fix: Windows platform improvements — re-enable Chroma, fix DB race, simplify env isolation

1. ProcessManager: Migrate spawnDaemon() from WMIC to PowerShell Start-Process
   - WMIC deprecated in Windows 11, PowerShell inherits env vars properly
   - Use -WindowStyle Hidden to prevent console popups
   - Fix redundant backslash escaping in PowerShell $_ variables

2. ChromaSync: Re-enable vector search on Windows
   - Remove overly defensive platform check that disabled all semantic search
   - Worker daemon starts with -WindowStyle Hidden; child processes inherit
   - MCP SDK's StdioClientTransport uses shell:false, no new console created

3. worker-service: Unified DB-ready gate middleware
   - Replace single-endpoint /api/sessions/init wait with global middleware
   - Hold all DB-dependent requests until database is initialized (30s timeout)
   - Whitelist static assets, /health, and viewer page for immediate response
   - Separate dbReadyPromise (DB only) from initializationComplete (full init)
   - Fixes "Database not initialized" errors on /stream, /summarize, /init

4. EnvManager: Switch from allowlist to blocklist for subprocess env
   - Only strip ANTHROPIC_API_KEY to prevent Issue #733 billing hijack
   - Pass through all other vars (ANTHROPIC_AUTH_TOKEN, ANTHROPIC_BASE_URL, etc.)
   - Simpler, less fragile than maintaining an exhaustive system vars allowlist

src/services/infrastructure/ProcessManager.ts

@@ -101,7 +101,7 @@ export async function getChildProcesses(parentPid: number): Promise<number[]> {
 
   try {
     // PowerShell Get-Process instead of WMIC (deprecated in Windows 11)
-    const cmd = `powershell -NoProfile -NonInteractive -Command "Get-Process | Where-Object { \\$_.ParentProcessId -eq ${parentPid} } | Select-Object -ExpandProperty Id"`;
+    const cmd = `powershell -NoProfile -NonInteractive -Command "Get-Process | Where-Object { $_.ParentProcessId -eq ${parentPid} } | Select-Object -ExpandProperty Id"`;
     const { stdout } = await execAsync(cmd, { timeout: HOOK_TIMEOUTS.POWERSHELL_COMMAND });
     // PowerShell outputs just numbers (one per line), simpler than WMIC's "ProcessId=1234" format
     return stdout
@@ -226,10 +226,10 @@ export async function cleanupOrphanedProcesses(): Promise<void> {
     if (isWindows) {
       // Windows: Use PowerShell Get-CimInstance with JSON output for age filtering
       const patternConditions = ORPHAN_PROCESS_PATTERNS
-        .map(p => `\\$_.CommandLine -like '*${p}*'`)
+        .map(p => `$_.CommandLine -like '*${p}*'`)
         .join(' -or ');
 
-      const cmd = `powershell -NoProfile -NonInteractive -Command "Get-CimInstance Win32_Process | Where-Object { (${patternConditions}) -and \\$_.ProcessId -ne ${currentPid} } | Select-Object ProcessId, CreationDate | ConvertTo-Json"`;
+      const cmd = `powershell -NoProfile -NonInteractive -Command "Get-CimInstance Win32_Process | Where-Object { (${patternConditions}) -and $_.ProcessId -ne ${currentPid} } | Select-Object ProcessId, CreationDate | ConvertTo-Json"`;
       const { stdout } = await execAsync(cmd, { timeout: HOOK_TIMEOUTS.POWERSHELL_COMMAND });
 
       if (!stdout.trim() || stdout.trim() === 'null') {
@@ -339,9 +339,9 @@ export async function cleanupOrphanedProcesses(): Promise<void> {
  * Spawn a detached daemon process
  * Returns the child PID or undefined if spawn failed
  *
- * On Windows, uses WMIC to spawn a truly independent process that
- * survives parent exit without console popups. WMIC creates processes
- * that are not associated with the parent's console.
+ * On Windows, uses PowerShell Start-Process with -WindowStyle Hidden to spawn
+ * a truly independent process without console popups. Unlike WMIC, PowerShell
+ * inherits environment variables from the parent process.
  *
  * On Unix, uses standard detached spawn.
  *
@@ -361,21 +361,19 @@ export function spawnDaemon(
   };
 
   if (isWindows) {
-    // Use WMIC to spawn a process that's independent of the parent console
-    // This avoids the console popup that occurs with detached: true
-    // Paths must be individually quoted for WMIC when they contain spaces
+    // Use PowerShell Start-Process to spawn a hidden, independent process
+    // Unlike WMIC, PowerShell inherits environment variables from parent
+    // -WindowStyle Hidden prevents console popup
     const execPath = process.execPath;
     const script = scriptPath;
-    // WMIC command format: wmic process call create "\"path1\" \"path2\" args"
-    const command = `wmic process call create "\\"${execPath}\\" \\"${script}\\" --daemon"`;
+    const psCommand = `Start-Process -FilePath '${execPath}' -ArgumentList '${script}','--daemon' -WindowStyle Hidden`;
 
     try {
-      execSync(command, {
+      execSync(`powershell -NoProfile -Command "${psCommand}"`, {
         stdio: 'ignore',
-        windowsHide: true
+        windowsHide: true,
+        env
       });
-      // WMIC returns immediately, we can't get the spawned PID easily
-      // Worker will write its own PID file after listen()
       return 0;
     } catch {
       return undefined;

src/services/sync/ChromaSync.ts

@@ -85,25 +85,15 @@ export class ChromaSync {
   private readonly VECTOR_DB_DIR: string;
   private readonly BATCH_SIZE = 100;
 
-  // Windows: Chroma disabled due to MCP SDK spawning console popups
-  // See: https://github.com/anthropics/claude-mem/issues/675
-  // Will be re-enabled when we migrate to persistent HTTP server
-  private readonly disabled: boolean;
+  // Windows popup concern resolved: the worker daemon starts with -WindowStyle Hidden,
+  // so child processes (uvx/chroma-mcp) inherit the hidden console and don't create new windows.
+  // MCP SDK's StdioClientTransport uses shell:false and no detached flag, so console is inherited.
+  private readonly disabled: boolean = false;
 
   constructor(project: string) {
     this.project = project;
     this.collectionName = `cm__${project}`;
     this.VECTOR_DB_DIR = path.join(os.homedir(), '.claude-mem', 'vector-db');
-
-    // Disable on Windows to prevent console popups from MCP subprocess spawning
-    // The MCP SDK's StdioClientTransport spawns Python processes that create visible windows
-    this.disabled = process.platform === 'win32';
-    if (this.disabled) {
-      logger.warn('CHROMA_SYNC', 'Vector search disabled on Windows (prevents console popups)', {
-        project: this.project,
-        reason: 'MCP SDK subprocess spawning causes visible console windows'
-      });
-    }
   }
 
   /**
@@ -203,7 +193,6 @@ export class ChromaSync {
       // See: https://github.com/thedotmack/claude-mem/issues/170 (Python 3.14 incompatibility)
       const settings = SettingsDefaultsManager.loadFromFile(USER_SETTINGS_PATH);
       const pythonVersion = settings.CLAUDE_MEM_PYTHON_VERSION;
-      const isWindows = process.platform === 'win32';
 
       // Get combined SSL certificate bundle for Zscaler/corporate proxy environments
       const combinedCertPath = this.getCombinedCertPath();
@@ -232,12 +221,9 @@ export class ChromaSync {
         });
       }
 
-      // CRITICAL: On Windows, try to hide console window to prevent PowerShell popups
-      // Note: windowsHide may not be supported by MCP SDK's StdioClientTransport
-      if (isWindows) {
-        transportOptions.windowsHide = true;
-        logger.debug('CHROMA_SYNC', 'Windows detected, attempting to hide console window', { project: this.project });
-      }
+      // Note: windowsHide is not needed here because the worker daemon starts with
+      // -WindowStyle Hidden, so child processes inherit the hidden console.
+      // The MCP SDK ignores custom windowsHide anyway (overridden internally).
 
       this.transport = new StdioClientTransport(transportOptions);
 

src/shared/EnvManager.ts

@@ -18,33 +18,15 @@ import { logger } from '../utils/logger.js';
 const DATA_DIR = join(homedir(), '.claude-mem');
 export const ENV_FILE_PATH = join(DATA_DIR, '.env');
 
-// Essential system environment variables that subprocesses need to function
-const ESSENTIAL_SYSTEM_VARS = [
-  'PATH',
-  'HOME',
-  'USER',
-  'SHELL',
-  'TMPDIR',
-  'TMP',
-  'TEMP',
-  'LANG',
-  'LC_ALL',
-  'LC_CTYPE',
-  // Node.js specific
-  'NODE_ENV',
-  'NODE_PATH',
-  // Platform specific
-  'SYSTEMROOT',      // Windows
-  'WINDIR',          // Windows
-  'PROGRAMFILES',    // Windows
-  'APPDATA',         // Windows
-  'LOCALAPPDATA',    // Windows
-  'XDG_RUNTIME_DIR', // Linux
-  'XDG_CONFIG_HOME', // Linux
-  'XDG_DATA_HOME',   // Linux
-  // Claude Code specific (not credentials)
-  'CLAUDE_CONFIG_DIR',
-  'CLAUDE_CODE_DEBUG_LOGS_DIR',
+// Environment variables to STRIP from subprocess environment (blocklist approach)
+// Only ANTHROPIC_API_KEY is stripped because it's the specific variable that causes
+// Issue #733: project .env files set ANTHROPIC_API_KEY which the SDK auto-discovers,
+// causing memory operations to bill personal API accounts instead of CLI subscription.
+//
+// All other env vars (ANTHROPIC_AUTH_TOKEN, ANTHROPIC_BASE_URL, system vars, etc.)
+// 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
 ];
 
 // Credential keys that claude-mem manages
@@ -191,39 +173,44 @@ export function saveClaudeMemEnv(env: ClaudeMemEnv): void {
 }
 
 /**
- * Build a clean, isolated environment for spawning SDK subprocesses
+ * Build a clean environment for spawning SDK subprocesses
  *
- * This is the key function that prevents Issue #733:
- * - Includes only essential system variables (PATH, HOME, etc.)
- * - Adds credentials ONLY from claude-mem's .env file
- * - Does NOT inherit random ANTHROPIC_API_KEY from user's shell
+ * Uses a BLOCKLIST approach: inherits the full process environment but strips
+ * only ANTHROPIC_API_KEY to prevent Issue #733 (accidental billing from project .env files).
  *
- * @param includeCredentials - Whether to include API keys (default: true)
+ * All other variables pass through, including:
+ * - ANTHROPIC_AUTH_TOKEN (CLI subscription auth)
+ * - ANTHROPIC_BASE_URL (custom proxy endpoints)
+ * - Platform-specific vars (USERPROFILE, XDG_*, etc.)
+ *
+ * If claude-mem has an explicit ANTHROPIC_API_KEY in ~/.claude-mem/.env, it's re-injected
+ * after stripping, so the managed credential takes precedence over any ambient value.
+ *
+ * @param includeCredentials - Whether to include API keys from ~/.claude-mem/.env (default: true)
  */
 export function buildIsolatedEnv(includeCredentials: boolean = true): Record<string, string> {
+  // 1. Start with full process environment
   const isolatedEnv: Record<string, string> = {};
-
-  // 1. Copy essential system variables from current process
-  for (const key of ESSENTIAL_SYSTEM_VARS) {
-    const value = process.env[key];
-    if (value !== undefined) {
+  for (const [key, value] of Object.entries(process.env)) {
+    if (value !== undefined && !BLOCKED_ENV_VARS.includes(key)) {
       isolatedEnv[key] = value;
     }
   }
 
-  // 2. Add SDK entrypoint marker
+  // 2. Override SDK entrypoint marker
   isolatedEnv.CLAUDE_CODE_ENTRYPOINT = 'sdk-ts';
 
-  // 3. Add credentials from claude-mem's .env file (NOT from process.env)
+  // 3. Re-inject managed credentials from claude-mem's .env file
   if (includeCredentials) {
     const credentials = loadClaudeMemEnv();
 
     // Only add ANTHROPIC_API_KEY if explicitly configured in claude-mem
-    // If not configured, CLI billing will be used (via pathToClaudeCodeExecutable)
+    // If not configured, CLI billing will be used (via ANTHROPIC_AUTH_TOKEN passthrough)
     if (credentials.ANTHROPIC_API_KEY) {
       isolatedEnv.ANTHROPIC_API_KEY = credentials.ANTHROPIC_API_KEY;
     }
-    // Note: GEMINI_API_KEY and OPENROUTER_API_KEY are handled by their respective agents
+    // Note: GEMINI_API_KEY and OPENROUTER_API_KEY pass through from process.env,
+    // but claude-mem's .env takes precedence if configured
     if (credentials.GEMINI_API_KEY) {
       isolatedEnv.GEMINI_API_KEY = credentials.GEMINI_API_KEY;
     }