feat(VoiceServer): local TTS support, voice personalities, and automatic ElevenLabs fallback

[salaheldinaz]

Summary

• Fix .env path bug — server loaded ~/.env but PAI stores the key at ~/.config/PAI/.env, causing elevenlabs_api_key_configured to always report false and silently skipping all TTS audio
• Add local TTS engine — uses macOS built-in say command (zero dependencies, no API key) via new playLocalSpeech()
• Automatic ElevenLabs fallback — when ElevenLabs fails for any reason (402 unpaid voice, network error, missing key), server silently retries with local TTS so voice notifications always play
• Voice personality catalogue — curated list of 22 realistic English macOS voices with accent, gender, and personality descriptions grouped into natural and classic categories
• GET /voices/local endpoint — lists voices installed on the system with the active voice marked and instructions for switching
• Improved /health response — now exposes tts_provider, local_voice, local_tts_available; renames api_key_configured → elevenlabs_api_key_configured

Configuration

No breaking changes. Existing installs behave identically. To customise local TTS add to ~/.claude/settings.json:

"voiceServer": {
  "tts_provider": "local",
  "local_voice": "Daniel"
}

tts_provider options: "elevenlabs" (default — ElevenLabs with local fallback) or "local" (always local, no API call).

Browse available voices on your system:

curl http://localhost:8888/voices/local

Test plan

• /health returns local_tts_available: true and correct tts_provider
• GET /voices/local returns catalogue with active voice marked
• ElevenLabs 402 / missing key → local TTS plays, response still 200
• tts_provider: "local" → local TTS used directly, no ElevenLabs call
• tts_provider: "elevenlabs" with valid paid key → ElevenLabs used, unchanged behaviour
• .env loaded correctly from ~/.config/PAI/.env

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