Fix phone sanitization and signal group lookup

apps/bridge-worker/lib/zammad.ts

@@ -100,19 +100,57 @@ export const Zammad = (
   };
 };
 
-export const getUser = async (zammad: ZammadClient, phoneNumber: string) => {
-  // Sanitize phone number: only allow digits and + symbol
-  const mungedNumber = phoneNumber.replace(/[^\d+]/g, "");
+/**
+ * Sanitizes phone number to E.164 format: +15554446666
+ * Strips all non-digit characters except +, ensures + prefix
+ * @param phoneNumber - Raw phone number (e.g., "(555) 444-6666", "5554446666", "+1 555 444 6666")
+ * @returns E.164 formatted phone number (e.g., "+15554446666")
+ * @throws Error if phone number is invalid
+ */
+export const sanitizePhoneNumber = (phoneNumber: string): string => {
+  // Remove all characters except digits and +
+  let cleaned = phoneNumber.replace(/[^\d+]/g, "");
 
-  // Validate phone number format (10-15 digits, optional + prefix)
-  if (!/^\+?\d{10,15}$/.test(mungedNumber)) {
+  // Ensure it starts with +
+  if (!cleaned.startsWith("+")) {
+    // Assume US/Canada if no country code (11 digits starting with 1, or 10 digits)
+    if (cleaned.length === 10) {
+      cleaned = "+1" + cleaned;
+    } else if (cleaned.length === 11 && cleaned.startsWith("1")) {
+      cleaned = "+" + cleaned;
+    } else if (cleaned.length >= 10) {
+      // International number without +, add it
+      cleaned = "+" + cleaned;
+    }
+  }
+
+  // Validate E.164 format: + followed by 10-15 digits
+  if (!/^\+\d{10,15}$/.test(cleaned)) {
     throw new Error(`Invalid phone number format: ${phoneNumber}`);
   }
 
-  // Remove + for search query
-  const searchNumber = mungedNumber.replace("+", "");
-  const results = await zammad.user.search(`phone:${searchNumber}`);
+  return cleaned;
+};
+
+export const getUser = async (zammad: ZammadClient, phoneNumber: string) => {
+  // Sanitize to E.164 format
+  const sanitized = sanitizePhoneNumber(phoneNumber);
+
+  // Remove + for Zammad search query
+  const searchNumber = sanitized.replace("+", "");
+
+  // Try sanitized format first (e.g., "6464229653" for "+16464229653")
+  let results = await zammad.user.search(`phone:${searchNumber}`);
   if (results.length > 0) return results[0];
+
+  // Fall back to searching for original input (handles legacy formatted numbers)
+  // This ensures we can find users with "(646) 422-9653" format in database
+  const originalCleaned = phoneNumber.replace(/[^\d+]/g, "").replace("+", "");
+  if (originalCleaned !== searchNumber) {
+    results = await zammad.user.search(`phone:${originalCleaned}`);
+    if (results.length > 0) return results[0];
+  }
+
   return undefined;
 };
 
@@ -123,8 +161,11 @@ export const getOrCreateUser = async (
   const customer = await getUser(zammad, phoneNumber);
   if (customer) return customer;
 
+  // Sanitize phone number to E.164 format before storing
+  const sanitized = sanitizePhoneNumber(phoneNumber);
+
   return zammad.user.create({
-    phone: phoneNumber,
+    phone: sanitized,
     note: "User created from incoming voice call",
   });
 };

apps/bridge-worker/tasks/formstack/create-ticket-from-form.ts

@@ -1,6 +1,6 @@
 import { createLogger } from "@link-stack/logger";
 import { db } from "@link-stack/bridge-common";
-import { Zammad, getUser } from "../../lib/zammad.js";
+import { Zammad, getUser, sanitizePhoneNumber } from "../../lib/zammad.js";
 import {
   loadFieldMapping,
   getFieldValue,
@@ -55,12 +55,35 @@ const createTicketFromFormTask = async (
 
   // Extract well-known fields used for special logic (all optional)
   const email = getFieldValue(formData, "email", mapping);
-  const phone = getFieldValue(formData, "phone", mapping);
-  const signalAccount = getFieldValue(formData, "signalAccount", mapping);
+  const rawPhone = getFieldValue(formData, "phone", mapping);
+  const rawSignalAccount = getFieldValue(formData, "signalAccount", mapping);
   const organization = getFieldValue(formData, "organization", mapping);
   const typeOfSupport = getFieldValue(formData, "typeOfSupport", mapping);
   const descriptionOfIssue = getFieldValue(formData, "descriptionOfIssue", mapping);
 
+  // Sanitize phone numbers to E.164 format (+15554446666)
+  let phone: string | undefined;
+  if (rawPhone) {
+    try {
+      phone = sanitizePhoneNumber(rawPhone);
+      logger.info({ rawPhone, sanitized: phone }, "Sanitized phone number");
+    } catch (error: any) {
+      logger.warn({ rawPhone, error: error.message }, "Invalid phone number format, ignoring");
+      phone = undefined;
+    }
+  }
+
+  let signalAccount: string | undefined;
+  if (rawSignalAccount) {
+    try {
+      signalAccount = sanitizePhoneNumber(rawSignalAccount);
+      logger.info({ rawSignalAccount, sanitized: signalAccount }, "Sanitized signal account");
+    } catch (error: any) {
+      logger.warn({ rawSignalAccount, error: error.message }, "Invalid signal account format, ignoring");
+      signalAccount = undefined;
+    }
+  }
+
   // Validate that at least one contact method is provided
   if (!email && !phone && !signalAccount) {
     logger.error(