feat(portal): sign Apple profiles — Verified instead of 'unsigned' warning

Unsigned .mobileconfig installs trip macOS warnings ('unknown developer')
and an extra System Settings hunt. The route now wraps the profile in
PKCS#7 SignedData (node-forge, SHA-256, full chain embedded) using the
portal's own cert-manager LE certificate mounted read-only into the pod
(PROFILE_SIGN_CERT/KEY). Publicly-trusted chain → Apple shows Verified.
Dev (no env) and any signing failure fall back to unsigned — the
download must never break over the badge. Signature round-trip verified
with openssl smime.

apps/portal/package.json

@@ -12,6 +12,7 @@
   },
   "dependencies": {
     "ioredis": "^5.11.1",
+    "node-forge": "^1.4.0",
     "nuxt": "^4.4.6",
     "nuxt-oidc-auth": "1.0.0-beta.11",
     "undici": "^7.2.1",
@@ -20,6 +21,7 @@
   },
   "devDependencies": {
     "@types/node": "^20.0.0",
+    "@types/node-forge": "^1.3.14",
     "typescript": "^5.6.0",
     "vue-tsc": "^3.2.6"
   },

apps/portal/pnpm-lock.yaml

@@ -11,6 +11,9 @@ importers:
       ioredis:
         specifier: ^5.11.1
         version: 5.11.1
+      node-forge:
+        specifier: ^1.4.0
+        version: 1.4.0
       nuxt:
         specifier: ^4.4.6
         version: 4.4.6(@babel/plugin-syntax-jsx@7.28.6(@babel/core@7.29.0))(@babel/plugin-syntax-typescript@7.28.6(@babel/core@7.29.0))(@parcel/watcher@2.5.6)(@types/node@20.19.41)(@vue/compiler-sfc@3.5.34)(cac@6.7.14)(db0@0.3.4)(ioredis@5.11.1)(magicast@0.5.3)(rollup-plugin-visualizer@7.0.1(rollup@4.60.4))(rollup@4.60.4)(srvx@0.11.16)(terser@5.48.0)(typescript@5.9.3)(vite@7.3.3(@types/node@20.19.41)(jiti@2.7.0)(terser@5.48.0)(yaml@2.9.0))(vue-tsc@3.3.2(typescript@5.9.3))(yaml@2.9.0)
@@ -30,6 +33,9 @@ importers:
       '@types/node':
         specifier: ^20.0.0
         version: 20.19.41
+      '@types/node-forge':
+        specifier: ^1.3.14
+        version: 1.3.14
       typescript:
         specifier: ^5.6.0
         version: 5.9.3
@@ -1406,6 +1412,9 @@ packages:
   '@types/json-schema@7.0.15':
     resolution: {integrity: sha512-5+fP8P8MFNC+AyZCDxrB2pkZFPGzqQWUzpSeuuVLvm8VMcorNYavBqoFcxK8bQz4Qsbn4oUEEem4wDLfcysGHA==}
 
+  '@types/node-forge@1.3.14':
+    resolution: {integrity: sha512-mhVF2BnD4BO+jtOp7z1CdzaK4mbuK0LLQYAvdOLqHTavxFNq4zA1EmYkpnFjP8HOUzedfQkRnp0E2ulSAYSzAw==}
+
   '@types/node@20.19.41':
     resolution: {integrity: sha512-ECymXOukMnOoVkC2bb1Vc/w/836DXncOg5m8Xj1RH7xSHZJWNYY6Zh7EH477vcnD5egKNNfy2RpNOmuChhFPgQ==}
 
@@ -5244,6 +5253,10 @@ snapshots:
 
   '@types/json-schema@7.0.15': {}
 
+  '@types/node-forge@1.3.14':
+    dependencies:
+      '@types/node': 20.19.41
+
   '@types/node@20.19.41':
     dependencies:
       undici-types: 6.21.0

apps/portal/server/api/apple-mailconfig.get.ts

@@ -12,6 +12,8 @@
 
 import { getUserSession } from 'nuxt-oidc-auth/runtime/server/utils/session.js'
 import { randomUUID } from 'node:crypto'
+import { readFileSync } from 'node:fs'
+import forge from 'node-forge'
 
 const EMAIL_RE = /^[^\s@]+@[^\s@]+\.[^\s@]+$/
 
@@ -124,5 +126,45 @@ export default defineEventHandler(async (event) => {
     'Content-Disposition',
     `attachment; filename="dezky-mail-${localPart.replace(/[^a-z0-9.-]/gi, '_')}.mobileconfig"`,
   )
-  return profile
+  return signProfile(profile)
 })
+
+// Sign the profile (PKCS#7 SignedData with embedded content) using the TLS
+// cert mounted from cert-manager (PROFILE_SIGN_CERT/KEY in production —
+// fleet/apps/portal.yaml). A publicly-trusted signature turns Apple's
+// "unsigned profile" warning into a green Verified badge. Unset env (dev)
+// → unsigned profile, still installable with the warning.
+function signProfile(profileXml: string): Buffer | string {
+  const certPath = process.env.PROFILE_SIGN_CERT
+  const keyPath = process.env.PROFILE_SIGN_KEY
+  if (!certPath || !keyPath) return profileXml
+  try {
+    const certPem = readFileSync(certPath, 'utf8')
+    const keyPem = readFileSync(keyPath, 'utf8')
+    // cert-manager's tls.crt is the full chain — leaf first. Include every
+    // cert so Apple can build the path to the trusted root.
+    const certs = certPem
+      .split(/(?=-----BEGIN CERTIFICATE-----)/)
+      .filter((c) => c.includes('BEGIN CERTIFICATE'))
+      .map((c) => forge.pki.certificateFromPem(c))
+    const p7 = forge.pkcs7.createSignedData()
+    p7.content = forge.util.createBuffer(profileXml, 'utf8')
+    for (const c of certs) p7.addCertificate(c)
+    p7.addSigner({
+      key: forge.pki.privateKeyFromPem(keyPem) as forge.pki.rsa.PrivateKey,
+      certificate: certs[0]!,
+      digestAlgorithm: forge.pki.oids.sha256!,
+      authenticatedAttributes: [
+        { type: forge.pki.oids.contentType!, value: forge.pki.oids.data! },
+        { type: forge.pki.oids.messageDigest! },
+        { type: forge.pki.oids.signingTime! },
+      ],
+    })
+    p7.sign()
+    return Buffer.from(forge.asn1.toDer(p7.toAsn1()).getBytes(), 'binary')
+  } catch (err) {
+    // Never fail the download over signing — fall back to unsigned.
+    console.error('apple-mailconfig: profile signing failed, serving unsigned:', err)
+    return profileXml
+  }
+}