fix: NextJS does not support non-ascii in NextResponse headers (#25148)

* fix: NextJS does not support non-ascii in NextResponse headers

* Fixed type error

apps/web/middleware.test.ts

@@ -1,6 +1,6 @@
 // Import mocked functions
 import { get as edgeConfigGet } from "@vercel/edge-config";
-import { NextRequest } from "next/server";
+import { NextRequest, NextResponse } from "next/server";
 import type { Mock } from "vitest";
 import { describe, it, expect, vi, beforeEach, afterEach } from "vitest";
 
@@ -405,6 +405,56 @@ describe("Middleware Integration Tests", () => {
     });
   });
 
+  describe("Header sanitization", () => {
+    it("sanitizes non-ASCII request header values to prevent Vercel Runtime Malformed Response Header", async () => {
+      const spy = vi.spyOn(NextResponse, "next");
+
+      const req = createTestRequest({
+        url: `${WEBAPP_URL}/team/test`,
+        // Next.js will translate request overrides into x-middleware-request-* headers internally
+        headers: {
+          "cf-region": "São Paulo", // contains non-ASCII "ã"
+        },
+      });
+
+      const res = await callMiddleware(req);
+      expectStatus(res, 200);
+
+      // Assert that middleware forwarded sanitized ASCII-only value
+      const initArg = (spy as unknown as Mock).mock.calls.at(-1)?.[0] as {
+        request?: { headers?: Headers };
+      };
+      expect(initArg?.request?.headers).toBeDefined();
+
+      const forwarded = initArg?.request?.headers as Headers;
+      expect(forwarded.get("cf-region")).toBe("Sao Paulo");
+
+      spy.mockRestore();
+    });
+
+    it("strips non-ASCII bytes in mojibake values (e.g., 'São Paulo' -> 'So Paulo')", async () => {
+      const spy = vi.spyOn(NextResponse, "next");
+
+      const req = createTestRequest({
+        url: `${WEBAPP_URL}/team/test`,
+        headers: {
+          "cf-region": "São Paulo", // mojibake for "São Paulo"; includes non-ASCII bytes
+        },
+      });
+
+      const res = await callMiddleware(req);
+      expectStatus(res, 200);
+
+      const initArg = (spy as unknown as Mock).mock.calls.at(-1)?.[0] as {
+        request?: { headers?: Headers };
+      };
+      const forwarded = initArg?.request?.headers as Headers;
+      expect(forwarded.get("cf-region")).toBe("So Paulo");
+
+      spy.mockRestore();
+    });
+  });
+
   describe("Multiple Features", () => {
 
     it("should handle embed route with routing forms rewrite", async () => {

apps/web/middleware.ts

@@ -85,6 +85,48 @@ export function checkPostMethod(req: NextRequest) {
   return null;
 }
 
+// Vercel/Edge rejects non‑ASCII header values (see: https://github.com/vercel/next.js/issues/85631)
+const isAscii = (s: string) => {
+  for (let i = 0; i < s.length; i++) if (s.charCodeAt(i) > 0x7f) return false;
+  return true;
+};
+const stripNonAscii = (s: string) => {
+  let out = "";
+  for (let i = 0; i < s.length; i++) if (s.charCodeAt(i) <= 0x7f) out += s[i];
+  return out;
+};
+const sanitizeRequestHeaders = (headers: Iterable<[string, string]>): Headers => {
+  const out = new Headers();
+  for (const [name, raw] of Array.from(headers)) {
+    if (!isAscii(name)) continue;
+    let value = raw;
+    if (!isAscii(value)) {
+      // Heuristic: if the string contains common mojibake markers (Ã: 0xC3, Â: 0xC2),
+      // prefer a simple strip (avoids introducing spurious ASCII letters like 'A').
+      let hasMojibakeMarker = false;
+      for (let i = 0; i < value.length; i++) {
+        const code = value.charCodeAt(i);
+        if (code === 0xc3 || code === 0xc2) {
+          hasMojibakeMarker = true;
+          break;
+        }
+      }
+
+      if (hasMojibakeMarker) {
+        value = stripNonAscii(value);
+      } else {
+        try {
+          value = stripNonAscii(value.normalize("NFKD"));
+        } catch {
+          value = stripNonAscii(value);
+        }
+      }
+    }
+    if (value) out.set(name, value);
+  }
+  return out;
+};
+
 const isPagePathRequest = (url: URL) => {
   const isNonPagePathPrefix = /^\/(?:_next|api)\//;
   const isFile = /\..*$/;
@@ -145,7 +187,7 @@ const middleware = async (req: NextRequest): Promise<NextResponse<unknown>> => {
 
   const res = NextResponse.next({
     request: {
-      headers: requestHeaders,
+      headers: sanitizeRequestHeaders(requestHeaders),
     },
   });