feat: add per-tier fallback support to ModelRouter

The router now accepts a tierFallbacks map so each model tier can have
its own fallback providers. Tier fallbacks are tried before the global
fallback chain in both chat() and chatStream().

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

src/models/router.test.ts

@@ -81,6 +81,83 @@ describe('ModelRouter', () => {
   });
 });
 
+describe('ModelRouter per-tier fallbacks', () => {
+  const createMockClient = (name: string, shouldFail = false): ModelClient => ({
+    chat: vi.fn().mockImplementation(async () => {
+      if (shouldFail) {
+        throw new Error(`${name} failed`);
+      }
+      return {
+        content: `Response from ${name}`,
+        stopReason: 'end_turn',
+        usage: { inputTokens: 10, outputTokens: 5 },
+      } satisfies ChatResponse;
+    }),
+  });
+
+  it('uses tier-specific fallback when tier client fails', async () => {
+    const defaultClient = createMockClient('default');
+    const failingFast = createMockClient('fast', true);
+    const fastFallback = createMockClient('fast-fallback');
+
+    const router = new ModelRouter({
+      default: defaultClient,
+      fast: failingFast,
+      fallbackChain: [],
+      tierFallbacks: new Map([['fast', [fastFallback]]]),
+    });
+
+    const response = await router.chat(
+      { messages: [{ role: 'user', content: 'Hi' }] },
+      'fast',
+    );
+
+    expect(response.content).toBe('Response from fast-fallback');
+    expect(response.fallback).toBe(true);
+    expect(defaultClient.chat).not.toHaveBeenCalled();
+  });
+
+  it('falls through to global chain when tier fallback also fails', async () => {
+    const failingFast = createMockClient('fast', true);
+    const failingTierFallback = createMockClient('tier-fallback', true);
+    const globalFallback = createMockClient('global-fallback');
+
+    const router = new ModelRouter({
+      default: createMockClient('default'),
+      fast: failingFast,
+      fallbackChain: [globalFallback],
+      tierFallbacks: new Map([['fast', [failingTierFallback]]]),
+    });
+
+    const response = await router.chat(
+      { messages: [{ role: 'user', content: 'Hi' }] },
+      'fast',
+    );
+
+    expect(response.content).toBe('Response from global-fallback');
+    expect(response.fallback).toBe(true);
+  });
+
+  it('skips tier fallbacks when none configured for that tier', async () => {
+    const failingComplex = createMockClient('complex', true);
+    const globalFallback = createMockClient('global-fallback');
+
+    const router = new ModelRouter({
+      default: createMockClient('default'),
+      complex: failingComplex,
+      fallbackChain: [globalFallback],
+      tierFallbacks: new Map([['fast', [createMockClient('fast-fb')]]]),
+    });
+
+    const response = await router.chat(
+      { messages: [{ role: 'user', content: 'Hi' }] },
+      'complex',
+    );
+
+    expect(response.content).toBe('Response from global-fallback');
+  });
+});
+
 describe('ModelRouter streaming', () => {
   it('streams from primary client', async () => {
     const mockStream = async function* (): AsyncIterable<ChatStreamEvent> {
@@ -147,6 +224,53 @@ describe('ModelRouter streaming', () => {
     expect(chunks).toEqual(['Fallback']);
     expect(fallbackWarning).toMatch(/Primary model failed/);
   });
+
+  it('uses tier fallback for streaming before global chain', async () => {
+    const failingStream = async function* (): AsyncIterable<ChatStreamEvent> {
+      yield { type: 'error', error: new Error('Primary failed') };
+    };
+
+    const tierFallbackStream = async function* (): AsyncIterable<ChatStreamEvent> {
+      yield { type: 'content', content: 'TierFallback' };
+      yield { type: 'done', usage: { inputTokens: 5, outputTokens: 3 } };
+    };
+
+    const globalStream = async function* (): AsyncIterable<ChatStreamEvent> {
+      yield { type: 'content', content: 'Global' };
+      yield { type: 'done', usage: { inputTokens: 5, outputTokens: 3 } };
+    };
+
+    const primaryClient = {
+      chat: vi.fn(),
+      chatStream: vi.fn().mockReturnValue(failingStream()),
+    };
+
+    const tierFallbackClient = {
+      chat: vi.fn(),
+      chatStream: vi.fn().mockReturnValue(tierFallbackStream()),
+    };
+
+    const globalClient = {
+      chat: vi.fn(),
+      chatStream: vi.fn().mockReturnValue(globalStream()),
+    };
+
+    const router = new ModelRouter({
+      default: primaryClient,
+      fallbackChain: [globalClient],
+      tierFallbacks: new Map([['default', [tierFallbackClient]]]),
+    });
+
+    const chunks: string[] = [];
+    for await (const event of router.chatStream({ messages: [] })) {
+      if (event.type === 'content' && event.content) {
+        chunks.push(event.content);
+      }
+    }
+
+    expect(chunks).toEqual(['TierFallback']);
+    expect(globalClient.chatStream).not.toHaveBeenCalled();
+  });
 });
 
 describe('ModelRouter local client switching', () => {

src/models/router.ts

@@ -10,6 +10,7 @@ export interface ModelRouterConfig {
   complex?: ModelClient;
   local?: ModelClient;
   fallbackChain: ModelClient[];
+  tierFallbacks?: Map<ModelTier, ModelClient[]>;
   retryConfig?: RetryConfig;
   labels?: Partial<Record<ModelTier, string>>;
 }
@@ -19,6 +20,7 @@ export class ModelRouter implements ModelClient {
   private labels: Map<ModelTier, string>;
   private defaultClient: ModelClient;
   private fallbackChain: ModelClient[];
+  private tierFallbacks: Map<ModelTier, ModelClient[]>;
   private currentTier: ModelTier = 'default';
   private localProviderName?: string;
   private retryConfig?: RetryConfig;
@@ -28,6 +30,7 @@ export class ModelRouter implements ModelClient {
     this.labels = new Map();
     this.defaultClient = config.default;
     this.fallbackChain = config.fallbackChain;
+    this.tierFallbacks = config.tierFallbacks ?? new Map();
     this.retryConfig = config.retryConfig;
 
     this.clients.set('default', config.default);
@@ -76,17 +79,31 @@ export class ModelRouter implements ModelClient {
       console.warn(`Primary model failed: ${errors[0].message}`);
     }
 
-    // Try fallback chain
+    // Try tier-specific fallbacks first
+    const tierFallbackList = this.tierFallbacks.get(useTier) ?? [];
+    for (let i = 0; i < tierFallbackList.length; i++) {
+      try {
+        const reason = `Primary model failed (${errors[0].message}), using tier fallback #${i + 1}`;
+        console.warn(reason);
+        const response = await tierFallbackList[i].chat(request);
+        return { ...response, fallback: true, fallbackReason: reason };
+      } catch (error) {
+        errors.push(error instanceof Error ? error : new Error(String(error)));
+        console.warn(`Tier fallback #${i + 1} failed: ${errors[errors.length - 1].message}`);
+      }
+    }
+
+    // Then try global fallback chain
     for (let i = 0; i < this.fallbackChain.length; i++) {
       const fallbackClient = this.fallbackChain[i];
       try {
-        const reason = `Primary model failed (${errors[0].message}), using fallback #${i + 1}`;
+        const reason = `Primary model failed (${errors[0].message}), using global fallback #${i + 1}`;
         console.warn(reason);
         const response = await fallbackClient.chat(request);
         return { ...response, fallback: true, fallbackReason: reason };
       } catch (error) {
         errors.push(error instanceof Error ? error : new Error(String(error)));
-        console.warn(`Fallback model #${i + 1} failed: ${errors[errors.length - 1].message}`);
+        console.warn(`Global fallback #${i + 1} failed: ${errors[errors.length - 1].message}`);
       }
     }
 
@@ -115,12 +132,13 @@ export class ModelRouter implements ModelClient {
       primaryError = 'Primary client does not support streaming';
     }
 
-    // Try fallback chain
-    for (let i = 0; i < this.fallbackChain.length; i++) {
-      const fallbackClient = this.fallbackChain[i];
+    // Try tier-specific fallbacks first
+    const tierFallbackList = this.tierFallbacks.get(useTier) ?? [];
+    for (let i = 0; i < tierFallbackList.length; i++) {
+      const fallbackClient = tierFallbackList[i];
       if (!fallbackClient.chatStream) continue;
 
-      const reason = `Primary model failed (${primaryError}), using fallback #${i + 1}`;
+      const reason = `Primary model failed (${primaryError}), using tier fallback #${i + 1}`;
       console.warn(reason);
       yield { type: 'fallback_warning', fallbackReason: reason };
 
@@ -128,7 +146,29 @@ export class ModelRouter implements ModelClient {
       for await (const event of fallbackClient.chatStream(request)) {
         if (event.type === 'error') {
           hasError = true;
-          console.warn(`Fallback stream #${i + 1} failed: ${event.error?.message}`);
+          console.warn(`Tier fallback stream #${i + 1} failed: ${event.error?.message}`);
+          break;
+        }
+        yield event;
+      }
+
+      if (!hasError) return;
+    }
+
+    // Then try global fallback chain
+    for (let i = 0; i < this.fallbackChain.length; i++) {
+      const fallbackClient = this.fallbackChain[i];
+      if (!fallbackClient.chatStream) continue;
+
+      const reason = `Primary model failed (${primaryError}), using global fallback #${i + 1}`;
+      console.warn(reason);
+      yield { type: 'fallback_warning', fallbackReason: reason };
+
+      let hasError = false;
+      for await (const event of fallbackClient.chatStream(request)) {
+        if (event.type === 'error') {
+          hasError = true;
+          console.warn(`Global fallback stream #${i + 1} failed: ${event.error?.message}`);
           break;
         }
         yield event;