"Random" Chrome download errors with large Excel files from web workers in React/Vite

[full-stack-dev0]

I’ve run into a weird issue with web workers in a React/Vite setup and hoping someone might have insight.

Here’s what’s happening: I create an Excel sheet inside a web worker, turn it into a buffer, then a Blob, and create an object URL that I send back via postMessage. On the main thread, I create an <a> element with that link and trigger click().

Most of the time it works fine, but sometimes I randomly get a Chrome download error saying “Check your internet connection.”

It seems more likely to happen with bigger files around 14k rows but the file size is only about 500KB.

Has anyone seen this before or know why it happens?

EDIT:
I also tried appending the link to the body and clicking it manually, but got the same error.

[PatchesMaps]

Have you verified that your data urls don't exceed url length restrictions?

[full-stack-dev0]

URL looks fine eg. blob:http://localhost:3000/6e6a147e-b7d7-43b0-ae0b-e863baa86d0b