diff --git a/CHANGELOG.md b/CHANGELOG.md
index e7f06e6..46111bc 100644
--- a/CHANGELOG.md
+++ b/CHANGELOG.md
@@ -9,6 +9,13 @@ Follows [Keep a Changelog](https://keepachangelog.com/en/1.0.0/) · versioned wi
 
 ---
 
+## [1.12.99] — 2026-07-05
+
+### Fixed
+- **"Design all" (Script Rehearser bulk voice design) silently did nothing** — confirmed via server logs: `/api/analyze-characters` succeeded every time, but `/api/voice-design` was never once called. Root cause: `rehState.cast[sp].voice` was accessed unguarded right after the (multi-second, for a large cast) analyze-characters request resolved; any cast-entry change during that window threw a TypeError with nothing to catch it, silently killing the whole run with no toast and no further requests. Guarded the access and wrapped the rest of the flow in a try/catch/finally so any future failure surfaces as a toast and always re-enables the button instead of leaving it stuck with no feedback.
+
+---
+
 ## [1.12.98] — 2026-07-05
 
 ### Added
diff --git a/VERSION b/VERSION
index f12b77f..d8e4738 100644
--- a/VERSION
+++ b/VERSION
@@ -1 +1 @@
-1.12.98
+1.12.99
diff --git a/static/index.html b/static/index.html
index 194a12f..3e21e7a 100644
--- a/static/index.html
+++ b/static/index.html
@@ -10,7 +10,7 @@
   <meta name="format-detection" content="telephone=no">
   <meta name="color-scheme" content="light dark">
   <meta name="theme-color" content="#2563EB">
-  <meta name="app-version" content="1.12.98">
+  <meta name="app-version" content="1.12.99">
   <link rel="manifest" href="/manifest.webmanifest">
   <link rel="icon" href="/static/icon.svg" type="image/svg+xml">
   <link rel="apple-touch-icon" href="/static/icon.svg">
@@ -27,7 +27,7 @@
 
   <!-- ── Core styles (local — no CDN dependency for first paint) ────────── -->
   <link rel="stylesheet" href="/static/vendor/mdi/materialdesignicons.min.css">
-  <link rel="stylesheet" href="/static/style.css?v=1.12.98">
+  <link rel="stylesheet" href="/static/style.css?v=1.12.99">
 
 
   <!-- ── Flag icons — non-blocking (loaded async, icons appear after JS) ── -->
@@ -365,7 +365,7 @@ window.toggleNavTree = function(treeId, chevronId) {
 </script>
 
 <!-- loader.js: fetches sections → loads JS modules → removes skeleton -->
-<script src="/static/loader.js?v=1.12.98"></script>
+<script src="/static/loader.js?v=1.12.99"></script>
 
 </body>
 </html>
diff --git a/static/js/rehearser.js b/static/js/rehearser.js
index 54d36dd..391496e 100644
--- a/static/js/rehearser.js
+++ b/static/js/rehearser.js
@@ -1880,9 +1880,24 @@ $('reh-autodesign-btn')?.addEventListener('click', async () => {
 
   // 2) For each character, design + save a voice
   let done = 0;
-  const designOnly = speakers.filter(sp => rehState.cast[sp].voice !== 'me');
+  // rehState.cast[sp] used to be assumed always present since `speakers` came
+  // from Object.keys(rehState.cast) moments earlier — but the analyze-characters
+  // await above can take many seconds for a large cast, and if anything
+  // removes/replaces a cast entry while that request is in flight, the plain
+  // `rehState.cast[sp].voice` access below threw a TypeError with nothing
+  // catching it (this whole loop sits outside the try/catch above), silently
+  // killing the click with no toast and no further requests — exactly the
+  // "clicked Design all and nothing happens" symptom, confirmed by server
+  // logs showing analyze-characters succeeding but voice-design never once
+  // being called. Guard it and keep going instead of crashing the whole run.
+  // The outer try/finally below is the same idea one level up: ANY unexpected
+  // exception here used to vanish into the console with the button stuck
+  // disabled — now it surfaces as a toast and always resets the UI.
+  try {
+  const designOnly = speakers.filter(sp => rehState.cast[sp]?.voice !== 'me');
   for (const sp of designOnly) {
     if (rehDesignCancelled) { toast('Cancelled', 'error'); break; }
+    if (!rehState.cast[sp]) { done++; continue; }
     const info = byName[sp.toUpperCase().trim()] || {};
     const gender = (info.gender || 'N').toUpperCase().charAt(0).replace(/[^MFN]/, 'N') || 'N';
     const desc = info.description ||
@@ -1948,11 +1963,15 @@ $('reh-autodesign-btn')?.addEventListener('click', async () => {
   // Refresh the broader voice library so avatars/pictures resolve
   if (typeof loadVoiceLibrary === 'function') await loadVoiceLibrary().catch(()=>{});
 
-  renderCastList();
-  populateNarratorSelect();
-  if (prog) prog.hidden = true;
-  btn.disabled = false;
   if (!rehDesignCancelled) toast(`Designed ${done} voice${done!==1?'s':''} — tagged "${tag}" + Rehearser`, 'success');
+  } catch (e) {
+    toast('Design all failed: ' + (e?.message || e), 'error');
+  } finally {
+    renderCastList();
+    populateNarratorSelect();
+    if (prog) prog.hidden = true;
+    btn.disabled = false;
+  }
 });
 
 // ── Match from library — LLM picks the best EXISTING voice for each character ──