Fastify 5 Reply was already sent, did you forget to "return reply"…

When it happens

All of:

1. An async onSend hook that awaits at least once before returning (await of anything — even await null — or real I/O).
2. An async route handler (or async preHandler) that calls reply.send(...) without returning reply or the payload, so the function resolves to undefined:

   app.get('/page', async (req, reply) => { reply.type('text/html').send(html) })  // no return

The same happens in an auth preHandler that does reply.code(401).send(...) and falls through.

Reproduction matrix, fastify 5.12.5, same route without return:

So a hook that happens not to await looks fine in tests; the first time someone adds an await inside it, every page without return reply starts logging 500s.

Cause

reply.send() runs the onSend hooks; with an async hook that awaits, the actual write is deferred to a later tick, so right after send() the response is neither ended nor has headers sent. The async handler then resolves with undefined. Fastify's promise wrapper sees "handler resolved, payload undefined, reply not sent yet" and calls reply.send(undefined) itself — a second send. When the first send finishes, the second one collides: "Reply was already sent", "Cannot write headers after they are sent", and the request is logged with an error status although the client already has the 200 body.

Fix

Write onSend hooks in callback style and call done synchronously:

app.addHook('onSend', (request, reply, payload, done) => {
  reply.header('x-content-type-options', 'nosniff')
  // compute the nonce synchronously (crypto.randomBytes(16).toString('base64') is sync)
  done(null, payload)
})

Also (belt and braces) return the reply from async handlers that call send():

app.get('/page', async (req, reply) => {
  return reply.type('text/html').send(html)
})

Either change alone removed the errors in the reproduction (callback hook with non-returning handlers; or async awaiting hook with return reply). We changed the hooks, because there were many routes and every new one would have to remember return.

Verify

Hit a page and a 401 route, then check the log has no double sends:

curl -s -o /dev/null -w '%{http_code}\n' http://localhost:3000/page     # 200
docker logs --since "$SINCE" api 2>&1 | grep -c 'Reply was already sent'  # 0

(SINCE=$(date -u +%FT%TZ) taken just before the requests, so older log lines are not counted.) In a unit test, collect the pino log lines and assert none has level >= 40 and every res.statusCode equals what the client got.

Notes

• inject() can under-report: with a hook that awaits, inject logged both a 200 and a 500 line; over real HTTP only 500s were logged. Test hooks through a real listener at least once.
• Returning payload vs. mutating it in the async hook made no difference; the await is what matters.
• Only 5.12.5 was tested on 2026-09-30; the behaviour follows from how Fastify 5 wraps async handlers, but other 5.x minors were not re-run here.
• The 401 case (async auth preHandler that sends and falls through) is from our production record; the table above covers the page-handler case.