How we stream ZIP archives on the fly at scale using nginx + mod_zip — no disk writes, no buffering, with local and remote files in a single archive.

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Instead of downloading files to disk, computing checksums, and building a ZIP before serving it, we use nginx + mod_zip to stream archives directly to the client. PHP returns a short manifest listing file URLs and sizes — nginx fetches each file via internal subrequests and pumps them into a ZIP stream in real time. No temp files, no buffering, no waiting. The main gotcha: file sizes are required upfront (ZIP format constraint), which is trivial for local files and requires a HEAD request for remote ones. We hit a production incident caused by zero sizes in metadata from an external team — silent broken archives, hard to debug because mod_zip subrequests don't surface in normal log pipelines.