refactor: return errors from NewCLIInstance instead of panicking

Change NewCLIInstance() and NewCLIInstanceWithFs() to return
(*Instance, error) instead of panicking on DetermineStateDir failure.

Callers in RunE contexts propagate the error. Callers in command
construction (for shell completion) use log.Fatalf. Test callers
use t.Fatalf.

Addresses review feedback on PR #18.

internal/cli/cli.go

@@ -17,30 +17,30 @@ type Instance struct {
 }
 
 // NewCLIInstance creates a new CLI instance with the real filesystem
-func NewCLIInstance() *Instance {
+func NewCLIInstance() (*Instance, error) {
 	fs := afero.NewOsFs()
 	stateDir, err := secret.DetermineStateDir("")
 	if err != nil {
-		panic(fmt.Sprintf("cannot determine state directory: %v", err))
+		return nil, fmt.Errorf("cannot determine state directory: %w", err)
 	}
 
 	return &Instance{
 		fs:       fs,
 		stateDir: stateDir,
-	}
+	}, nil
 }
 
 // NewCLIInstanceWithFs creates a new CLI instance with the given filesystem (for testing)
-func NewCLIInstanceWithFs(fs afero.Fs) *Instance {
+func NewCLIInstanceWithFs(fs afero.Fs) (*Instance, error) {
 	stateDir, err := secret.DetermineStateDir("")
 	if err != nil {
-		panic(fmt.Sprintf("cannot determine state directory: %v", err))
+		return nil, fmt.Errorf("cannot determine state directory: %w", err)
 	}
 
 	return &Instance{
 		fs:       fs,
 		stateDir: stateDir,
-	}
+	}, nil
 }
 
 // NewCLIInstanceWithStateDir creates a new CLI instance with custom state directory (for testing)

internal/cli/cli_test.go

@@ -25,7 +25,10 @@ func TestCLIInstanceStateDir(t *testing.T) {
 func TestCLIInstanceWithFs(t *testing.T) {
 	// Test creating CLI instance with custom filesystem
 	fs := afero.NewMemMapFs()
-	cli := NewCLIInstanceWithFs(fs)
+	cli, err := NewCLIInstanceWithFs(fs)
+	if err != nil {
+		t.Fatalf("failed to initialize CLI: %v", err)
+	}
 
 	// The state directory should be determined automatically
 	stateDir := cli.GetStateDir()

internal/cli/crypto.go

@@ -22,7 +22,10 @@ func newEncryptCmd() *cobra.Command {
 			inputFile, _ := cmd.Flags().GetString("input")
 			outputFile, _ := cmd.Flags().GetString("output")
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 			cli.cmd = cmd
 
 			return cli.Encrypt(args[0], inputFile, outputFile)
@@ -45,7 +48,10 @@ func newDecryptCmd() *cobra.Command {
 			inputFile, _ := cmd.Flags().GetString("input")
 			outputFile, _ := cmd.Flags().GetString("output")
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 			cli.cmd = cmd
 
 			return cli.Decrypt(args[0], inputFile, outputFile)

internal/cli/generate.go

@@ -38,7 +38,10 @@ func newGenerateMnemonicCmd() *cobra.Command {
 			`mnemonic phrase that can be used with 'secret init' ` +
 			`or 'secret import'.`,
 		RunE: func(cmd *cobra.Command, _ []string) error {
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.GenerateMnemonic(cmd)
 		},
@@ -56,7 +59,10 @@ func newGenerateSecretCmd() *cobra.Command {
 			secretType, _ := cmd.Flags().GetString("type")
 			force, _ := cmd.Flags().GetBool("force")
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.GenerateSecret(cmd, args[0], length, secretType, force)
 		},

internal/cli/info.go

@@ -1,6 +1,7 @@
 package cli
 
 import (
+	"log"
 	"encoding/json"
 	"fmt"
 	"io"
@@ -40,7 +41,10 @@ type InfoOutput struct {
 
 // newInfoCmd returns the info command
 func newInfoCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 
 	var jsonOutput bool
 

internal/cli/init.go

@@ -1,6 +1,7 @@
 package cli
 
 import (
+	"log"
 	"fmt"
 	"log/slog"
 	"os"
@@ -27,7 +28,10 @@ func NewInitCmd() *cobra.Command {
 
 // RunInit is the exported function that handles the init command
 func RunInit(cmd *cobra.Command, _ []string) error {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 
 	return cli.Init(cmd)
 }

internal/cli/secrets.go

@@ -1,6 +1,7 @@
 package cli
 
 import (
+	"log"
 	"encoding/json"
 	"fmt"
 	"io"
@@ -44,7 +45,10 @@ func newAddCmd() *cobra.Command {
 			force, _ := cmd.Flags().GetBool("force")
 			secret.Debug("Got force flag", "force", force)
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 			cli.cmd = cmd // Set the command for stdin access
 			secret.Debug("Created CLI instance, calling AddSecret")
 
@@ -58,7 +62,10 @@ func newAddCmd() *cobra.Command {
 }
 
 func newGetCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 	cmd := &cobra.Command{
 		Use:               "get <secret-name>",
 		Short:             "Retrieve a secret from the vault",
@@ -66,7 +73,10 @@ func newGetCmd() *cobra.Command {
 		ValidArgsFunction: getSecretNamesCompletionFunc(cli.fs, cli.stateDir),
 		RunE: func(cmd *cobra.Command, args []string) error {
 			version, _ := cmd.Flags().GetString("version")
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.GetSecretWithVersion(cmd, args[0], version)
 		},
@@ -93,7 +103,10 @@ func newListCmd() *cobra.Command {
 				filter = args[0]
 			}
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.ListSecrets(cmd, jsonOutput, quietOutput, filter)
 		},
@@ -115,7 +128,10 @@ func newImportCmd() *cobra.Command {
 			sourceFile, _ := cmd.Flags().GetString("source")
 			force, _ := cmd.Flags().GetBool("force")
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.ImportSecret(cmd, args[0], sourceFile, force)
 		},
@@ -129,7 +145,10 @@ func newImportCmd() *cobra.Command {
 }
 
 func newRemoveCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 	cmd := &cobra.Command{
 		Use:     "remove <secret-name>",
 		Aliases: []string{"rm"},
@@ -139,7 +158,10 @@ func newRemoveCmd() *cobra.Command {
 		Args:              cobra.ExactArgs(1),
 		ValidArgsFunction: getSecretNamesCompletionFunc(cli.fs, cli.stateDir),
 		RunE: func(cmd *cobra.Command, args []string) error {
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.RemoveSecret(cmd, args[0], false)
 		},
@@ -149,7 +171,10 @@ func newRemoveCmd() *cobra.Command {
 }
 
 func newMoveCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 	cmd := &cobra.Command{
 		Use:     "move <source> <destination>",
 		Aliases: []string{"mv", "rename"},
@@ -172,7 +197,10 @@ The source secret is deleted after successful copy.`,
 		},
 		RunE: func(cmd *cobra.Command, args []string) error {
 			force, _ := cmd.Flags().GetBool("force")
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.MoveSecret(cmd, args[0], args[1], force)
 		},

internal/cli/secrets_size_test.go

@@ -113,7 +113,10 @@ func TestAddSecretVariousSizes(t *testing.T) {
 			cmd.SetIn(stdin)
 
 			// Create CLI instance
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				t.Fatalf("failed to initialize CLI: %v", err)
+			}
 			cli.fs = fs
 			cli.stateDir = stateDir
 			cli.cmd = cmd
@@ -230,7 +233,10 @@ func TestImportSecretVariousSizes(t *testing.T) {
 			cmd := &cobra.Command{}
 
 			// Create CLI instance
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				t.Fatalf("failed to initialize CLI: %v", err)
+			}
 			cli.fs = fs
 			cli.stateDir = stateDir
 
@@ -318,7 +324,10 @@ func TestAddSecretBufferGrowth(t *testing.T) {
 			cmd.SetIn(stdin)
 
 			// Create CLI instance
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				t.Fatalf("failed to initialize CLI: %v", err)
+			}
 			cli.fs = fs
 			cli.stateDir = stateDir
 			cli.cmd = cmd
@@ -377,7 +386,10 @@ func TestAddSecretStreamingBehavior(t *testing.T) {
 	cmd.SetIn(slowReader)
 
 	// Create CLI instance
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		t.Fatalf("failed to initialize CLI: %v", err)
+	}
 	cli.fs = fs
 	cli.stateDir = stateDir
 	cli.cmd = cmd

internal/cli/unlockers.go

@@ -1,6 +1,7 @@
 package cli
 
 import (
+	"log"
 	"encoding/json"
 	"fmt"
 	"os"
@@ -96,7 +97,10 @@ func newUnlockerListCmd() *cobra.Command {
 		RunE: func(cmd *cobra.Command, _ []string) error {
 			jsonOutput, _ := cmd.Flags().GetBool("json")
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 			cli.cmd = cmd
 
 			return cli.UnlockersList(jsonOutput)
@@ -153,7 +157,10 @@ to access the same vault. This provides flexibility and backup access options.`,
 		Args:      cobra.ExactArgs(1),
 		ValidArgs: strings.Split(supportedTypes, ", "),
 		RunE: func(cmd *cobra.Command, args []string) error {
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 			unlockerType := args[0]
 
 			// Validate unlocker type
@@ -186,7 +193,10 @@ to access the same vault. This provides flexibility and backup access options.`,
 }
 
 func newUnlockerRemoveCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 	cmd := &cobra.Command{
 		Use:     "remove <unlocker-id>",
 		Aliases: []string{"rm"},
@@ -198,7 +208,10 @@ func newUnlockerRemoveCmd() *cobra.Command {
 		ValidArgsFunction: getUnlockerIDsCompletionFunc(cli.fs, cli.stateDir),
 		RunE: func(cmd *cobra.Command, args []string) error {
 			force, _ := cmd.Flags().GetBool("force")
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.UnlockersRemove(args[0], force, cmd)
 		},
@@ -210,7 +223,10 @@ func newUnlockerRemoveCmd() *cobra.Command {
 }
 
 func newUnlockerSelectCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 
 	return &cobra.Command{
 		Use:               "select <unlocker-id>",
@@ -218,7 +234,10 @@ func newUnlockerSelectCmd() *cobra.Command {
 		Args:              cobra.ExactArgs(1),
 		ValidArgsFunction: getUnlockerIDsCompletionFunc(cli.fs, cli.stateDir),
 		RunE: func(_ *cobra.Command, args []string) error {
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.UnlockerSelect(args[0])
 		},

internal/cli/vault.go

@@ -1,6 +1,7 @@
 package cli
 
 import (
+	"log"
 	"encoding/json"
 	"fmt"
 	"os"
@@ -41,7 +42,10 @@ func newVaultListCmd() *cobra.Command {
 		RunE: func(cmd *cobra.Command, _ []string) error {
 			jsonOutput, _ := cmd.Flags().GetBool("json")
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.ListVaults(cmd, jsonOutput)
 		},
@@ -58,7 +62,10 @@ func newVaultCreateCmd() *cobra.Command {
 		Short: "Create a new vault",
 		Args:  cobra.ExactArgs(1),
 		RunE: func(cmd *cobra.Command, args []string) error {
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.CreateVault(cmd, args[0])
 		},
@@ -66,7 +73,10 @@ func newVaultCreateCmd() *cobra.Command {
 }
 
 func newVaultSelectCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 
 	return &cobra.Command{
 		Use:               "select <name>",
@@ -74,7 +84,10 @@ func newVaultSelectCmd() *cobra.Command {
 		Args:              cobra.ExactArgs(1),
 		ValidArgsFunction: getVaultNamesCompletionFunc(cli.fs, cli.stateDir),
 		RunE: func(cmd *cobra.Command, args []string) error {
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.SelectVault(cmd, args[0])
 		},
@@ -82,7 +95,10 @@ func newVaultSelectCmd() *cobra.Command {
 }
 
 func newVaultImportCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 
 	return &cobra.Command{
 		Use:               "import <vault-name>",
@@ -96,7 +112,10 @@ func newVaultImportCmd() *cobra.Command {
 				vaultName = args[0]
 			}
 
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.VaultImport(cmd, vaultName)
 		},
@@ -104,7 +123,10 @@ func newVaultImportCmd() *cobra.Command {
 }
 
 func newVaultRemoveCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 	cmd := &cobra.Command{
 		Use:     "remove <name>",
 		Aliases: []string{"rm"},
@@ -115,7 +137,10 @@ func newVaultRemoveCmd() *cobra.Command {
 		ValidArgsFunction: getVaultNamesCompletionFunc(cli.fs, cli.stateDir),
 		RunE: func(cmd *cobra.Command, args []string) error {
 			force, _ := cmd.Flags().GetBool("force")
-			cli := NewCLIInstance()
+			cli, err := NewCLIInstance()
+			if err != nil {
+				return fmt.Errorf("failed to initialize CLI: %w", err)
+			}
 
 			return cli.RemoveVault(cmd, args[0], force)
 		},

internal/cli/version.go

@@ -1,6 +1,7 @@
 package cli
 
 import (
+	"log"
 	"fmt"
 	"path/filepath"
 	"strings"
@@ -18,7 +19,10 @@ const (
 
 // newVersionCmd returns the version management command
 func newVersionCmd() *cobra.Command {
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		log.Fatalf("failed to initialize CLI: %v", err)
+	}
 
 	return VersionCommands(cli)
 }

internal/cli/version_test.go

@@ -266,7 +266,10 @@ func TestGetSecretWithVersion(t *testing.T) {
 
 func TestVersionCommandStructure(t *testing.T) {
 	// Test that version commands are properly structured
-	cli := NewCLIInstance()
+	cli, err := NewCLIInstance()
+	if err != nil {
+		t.Fatalf("failed to initialize CLI: %v", err)
+	}
 	cmd := VersionCommands(cli)
 
 	assert.Equal(t, "version", cmd.Use)