  return (e.code ?? e.message ?? 'SMTP_ERROR').slice(0, 60);
+}
+
+function defaultTransport(id: SmtpIdentity): MailTransport {
+  return createTransport({ host: id.host, port: id.port, secure: id.secure, auth: { user: id.user, pass: id.pass } }) as unknown as MailTransport;
+}

pnpm-lock.yaml

@@ -376,6 +376,9 @@ importers:
       jwks-rsa:
         specifier: ^4.1.0
         version: 4.1.0
+      nodemailer:
+        specifier: ^9.0.3
+        version: 9.0.3
       prisma:
         specifier: ^6.2.1
         version: 6.19.3(typescript@5.9.3)
@@ -410,6 +413,9 @@ importers:
       '@types/node':
         specifier: ^26.0.1
         version: 26.0.1
+      '@types/nodemailer':
+        specifier: ^8.0.1
+        version: 8.0.1
       '@types/web-push':
         specifier: ^3.6.4
         version: 3.6.4
@@ -1520,6 +1526,9 @@ packages:
   '@types/node@26.0.1':
     resolution: {integrity: sha512-fc3KiUoBt6kie0N9bIW3E47vZsuaMf0PM2AaUpLCLT0s/LvX1nxAim6Fc049cNxODPpGm6qRAuUOB86SkRuPQw==}
 
+  '@types/nodemailer@8.0.1':
+    resolution: {integrity: sha512-PxpaInm8V1JQDd4j0ds5HfvWQk8JupS1C0Picb96QJsrrRDjBH+DlK7L4ZdNSqNULhiZRQHc40nLVShaGxXAMw==}
+
   '@types/qs@6.15.1':
     resolution: {integrity: sha512-GZHUBZR9hckSUhrxmp1nG6NwdpM9fCunJwyThLW1X3AyHgd9IlHb6VANpQQqDr2o/qQp6McZ3y/IA2rVzKzSbw==}
 
@@ -2545,6 +2554,10 @@ packages:
     resolution: {integrity: sha512-J6l92tKHX6w8Jy5nO1Vuc01NoIiRGi/d6qBKVxh+IQ8Cr3b6HbVNfKiF8ZpFKufTwpwxMmce2W3iQZ861ZRyTg==}
     engines: {node: '>=18'}
 
+  nodemailer@9.0.3:
+    resolution: {integrity: sha512-n+YP+NKwR5zRWa60k3GiQ6Q3B4KXCoAw40dAKeCtYn020iNN74aWK2liXIC3ZEATeGql7we3tE3t8QwhY0eskw==}
+    engines: {node: '>=6.0.0'}
+
   notepack.io@3.0.1:
     resolution: {integrity: sha512-TKC/8zH5pXIAMVQio2TvVDTtPRX+DJPHDqjRbxogtFiByHyzKmy96RA0JtCQJ+WouyyL4A10xomQzgbUT+1jCg==}
 
@@ -4195,6 +4208,10 @@ snapshots:
     dependencies:
       undici-types: 8.3.0
 
+  '@types/nodemailer@8.0.1':
+    dependencies:
+      '@types/node': 26.0.1
+
   '@types/qs@6.15.1': {}
 
   '@types/range-parser@1.2.7': {}
@@ -5317,6 +5334,8 @@ snapshots:
 
   node-releases@2.0.50: {}
 
+  nodemailer@9.0.3: {}
+
   notepack.io@3.0.1: {}
 
   nypm@0.6.8: