fix(game): numbered name fallback when pool exhausted — server no longer freezes past 128 systems

Production freeze reported after the v0.9.3 (#21) deploy: every API route
hung and all panels stayed at LOADING. Root cause was not the #21 layout
(verified healthy across all 7 tabs/viewports) but makeName's unbounded
rejection loop over a finite 16x8=128 system-name pool — once a save grew
past ~128 systems, any jump into an undiscovered system spun forever on
Node's single thread (sql.js is synchronous), blocking the whole process.

makeName and makeCrewName now fall back to numbered variants ('Kepler Drift 2')
once their pools are exhausted, so they always terminate.

lib/game/crew.test.ts

@@ -71,4 +71,17 @@ describe('makeCrewName', () => {
     for (let i = 0; i < 40; i++) makeCrewName(rng, taken)
     expect(taken.size).toBe(40)
   })
+
+  it('terminates with numbered variants once all 352 base names are taken', () => {
+    const rng = startingCrewRng('7')
+    const taken = new Set<string>()
+    for (let i = 0; i < 352; i++) makeCrewName(rng, taken) // exhaust the whole pool
+    expect(taken.size).toBe(352)
+
+    const a = makeCrewName(rng, taken) // must return instead of spinning forever
+    const b = makeCrewName(rng, taken)
+    expect(a).not.toBe(b)
+    expect(taken.has(a)).toBe(true)
+    expect(taken.has(b)).toBe(true)
+  })
 })

lib/game/crew.ts

@@ -49,13 +49,23 @@ function pick<T>(rng: () => number, arr: T[]): T {
 }
 
 // A name unique against `taken` (the current roster), claimed into the set on success.
-// 16×22 = 352 combinations — a roster realistically never approaches that size.
+// The pool is finite (16×22=352) and the roster has no cap, so — like makeName — fall back to
+// numbered variants once every base is taken instead of spinning forever.
 export function makeCrewName(rng: () => number, taken: Set<string>): string {
   for (;;) {
-    const name = `${title(pick(rng, FIRST_NAMES))} ${pick(rng, LAST_NAMES)}`
-    if (!taken.has(name)) {
-      taken.add(name)
-      return name
+    const base = `${title(pick(rng, FIRST_NAMES))} ${pick(rng, LAST_NAMES)}`
+    if (!taken.has(base)) {
+      taken.add(base)
+      return base
+    }
+    if (taken.size >= FIRST_NAMES.length * LAST_NAMES.length) {
+      for (let n = 2; ; n++) {
+        const name = `${base} ${n}`
+        if (!taken.has(name)) {
+          taken.add(name)
+          return name
+        }
+      }
     }
   }
 }

lib/game/world.test.ts

@@ -76,6 +76,19 @@ describe('generateRing (expansion)', () => {
     for (let i = 0; i < 40; i++) makeName(rng, taken)
     expect(taken.size).toBe(40)
   })
+
+  it('terminates with numbered variants once all 128 base names are taken', () => {
+    const rng = mulberry32(9)
+    const taken = new Set<string>()
+    for (let i = 0; i < 128; i++) makeName(rng, taken) // exhaust the whole pool
+    expect(taken.size).toBe(128)
+
+    const a = makeName(rng, taken) // must return instead of spinning forever
+    const b = makeName(rng, taken)
+    expect(a).not.toBe(b)
+    expect(taken.has(a)).toBe(true)
+    expect(taken.has(b)).toBe(true)
+  })
 })
 
 describe('generatePlanets', () => {

lib/game/world.ts

@@ -36,13 +36,25 @@ function title(word: string): string {
   return word.charAt(0) + word.slice(1).toLowerCase()
 }
 
-// Picks a name not in `taken` and adds it, so callers can't accidentally reuse one.
+// Picks a name not in `taken` and adds it, so callers can't accidentally reuse one. The base
+// pool is finite (16×8=128), so once every base is taken the loop would spin forever — which
+// froze the whole server on a save that had grown past 128 systems (synchronous sql.js runs on
+// Node's single thread). Numbered variants keep names unique and terminate.
 export function makeName(rng: () => number, taken: Set<string>): string {
   for (;;) {
-    const name = `${title(FIRST[Math.floor(rng() * FIRST.length)])} ${title(SECOND[Math.floor(rng() * SECOND.length)])}`
-    if (!taken.has(name)) {
-      taken.add(name)
-      return name
+    const base = `${title(FIRST[Math.floor(rng() * FIRST.length)])} ${title(SECOND[Math.floor(rng() * SECOND.length)])}`
+    if (!taken.has(base)) {
+      taken.add(base)
+      return base
+    }
+    if (taken.size >= FIRST.length * SECOND.length) {
+      for (let n = 2; ; n++) {
+        const name = `${base} ${n}`
+        if (!taken.has(name)) {
+          taken.add(name)
+          return name
+        }
+      }
     }
   }
 }