fix(portal): security hardening for pilot readiness

- C1: Rewrite /api/usage to resolve teamId server-side from tenant CR;
  customers can no longer pass arbitrary teamId (IDOR fix)
- C2: Remove POST /api/tenants — tenants are only created via admin
  approval flow
- H1: Validate packages against catalog, workspaceFiles against allowlist,
  and field lengths in PATCH /api/tenants/[name]
- H2: Remove full ZITADEL profile claims logging from JWT callback
- H3: Add safeError() utility; sanitize all error responses to clients,
  toggle raw errors via PORTAL_DEBUG_ERRORS=true
- H4/H5: Escape HTML entities in all email templates (contactName,
  companyName, adminNotes)

src/app/api/admin/requests/[id]/approve/route.ts

@@ -14,6 +14,7 @@ import {
   getDefaultAgentsMd,
   generateToolsMd,
 } from "@/lib/workspace-defaults";
+import { safeError } from "@/lib/errors";
 
 /**
  * POST /api/admin/requests/[id]/approve
@@ -133,7 +134,7 @@ export async function POST(
   } catch (e: any) {
     console.error("Failed to create tenant:", e);
     return NextResponse.json(
-      { error: `Failed to create tenant: ${e.message}` },
+      { error: safeError(e, "Failed to create tenant") },
       { status: 500 }
     );
   }

src/app/api/admin/tenants/[name]/delete/route.ts

@@ -2,6 +2,7 @@ import { NextResponse } from "next/server";
 import { requirePlatformRole } from "@/lib/session";
 import { getTenant, deleteTenant } from "@/lib/k8s";
 import { markTenantRequestDeletedByTenantName } from "@/lib/db";
+import { safeError } from "@/lib/errors";
 
 /**
  * POST /api/admin/tenants/[name]/delete
@@ -42,7 +43,7 @@ export async function POST(
   } catch (e: any) {
     console.error("Failed to delete tenant:", e);
     return NextResponse.json(
-      { error: `Failed to delete tenant: ${e.message}` },
+      { error: safeError(e, "Failed to delete tenant") },
       { status: 500 }
     );
   }

src/app/api/admin/tenants/[name]/suspend/route.ts

@@ -1,6 +1,7 @@
 import { NextResponse } from "next/server";
 import { requirePlatformRole } from "@/lib/session";
 import { getTenant, patchTenantSpec } from "@/lib/k8s";
+import { safeError } from "@/lib/errors";
 
 /**
  * POST /api/admin/tenants/[name]/suspend
@@ -35,7 +36,7 @@ export async function POST(
   } catch (e: any) {
     console.error("Failed to update tenant suspend state:", e);
     return NextResponse.json(
-      { error: `Failed to update tenant: ${e.message}` },
+      { error: safeError(e, "Failed to update tenant") },
       { status: 500 }
     );
   }

src/app/api/tenants/[name]/route.ts

@@ -1,6 +1,11 @@
 import { NextRequest, NextResponse } from "next/server";
 import { getSessionUser } from "@/lib/session";
 import { getTenant, patchTenantSpec } from "@/lib/k8s";
+import { getPackageDef } from "@/lib/packages";
+import { safeError } from "@/lib/errors";
+
+const ALLOWED_WORKSPACE_FILES = ["SOUL.md", "AGENTS.md", "TOOLS.md"];
+const MAX_WORKSPACE_FILE_SIZE = 10_000;
 
 export async function GET(
   _req: NextRequest,
@@ -27,7 +32,7 @@ export async function GET(
     return NextResponse.json(tenant);
   } catch (e: any) {
     return NextResponse.json(
-      { error: e.message },
+      { error: safeError(e, "Failed to fetch tenant") },
       { status: e.statusCode || 500 }
     );
   }
@@ -61,20 +66,130 @@ export async function PATCH(
     }
 
     const specPatch: Record<string, any> = {};
-    if (body.packages !== undefined) specPatch.packages = body.packages;
+
-    if (body.workspaceFiles !== undefined)
+    // ── Validate packages against catalog ──
+    if (body.packages !== undefined) {
+      if (!Array.isArray(body.packages) || body.packages.length > 10) {
+        return NextResponse.json(
+          { error: "Invalid packages: must be an array of at most 10 items" },
+          { status: 400 }
+        );
+      }
+      for (const pkg of body.packages) {
+        if (typeof pkg !== "string" || !getPackageDef(pkg)) {
+          return NextResponse.json(
+            { error: `Unknown package: ${pkg}` },
+            { status: 400 }
+          );
+        }
+      }
+      specPatch.packages = body.packages;
+    }
+
+    // ── Validate workspaceFiles ──
+    if (body.workspaceFiles !== undefined) {
+      if (
+        typeof body.workspaceFiles !== "object" ||
+        body.workspaceFiles === null ||
+        Array.isArray(body.workspaceFiles)
+      ) {
+        return NextResponse.json(
+          { error: "Invalid workspaceFiles: must be an object" },
+          { status: 400 }
+        );
+      }
+      for (const [key, value] of Object.entries(body.workspaceFiles)) {
+        if (!ALLOWED_WORKSPACE_FILES.includes(key)) {
+          return NextResponse.json(
+            {
+              error: `Invalid workspace file: ${key}. Allowed: ${ALLOWED_WORKSPACE_FILES.join(", ")}`,
+            },
+            { status: 400 }
+          );
+        }
+        if (
+          typeof value !== "string" ||
+          value.length > MAX_WORKSPACE_FILE_SIZE
+        ) {
+          return NextResponse.json(
+            {
+              error: `Workspace file ${key} must be a string of at most ${MAX_WORKSPACE_FILE_SIZE} characters`,
+            },
+            { status: 400 }
+          );
+        }
+      }
       specPatch.workspaceFiles = body.workspaceFiles;
-    if (body.displayName !== undefined)
+    }
+
+    // ── Simple string fields ──
+    if (body.displayName !== undefined) {
+      if (
+        typeof body.displayName !== "string" ||
+        body.displayName.length < 1 ||
+        body.displayName.length > 100
+      ) {
+        return NextResponse.json(
+          { error: "displayName must be 1-100 characters" },
+          { status: 400 }
+        );
+      }
       specPatch.displayName = body.displayName;
-    if (body.agentName !== undefined) specPatch.agentName = body.agentName;
+    }
-    if (body.channelUsers !== undefined)
+
+    if (body.agentName !== undefined) {
+      if (
+        typeof body.agentName !== "string" ||
+        body.agentName.length < 1 ||
+        body.agentName.length > 50
+      ) {
+        return NextResponse.json(
+          { error: "agentName must be 1-50 characters" },
+          { status: 400 }
+        );
+      }
+      specPatch.agentName = body.agentName;
+    }
+
+    // ── channelUsers (basic shape validation) ──
+    if (body.channelUsers !== undefined) {
+      if (
+        typeof body.channelUsers !== "object" ||
+        body.channelUsers === null ||
+        Array.isArray(body.channelUsers)
+      ) {
+        return NextResponse.json(
+          { error: "Invalid channelUsers: must be an object" },
+          { status: 400 }
+        );
+      }
+      for (const [channel, users] of Object.entries(body.channelUsers)) {
+        if (typeof channel !== "string" || channel.length > 50) {
+          return NextResponse.json(
+            { error: `Invalid channel name: ${channel}` },
+            { status: 400 }
+          );
+        }
+        if (
+          !Array.isArray(users) ||
+          (users as any[]).some(
+            (u: any) => typeof u !== "string" || u.length > 100
+          )
+        ) {
+          return NextResponse.json(
+            { error: `Invalid user IDs for channel ${channel}` },
+            { status: 400 }
+          );
+        }
+      }
       specPatch.channelUsers = body.channelUsers;
+    }
 
     const updated = await patchTenantSpec(name, specPatch);
     return NextResponse.json(updated);
   } catch (e: any) {
     return NextResponse.json(
-      { error: e.message },
+      { error: safeError(e, "Failed to update tenant") },
       { status: e.statusCode || 500 }
     );
   }

src/app/api/tenants/route.ts

@@ -1,7 +1,6 @@
 import { NextResponse } from "next/server";
 import { getSessionUser } from "@/lib/session";
-import { listTenants, getTenant, createTenant } from "@/lib/k8s";
+import { listTenants } from "@/lib/k8s";
-import type { PiecedTenantSpec } from "@/types";
 
 export async function GET() {
   const user = await getSessionUser();
@@ -20,37 +19,3 @@ export async function GET() {
   );
   return NextResponse.json(own);
 }
-
-export async function POST(request: Request) {
-  const user = await getSessionUser();
-  if (!user)
-    return NextResponse.json({ error: "Unauthorized" }, { status: 401 });
-  if (!user.isPlatform && !user.roles.includes("owner")) {
-    return NextResponse.json({ error: "Forbidden" }, { status: 403 });
-  }
-
-  const body = (await request.json()) as {
-    name: string;
-    spec: PiecedTenantSpec;
-  };
-
-  if (!/^[a-z0-9][a-z0-9-]*[a-z0-9]$/.test(body.name) || body.name.length > 63) {
-    return NextResponse.json(
-      { error: "Invalid tenant name: lowercase alphanumeric and hyphens, 2-63 chars" },
-      { status: 400 }
-    );
-  }
-
-  const existing = await getTenant(body.name);
-  if (existing) {
-    return NextResponse.json(
-      { error: "Tenant already exists" },
-      { status: 409 }
-    );
-  }
-
-  const tenant = await createTenant(body.name, body.spec, {
-    "pieced.ch/zitadel-org-id": user.orgId,
-  });
-  return NextResponse.json(tenant, { status: 201 });
-}

src/app/api/usage/route.ts

@@ -1,20 +1,49 @@
 import { NextRequest, NextResponse } from "next/server";
 import { getSessionUser } from "@/lib/session";
+import { listTenants } from "@/lib/k8s";
 import { getTeamInfo, getTeamSpendLogsV2 } from "@/lib/litellm";
+import { safeError } from "@/lib/errors";
 
+/**
+ * GET /api/usage
+ *
+ * Customers: teamId is resolved server-side from the tenant matching the
+ *            user's orgId. No client-supplied teamId accepted.
+ * Platform admins: may pass ?teamId=... to inspect any tenant's usage.
+ */
 export async function GET(req: NextRequest) {
   const user = await getSessionUser();
   if (!user)
     return NextResponse.json({ error: "Unauthorized" }, { status: 401 });
 
-  const teamId = req.nextUrl.searchParams.get("teamId");
+  let teamId: string | null = null;
-  if (!teamId)
+
-    return NextResponse.json({ error: "teamId required" }, { status: 400 });
+  if (user.isPlatform) {
+    // Admins may pass a specific teamId to inspect any tenant
+    teamId = req.nextUrl.searchParams.get("teamId") ?? null;
+  }
+
+  // For customers (or admins without explicit teamId): resolve from their tenant
+  if (!teamId) {
+    const tenants = await listTenants();
+    const orgTenant = tenants.find(
+      (t) => t.metadata.labels?.["pieced.ch/zitadel-org-id"] === user.orgId
+    );
+
+    if (!orgTenant?.status?.litellmTeamId) {
+      return NextResponse.json(
+        { error: "No active tenant found for your organization" },
+        { status: 404 }
+      );
+    }
+    teamId = orgTenant.status.litellmTeamId;
+  }
 
   // Month param: YYYY-MM, defaults to current month
   const now = new Date();
-  const monthParam = req.nextUrl.searchParams.get("month")
+  const monthParam =
-    || `${now.getFullYear()}-${String(now.getMonth() + 1).padStart(2, "0")}`;
+    req.nextUrl.searchParams.get("month") ||
+    `${now.getFullYear()}-${String(now.getMonth() + 1).padStart(2, "0")}`;
 
   const [year, month] = monthParam.split("-").map(Number);
   const startDate = new Date(year, month - 1, 1);
@@ -30,18 +59,28 @@ export async function GET(req: NextRequest) {
     const allRequests: any[] = [];
     let page = 1;
     while (true) {
-      const result = await getTeamSpendLogsV2(teamId, startStr, endStr, page, 100);
+      const result = await getTeamSpendLogsV2(
+        teamId,
+        startStr,
+        endStr,
+        page,
+        100
+      );
       allRequests.push(...(result.data || []));
       if (page >= (result.total_pages || 1)) break;
       page++;
     }
 
     // Aggregate by day
-    const byDay: Record<string, { inputTokens: number; outputTokens: number; spend: number }> = {};
+    const byDay: Record<
+      string,
+      { inputTokens: number; outputTokens: number; spend: number }
+    > = {};
     for (const r of allRequests) {
       const day = (r.startTime || r.endTime || "").slice(0, 10);
       if (!day) continue;
-      if (!byDay[day]) byDay[day] = { inputTokens: 0, outputTokens: 0, spend: 0 };
+      if (!byDay[day])
+        byDay[day] = { inputTokens: 0, outputTokens: 0, spend: 0 };
       byDay[day].inputTokens += r.prompt_tokens || 0;
       byDay[day].outputTokens += r.completion_tokens || 0;
       byDay[day].spend += r.spend || 0;
@@ -51,8 +90,14 @@ export async function GET(req: NextRequest) {
       .sort(([a], [b]) => a.localeCompare(b))
       .map(([date, d]) => ({ date, ...d }));
 
-    const totalInput = allRequests.reduce((s, r) => s + (r.prompt_tokens || 0), 0);
+    const totalInput = allRequests.reduce(
-    const totalOutput = allRequests.reduce((s, r) => s + (r.completion_tokens || 0), 0);
+      (s, r) => s + (r.prompt_tokens || 0),
+      0
+    );
+    const totalOutput = allRequests.reduce(
+      (s, r) => s + (r.completion_tokens || 0),
+      0
+    );
     const totalSpend = allRequests.reduce((s, r) => s + (r.spend || 0), 0);
 
     return NextResponse.json({
@@ -79,6 +124,9 @@ export async function GET(req: NextRequest) {
     });
   } catch (e: any) {
     console.error("Usage fetch error:", e.message);
-    return NextResponse.json({ error: "Failed to fetch usage" }, { status: 500 });
+    return NextResponse.json(
+      { error: safeError(e, "Failed to fetch usage") },
+      { status: 500 }
+    );
   }
-}
+}

src/lib/auth.ts

@@ -39,7 +39,6 @@ export const authConfig: NextAuthConfig = {
   callbacks: {
     async jwt({ token, account, profile }) {
       if (account && profile) {
-        console.log("ZITADEL profile claims:", JSON.stringify(profile, null, 2));
         const claims = profile as unknown as ZitadelClaims;
         token.orgId = claims["urn:zitadel:iam:user:resourceowner:id"];
         token.orgName = claims["urn:zitadel:iam:user:resourceowner:name"];

src/lib/email.ts

@@ -42,11 +42,26 @@ function getFrom(): string {
   );
 }
 
+/**
+ * Escape HTML entities to prevent injection in HTML emails.
+ */
+function escapeHtml(str: string): string {
+  return str
+    .replace(/&/g, "&")
+    .replace(/</g, "&lt;")
+    .replace(/>/g, "&gt;")
+    .replace(/"/g, "&quot;")
+    .replace(/'/g, "&#39;");
+}
+
 export async function sendApprovalEmail(
   to: string,
   contactName: string,
   companyName: string
 ): Promise<void> {
+  const safeName = escapeHtml(contactName);
+  const safeCompany = escapeHtml(companyName);
+
   try {
     await getTransporter().sendMail({
       from: getFrom(),
@@ -68,8 +83,8 @@ export async function sendApprovalEmail(
       html: `
         <div style="font-family: -apple-system, BlinkMacSystemFont, 'Segoe UI', sans-serif; max-width: 560px; margin: 0 auto; color: #e0e0e0; background: #1a1a1a; padding: 32px; border-radius: 12px;">
           <h2 style="color: #ffffff; margin-top: 0;">Your AI assistant is being set up</h2>
-          <p>Hello ${contactName},</p>
+          <p>Hello ${safeName},</p>
-          <p>Great news! Your onboarding request for <strong>${companyName}</strong> has been approved.</p>
+          <p>Great news! Your onboarding request for <strong>${safeCompany}</strong> has been approved.</p>
           <p>Your AI assistant instance is now being provisioned. This usually takes a few minutes.</p>
           <p>
             <a href="https://app.pieced.ch" style="display: inline-block; padding: 10px 24px; background: #3b82f6; color: #ffffff; text-decoration: none; border-radius: 8px; font-weight: 500;">
@@ -95,14 +110,18 @@ export async function sendRejectionEmail(
   companyName: string,
   adminNotes?: string
 ): Promise<void> {
+  const safeName = escapeHtml(contactName);
+  const safeCompany = escapeHtml(companyName);
+  const safeNotes = adminNotes ? escapeHtml(adminNotes) : "";
+
   try {
     const notesBlock = adminNotes
       ? `\nNote from our team:\n${adminNotes}\n`
       : "";
-    const notesHtml = adminNotes
+    const notesHtml = safeNotes
       ? `<div style="background: #2a2a2a; border-left: 3px solid #ef4444; padding: 12px 16px; border-radius: 6px; margin: 16px 0;">
            <p style="color: #ccc; font-size: 13px; margin: 0;"><strong>Note from our team:</strong></p>
-           <p style="color: #aaa; font-size: 13px; margin: 8px 0 0 0;">${adminNotes}</p>
+           <p style="color: #aaa; font-size: 13px; margin: 8px 0 0 0;">${safeNotes}</p>
          </div>`
       : "";
 
@@ -123,8 +142,8 @@ export async function sendRejectionEmail(
       html: `
         <div style="font-family: -apple-system, BlinkMacSystemFont, 'Segoe UI', sans-serif; max-width: 560px; margin: 0 auto; color: #e0e0e0; background: #1a1a1a; padding: 32px; border-radius: 12px;">
           <h2 style="color: #ffffff; margin-top: 0;">Update on your onboarding request</h2>
-          <p>Hello ${contactName},</p>
+          <p>Hello ${safeName},</p>
-          <p>Thank you for your interest in PieCed IT. Unfortunately, we were unable to approve your onboarding request for <strong>${companyName}</strong> at this time.</p>
+          <p>Thank you for your interest in PieCed IT. Unfortunately, we were unable to approve your onboarding request for <strong>${safeCompany}</strong> at this time.</p>
           ${notesHtml}
           <p>If you have questions or would like to discuss this further, please reply to this email.</p>
           <hr style="border: none; border-top: 1px solid #333; margin: 24px 0;" />
@@ -145,6 +164,10 @@ export async function sendAdminNotificationEmail(
   const adminEmail = process.env.ADMIN_NOTIFICATION_EMAIL;
   if (!adminEmail) return;
 
+  const safeCompany = escapeHtml(companyName);
+  const safeName = escapeHtml(contactName);
+  const safeEmail = escapeHtml(contactEmail);
+
   try {
     await getTransporter().sendMail({
       from: getFrom(),
@@ -158,6 +181,23 @@ export async function sendAdminNotificationEmail(
         "",
         `Review it at https://app.pieced.ch/admin`,
       ].join("\n"),
+      html: `
+        <div style="font-family: -apple-system, BlinkMacSystemFont, 'Segoe UI', sans-serif; max-width: 560px; margin: 0 auto; color: #e0e0e0; background: #1a1a1a; padding: 32px; border-radius: 12px;">
+          <h2 style="color: #ffffff; margin-top: 0;">New onboarding request</h2>
+          <p>A new onboarding request has been submitted.</p>
+          <table style="color: #ccc; font-size: 14px; margin: 16px 0;">
+            <tr><td style="padding: 4px 12px 4px 0; color: #888;">Company:</td><td>${safeCompany}</td></tr>
+            <tr><td style="padding: 4px 12px 4px 0; color: #888;">Contact:</td><td>${safeName} (${safeEmail})</td></tr>
+          </table>
+          <p>
+            <a href="https://app.pieced.ch/admin" style="display: inline-block; padding: 10px 24px; background: #3b82f6; color: #ffffff; text-decoration: none; border-radius: 8px; font-weight: 500;">
+              Review Request
+            </a>
+          </p>
+          <hr style="border: none; border-top: 1px solid #333; margin: 24px 0;" />
+          <p style="color: #666; font-size: 12px;">PieCed IT — Hosted on-premises in Switzerland</p>
+        </div>
+      `,
     });
   } catch (err) {
     console.error("Failed to send admin notification email:", err);

src/lib/errors.ts

@@ -0,0 +1,37 @@
+/**
+ * Error sanitization for API responses.
+ *
+ * By default, returns a generic message to the client and logs the full
+ * error server-side. Set PORTAL_DEBUG_ERRORS=true to return the raw
+ * error message to the client (useful during development/debugging).
+ */
+
+const DEBUG_ERRORS = process.env.PORTAL_DEBUG_ERRORS === "true";
+
+/**
+ * Returns a safe error string for API responses.
+ *
+ * - In debug mode (PORTAL_DEBUG_ERRORS=true): returns the raw e.message
+ * - In production mode: returns the fallback string and logs the real error
+ *
+ * Recognises common HTTP status codes from k8s/vault errors and returns
+ * appropriate short messages even in production mode.
+ */
+export function safeError(e: unknown, fallback: string): string {
+  const err = e instanceof Error ? e : new Error(String(e));
+  const statusCode = (err as any).statusCode as number | undefined;
+
+  if (DEBUG_ERRORS) {
+    return err.message;
+  }
+
+  // Map well-known status codes to safe messages
+  if (statusCode === 404) return "Not found";
+  if (statusCode === 403) return "Forbidden";
+  if (statusCode === 409) return "Conflict";
+  if (statusCode === 401) return "Unauthorized";
+
+  // Log full error server-side, return generic to client
+  console.error(`${fallback}:`, err.message);
+  return fallback;
+}