fix: resolve SDK spawn failures and sharp native binary crashes

- Strip CLAUDECODE env var from SDK subprocesses to prevent "cannot be
  launched inside another Claude Code session" error (Claude Code 2.1.42+)
- Lazy-load @chroma-core/default-embed to avoid eagerly pulling in
  sharp native binaries at bundle startup (fixes ERR_DLOPEN_FAILED)
- Add stderr capture to SDK spawn for diagnosing future process failures
- Exclude lockfiles from marketplace rsync and delete stale lockfiles
  before npm install to prevent native dep version mismatches

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

scripts/sync-marketplace.cjs

@@ -61,10 +61,20 @@ function getPluginVersion() {
 console.log('Syncing to marketplace...');
 try {
   execSync(
-    'rsync -av --delete --exclude=.git --exclude=/.mcp.json ./ ~/.claude/plugins/marketplaces/thedotmack/',
+    'rsync -av --delete --exclude=.git --exclude=/.mcp.json --exclude=bun.lock --exclude=package-lock.json ./ ~/.claude/plugins/marketplaces/thedotmack/',
     { stdio: 'inherit' }
   );
 
+  // Remove stale lockfiles before install — they pin old native dep versions
+  const { unlinkSync } = require('fs');
+  for (const lockfile of ['package-lock.json', 'bun.lock']) {
+    const lockpath = path.join(INSTALLED_PATH, lockfile);
+    if (existsSync(lockpath)) {
+      unlinkSync(lockpath);
+      console.log(`Removed stale ${lockfile}`);
+    }
+  }
+
   console.log('Running npm install in marketplace...');
   execSync(
     'cd ~/.claude/plugins/marketplaces/thedotmack/ && npm install',

src/services/sync/ChromaSync.ts

@@ -13,7 +13,6 @@
  */
 
 import { ChromaClient, Collection } from 'chromadb';
-import { DefaultEmbeddingFunction } from '@chroma-core/default-embed';
 import { ParsedObservation, ParsedSummary } from '../../sdk/parser.js';
 import { SessionStore } from '../sqlite/SessionStore.js';
 import { logger } from '../../utils/logger.js';
@@ -191,7 +190,9 @@ export class ChromaSync {
 
     try {
       // getOrCreateCollection handles both cases
-      // Use DefaultEmbeddingFunction for local embeddings (all-MiniLM-L6-v2)
+      // Lazy-load DefaultEmbeddingFunction to avoid eagerly pulling in
+      // @huggingface/transformers → sharp native binaries at bundle startup
+      const { DefaultEmbeddingFunction } = await import('@chroma-core/default-embed');
       const embeddingFunction = new DefaultEmbeddingFunction();
       this.collection = await this.chromaClient.getOrCreateCollection({
         name: this.collectionName,

src/services/worker/ProcessRegistry.ts

@@ -290,12 +290,22 @@ export function createPidCapturingSpawn(sessionDbId: number) {
       windowsHide: true
     });
 
+    // Capture stderr for debugging spawn failures
+    if (child.stderr) {
+      child.stderr.on('data', (data: Buffer) => {
+        logger.debug('SDK_SPAWN', `[session-${sessionDbId}] stderr: ${data.toString().trim()}`);
+      });
+    }
+
     // Register PID
     if (child.pid) {
       registerProcess(child.pid, sessionDbId, child);
 
       // Auto-unregister on exit
-      child.on('exit', () => {
+      child.on('exit', (code: number | null, signal: string | null) => {
+        if (code !== 0) {
+          logger.warn('SDK_SPAWN', `[session-${sessionDbId}] Claude process exited`, { code, signal, pid: child.pid });
+        }
         if (child.pid) {
           unregisterProcess(child.pid);
         }
@@ -306,6 +316,7 @@ export function createPidCapturingSpawn(sessionDbId: number) {
     return {
       stdin: child.stdin,
       stdout: child.stdout,
+      stderr: child.stderr,
       get killed() { return child.killed; },
       get exitCode() { return child.exitCode; },
       kill: child.kill.bind(child),

src/shared/EnvManager.ts

@@ -27,6 +27,7 @@ export const ENV_FILE_PATH = join(DATA_DIR, '.env');
 // are passed through to avoid breaking CLI authentication, proxies, and platform features.
 const BLOCKED_ENV_VARS = [
   'ANTHROPIC_API_KEY',  // Issue #733: Prevent auto-discovery from project .env files
+  'CLAUDECODE',         // Prevent "cannot be launched inside another Claude Code session" error
 ];
 
 // Credential keys that claude-mem manages