chore(desktop): remove Claude binary from build pipeline

apps/desktop/electron-builder.ts

@@ -56,13 +56,13 @@ const config: Configuration = {
 			to: "resources/migrations",
 			filter: ["**/*"],
 		},
-		// Claude Code binary - bundled for AI chat functionality
-		{
-			// biome-ignore lint/suspicious/noTemplateCurlyInString: electron-builder variable interpolation
-			from: "resources/bin/${platform}-${arch}",
-			to: "bin",
-			filter: ["**/*"],
-		},
+		// Claude Code binary - no longer bundled; the SDK resolves it at runtime
+		// {
+		// 	// biome-ignore lint/suspicious/noTemplateCurlyInString: electron-builder variable interpolation
+		// 	from: "resources/bin/${platform}-${arch}",
+		// 	to: "bin",
+		// 	filter: ["**/*"],
+		// },
 	],
 
 	files: [

apps/desktop/package.json

@@ -22,9 +22,9 @@
 		"copy:native-modules": "bun run scripts/copy-native-modules.ts",
 		"download:claude": "bun run scripts/download-claude-binary.ts",
 		"upgrade:claude": "bun run scripts/upgrade-claude-binary.ts",
-		"prebuild": "bun run clean:dev && bun run compile:app && bun run copy:native-modules && bun run download:claude",
+		"prebuild": "bun run clean:dev && bun run compile:app && bun run copy:native-modules",
 		"build": "cross-env CSC_IDENTITY_AUTO_DISCOVERY=false electron-builder --publish never",
-		"prepackage": "bun run copy:native-modules && bun run download:claude",
+		"prepackage": "bun run copy:native-modules",
 		"package": "electron-builder --config electron-builder.ts",
 		"install:deps": "electron-builder install-app-deps",
 		"release": "electron-builder --publish always",

apps/desktop/src/lib/trpc/routers/ai-chat/utils/session-manager/agent-execution.ts

@@ -1,3 +1,4 @@
+import { existsSync } from "node:fs";
 import { join } from "node:path";
 import {
 	createPermissionRequest,
@@ -10,19 +11,30 @@ import type { SessionStore } from "../session-store";
 import type { PermissionRequestEvent } from "./session-events";
 import type { ActiveSession } from "./session-types";
 
-function getClaudeBinaryPath(): string {
+function getClaudeBinaryPath(): string | null {
+	let binaryPath: string;
 	if (app.isPackaged) {
-		return join(process.resourcesPath, "bin", "claude");
+		binaryPath = join(process.resourcesPath, "bin", "claude");
+	} else {
+		const platform = process.platform;
+		const arch = process.arch;
+		binaryPath = join(
+			app.getAppPath(),
+			"resources",
+			"bin",
+			`${platform}-${arch}`,
+			"claude",
+		);
 	}
-	const platform = process.platform;
-	const arch = process.arch;
-	return join(
-		app.getAppPath(),
-		"resources",
-		"bin",
-		`${platform}-${arch}`,
-		"claude",
-	);
+
+	if (!existsSync(binaryPath)) {
+		console.warn(
+			`[chat/agent] Claude binary not found at ${binaryPath} — will rely on SDK to resolve`,
+		);
+		return null;
+	}
+
+	return binaryPath;
 }
 
 export interface ResolvePermissionInput {
@@ -56,12 +68,15 @@ export class AgentExecution {
 		onChunk,
 	}: ExecuteAgentInput): Promise<void> {
 		const agentEnv = buildClaudeEnv();
+		const claudeBinaryPath = getClaudeBinaryPath();
 
 		await executeAgent({
 			sessionId,
 			prompt,
 			cwd: session.cwd,
-			pathToClaudeCodeExecutable: getClaudeBinaryPath(),
+			...(claudeBinaryPath && {
+				pathToClaudeCodeExecutable: claudeBinaryPath,
+			}),
 			env: agentEnv,
 			model: session.model,
 			permissionMode: session.permissionMode ?? "default",