fix(cli): treat staging and temp-file failures as archive errors

`create_project_zip` only wrapped the ZIP write, so an `OSError` while
staging files or creating the temporary archive escaped as a bare
`OSError` and the deploy command recorded it as `unexpected` instead of
`zip_error`. The archive boundary now covers staging, temp-file creation
and the write; the staging directory is removed on every path, and no
partial archive is left behind.

Co-Authored-By: Claude Fable 5.1 <noreply@anthropic.com>

lib/cli/src/crewai_cli/deploy/archive.py

@@ -51,33 +51,25 @@ def create_project_zip(
     project_dir: Path | None = None,
     repository: git.Repository | None = None,
 ) -> Path:
-    """Create a deployable ZIP archive for a CrewAI project."""
+    """Create a deployable ZIP archive for a CrewAI project.
+
+    Raises:
+        ArchiveError: Nothing deployable was found, or the project could not be
+            staged or written to the archive. No partial archive is left behind.
+    """
     root = (project_dir or Path.cwd()).resolve()
     files = _project_files(root, repository)
     if not files:
         raise ArchiveError("No deployable project files were found.")
 
-    staged_root = _stage_project(root, files)
-    archive_handle = tempfile.NamedTemporaryFile(
-        prefix=f"{project_name}-",
-        suffix=".zip",
-        delete=False,
-    )
-    archive_path = Path(archive_handle.name)
-    archive_handle.close()
-
     try:
-        with zipfile.ZipFile(archive_path, "w", zipfile.ZIP_DEFLATED) as zip_file:
-            for relative_path in _walk_files(staged_root):
-                absolute_path = staged_root / relative_path
-                zip_file.write(absolute_path, relative_path.as_posix())
+        staged_root = _stage_project(root, files)
+        try:
+            return _write_archive(project_name, staged_root)
+        finally:
+            shutil.rmtree(staged_root, ignore_errors=True)
     except (OSError, zipfile.BadZipFile) as exc:
-        archive_path.unlink(missing_ok=True)
         raise ArchiveError(f"Could not build the project ZIP: {exc}") from exc
-    finally:
-        shutil.rmtree(staged_root, ignore_errors=True)
-
-    return archive_path
 
 
 def _project_files(root: Path, repository: git.Repository | None = None) -> list[Path]:
@@ -153,3 +145,24 @@ def _stage_project(root: Path, files: list[Path]) -> Path:
         shutil.rmtree(staging_root, ignore_errors=True)
         raise
     return staging_root
+
+
+def _write_archive(project_name: str, staged_root: Path) -> Path:
+    """Zip the staged tree into a new temporary file, removing it if the write fails."""
+    archive_handle = tempfile.NamedTemporaryFile(
+        prefix=f"{project_name}-",
+        suffix=".zip",
+        delete=False,
+    )
+    archive_path = Path(archive_handle.name)
+    archive_handle.close()
+
+    try:
+        with zipfile.ZipFile(archive_path, "w", zipfile.ZIP_DEFLATED) as zip_file:
+            for relative_path in _walk_files(staged_root):
+                absolute_path = staged_root / relative_path
+                zip_file.write(absolute_path, relative_path.as_posix())
+    except (OSError, zipfile.BadZipFile):
+        archive_path.unlink(missing_ok=True)
+        raise
+    return archive_path

lib/cli/tests/deploy/test_archive.py

@@ -1,5 +1,6 @@
 from pathlib import Path
 import subprocess
+import tempfile
 import zipfile
 
 import pytest
@@ -333,3 +334,32 @@ def test_create_project_zip_wraps_a_write_failure_and_removes_the_partial_file(
         create_project_zip("demo", project_dir=tmp_path)
 
     assert created and not created[0].exists()
+
+
+@pytest.mark.parametrize(
+    "failing_step",
+    [
+        "crewai_cli.deploy.archive.shutil.copy2",
+        "crewai_cli.deploy.archive.tempfile.NamedTemporaryFile",
+    ],
+)
+def test_create_project_zip_wraps_staging_and_temp_file_failures_and_cleans_up(
+    tmp_path: Path, monkeypatch: pytest.MonkeyPatch, failing_step: str
+):
+    """A full disk while staging or creating the archive is an archive failure too."""
+    project = tmp_path / "project"
+    project.mkdir()
+    (project / "pyproject.toml").write_text("[project]\nname = 'demo'\n")
+    scratch = tmp_path / "scratch"
+    scratch.mkdir()
+    monkeypatch.setattr(tempfile, "tempdir", str(scratch))
+
+    def fail(*args, **kwargs):
+        raise OSError("disk full")
+
+    monkeypatch.setattr(failing_step, fail)
+
+    with pytest.raises(ArchiveError, match="Could not build the project ZIP: disk full"):
+        create_project_zip("demo", project_dir=project)
+
+    assert list(scratch.iterdir()) == []