fix(channels): isolate bundled load failures

src/channels/plugins/bootstrap-registry.ts

@@ -127,8 +127,15 @@ export function getBootstrapChannelPlugin(id: ChannelId): ChannelPlugin | undefi
   if (registry.missingIds.has(resolvedId)) {
     return undefined;
   }
-  const runtimePlugin = getBundledChannelPlugin(resolvedId);
-  const setupPlugin = getBundledChannelSetupPlugin(resolvedId);
+  let runtimePlugin: ChannelPlugin | undefined;
+  let setupPlugin: ChannelPlugin | undefined;
+  try {
+    runtimePlugin = getBundledChannelPlugin(resolvedId);
+    setupPlugin = getBundledChannelSetupPlugin(resolvedId);
+  } catch {
+    registry.missingIds.add(resolvedId);
+    return undefined;
+  }
   const merged =
     runtimePlugin && setupPlugin
       ? mergeBootstrapPlugin(runtimePlugin, setupPlugin)
@@ -154,11 +161,21 @@ export function getBootstrapChannelSecrets(id: ChannelId): ChannelPlugin["secret
   if (registry.secretsById.has(resolvedId)) {
     return undefined;
   }
-  const runtimeSecrets = getBundledChannelSecrets(resolvedId);
-  const setupSecrets = getBundledChannelSetupSecrets(resolvedId);
-  const merged = mergePluginSection(runtimeSecrets, setupSecrets);
-  registry.secretsById.set(resolvedId, merged ?? null);
-  return merged;
+  if (registry.missingIds.has(resolvedId)) {
+    registry.secretsById.set(resolvedId, null);
+    return undefined;
+  }
+  try {
+    const runtimeSecrets = getBundledChannelSecrets(resolvedId);
+    const setupSecrets = getBundledChannelSetupSecrets(resolvedId);
+    const merged = mergePluginSection(runtimeSecrets, setupSecrets);
+    registry.secretsById.set(resolvedId, merged ?? null);
+    return merged;
+  } catch {
+    registry.missingIds.add(resolvedId);
+    registry.secretsById.set(resolvedId, null);
+    return undefined;
+  }
 }
 
 export function clearBootstrapChannelPluginCache(): void {

src/channels/plugins/bundled-root-caches.test.ts

@@ -144,4 +144,78 @@ describe("bundled root-aware caches", () => {
       bootstrapRegistry.getBootstrapChannelSecrets("beta")?.secretTargetRegistryEntries?.[0]?.id,
     ).toBe("setup-beta-B");
   });
+
+  it("marks bundled plugin ids missing when bootstrap plugin loading throws", async () => {
+    const root = makeBundledRoot("openclaw-bootstrap-plugin-throw-");
+
+    vi.doMock("./bundled-ids.js", () => ({
+      listBundledChannelPluginIdsForRoot: (cacheKey: string) =>
+        cacheKey === root.pluginsDir ? ["alpha"] : [],
+    }));
+
+    const getBundledChannelPluginMock = vi.fn(() => {
+      throw new Error("Cannot find module 'nostr-tools'");
+    });
+    const getBundledChannelSecretsMock = vi.fn(() => {
+      throw new Error("secrets should not load after plugin is marked missing");
+    });
+
+    vi.doMock("./bundled.js", () => ({
+      getBundledChannelPlugin: getBundledChannelPluginMock,
+      getBundledChannelSetupPlugin: vi.fn(() => undefined),
+      getBundledChannelSecrets: getBundledChannelSecretsMock,
+      getBundledChannelSetupSecrets: vi.fn(() => undefined),
+    }));
+
+    const bootstrapRegistry = await importFreshModule<typeof import("./bootstrap-registry.js")>(
+      import.meta.url,
+      "./bootstrap-registry.js?scope=bootstrap-plugin-load-guard",
+    );
+
+    process.env.OPENCLAW_BUNDLED_PLUGINS_DIR = root.pluginsDir;
+    expect(bootstrapRegistry.listBootstrapChannelPluginIds()).toEqual(["alpha"]);
+    expect(bootstrapRegistry.getBootstrapChannelPlugin("alpha")).toBeUndefined();
+    expect(bootstrapRegistry.getBootstrapChannelPlugin("alpha")).toBeUndefined();
+    expect(bootstrapRegistry.getBootstrapChannelSecrets("alpha")).toBeUndefined();
+    expect(getBundledChannelPluginMock).toHaveBeenCalledTimes(1);
+    expect(getBundledChannelSecretsMock).not.toHaveBeenCalled();
+  });
+
+  it("marks bundled plugin ids missing when bootstrap secrets loading throws", async () => {
+    const root = makeBundledRoot("openclaw-bootstrap-secrets-throw-");
+
+    vi.doMock("./bundled-ids.js", () => ({
+      listBundledChannelPluginIdsForRoot: (cacheKey: string) =>
+        cacheKey === root.pluginsDir ? ["alpha"] : [],
+    }));
+
+    const getBundledChannelSecretsMock = vi.fn(() => {
+      throw new Error("Cannot find module '@larksuiteoapi/node-sdk'");
+    });
+    const getBundledChannelPluginMock = vi.fn(() => ({
+      id: "alpha",
+      meta: { id: "alpha", label: "Alpha" },
+      capabilities: {},
+      config: {},
+    }));
+
+    vi.doMock("./bundled.js", () => ({
+      getBundledChannelPlugin: getBundledChannelPluginMock,
+      getBundledChannelSetupPlugin: vi.fn(() => undefined),
+      getBundledChannelSecrets: getBundledChannelSecretsMock,
+      getBundledChannelSetupSecrets: vi.fn(() => undefined),
+    }));
+
+    const bootstrapRegistry = await importFreshModule<typeof import("./bootstrap-registry.js")>(
+      import.meta.url,
+      "./bootstrap-registry.js?scope=bootstrap-secrets-load-guard",
+    );
+
+    process.env.OPENCLAW_BUNDLED_PLUGINS_DIR = root.pluginsDir;
+    expect(bootstrapRegistry.getBootstrapChannelSecrets("alpha")).toBeUndefined();
+    expect(bootstrapRegistry.getBootstrapChannelSecrets("alpha")).toBeUndefined();
+    expect(bootstrapRegistry.getBootstrapChannelPlugin("alpha")).toBeUndefined();
+    expect(getBundledChannelSecretsMock).toHaveBeenCalledTimes(1);
+    expect(getBundledChannelPluginMock).not.toHaveBeenCalled();
+  });
 });

src/channels/plugins/bundled.shape-guard.test.ts

@@ -635,6 +635,95 @@ describe("bundled channel entry shape guards", () => {
     }
   });
 
+  it("swallows and caches bundled plugin and setup load failures", async () => {
+    const root = fs.mkdtempSync(path.join(os.tmpdir(), "openclaw-bundled-load-failure-"));
+    const previousBundledPluginsDir = process.env.OPENCLAW_BUNDLED_PLUGINS_DIR;
+    const pluginDir = path.join(root, "dist", "extensions", "alpha");
+    const testGlobal = globalThis as typeof globalThis & {
+      __bundledPluginFailureLoads?: number;
+      __bundledSetupFailureLoads?: number;
+      __bundledSecretsFailureLoads?: number;
+      __bundledSetupSecretsFailureLoads?: number;
+    };
+    fs.mkdirSync(pluginDir, { recursive: true });
+    fs.writeFileSync(
+      path.join(root, "package.json"),
+      JSON.stringify({ name: "openclaw", version: "2026.4.21" }),
+      "utf8",
+    );
+    fs.writeFileSync(
+      path.join(pluginDir, "index.js"),
+      [
+        "export default {",
+        "  kind: 'bundled-channel-entry',",
+        "  id: 'alpha',",
+        "  name: 'Alpha',",
+        "  description: 'Alpha',",
+        "  register() {},",
+        "  loadChannelSecrets() {",
+        "    globalThis.__bundledSecretsFailureLoads = (globalThis.__bundledSecretsFailureLoads ?? 0) + 1;",
+        "    throw new Error('missing channel secrets dep');",
+        "  },",
+        "  loadChannelPlugin() {",
+        "    globalThis.__bundledPluginFailureLoads = (globalThis.__bundledPluginFailureLoads ?? 0) + 1;",
+        "    throw new Error('missing channel plugin dep');",
+        "  },",
+        "};",
+        "",
+      ].join("\n"),
+      "utf8",
+    );
+    fs.writeFileSync(
+      path.join(pluginDir, "setup-entry.js"),
+      [
+        "export default {",
+        "  kind: 'bundled-channel-setup-entry',",
+        "  loadSetupSecrets() {",
+        "    globalThis.__bundledSetupSecretsFailureLoads = (globalThis.__bundledSetupSecretsFailureLoads ?? 0) + 1;",
+        "    throw new Error('missing setup secrets dep');",
+        "  },",
+        "  loadSetupPlugin() {",
+        "    globalThis.__bundledSetupFailureLoads = (globalThis.__bundledSetupFailureLoads ?? 0) + 1;",
+        "    throw new Error('missing setup plugin dep');",
+        "  },",
+        "};",
+        "",
+      ].join("\n"),
+      "utf8",
+    );
+
+    mockAlphaDistExtensionRuntime();
+
+    try {
+      process.env.OPENCLAW_BUNDLED_PLUGINS_DIR = path.join(root, "dist", "extensions");
+
+      const bundled = await importFreshModule<typeof import("./bundled.js")>(
+        import.meta.url,
+        "./bundled.js?scope=bundled-load-failure",
+      );
+
+      expect(bundled.getBundledChannelPlugin("alpha")).toBeUndefined();
+      expect(bundled.getBundledChannelPlugin("alpha")).toBeUndefined();
+      expect(bundled.getBundledChannelSetupPlugin("alpha")).toBeUndefined();
+      expect(bundled.getBundledChannelSetupPlugin("alpha")).toBeUndefined();
+      expect(bundled.getBundledChannelSecrets("alpha")).toBeUndefined();
+      expect(bundled.getBundledChannelSecrets("alpha")).toBeUndefined();
+      expect(bundled.getBundledChannelSetupSecrets("alpha")).toBeUndefined();
+      expect(bundled.getBundledChannelSetupSecrets("alpha")).toBeUndefined();
+      expect(testGlobal.__bundledPluginFailureLoads).toBe(1);
+      expect(testGlobal.__bundledSetupFailureLoads).toBe(1);
+      expect(testGlobal.__bundledSecretsFailureLoads).toBe(1);
+      expect(testGlobal.__bundledSetupSecretsFailureLoads).toBe(1);
+    } finally {
+      restoreBundledPluginsDir(previousBundledPluginsDir);
+      fs.rmSync(root, { recursive: true, force: true });
+      delete testGlobal.__bundledPluginFailureLoads;
+      delete testGlobal.__bundledSetupFailureLoads;
+      delete testGlobal.__bundledSecretsFailureLoads;
+      delete testGlobal.__bundledSetupSecretsFailureLoads;
+    }
+  });
+
   it("keeps channel entrypoints on the dedicated entry-contract SDK surface", () => {
     const offenders = collectBundledChannelEntrypointOffenders(
       bundledPluginRoots,

src/channels/plugins/bundled.ts

@@ -66,8 +66,8 @@ type BundledChannelCacheContext = {
   setupEntryLoadInProgressIds: Set<ChannelId>;
   lazyEntriesById: Map<ChannelId, GeneratedBundledChannelEntry | null>;
   lazySetupEntriesById: Map<ChannelId, BundledChannelSetupEntryRuntimeContract | null>;
-  lazyPluginsById: Map<ChannelId, ChannelPlugin>;
-  lazySetupPluginsById: Map<ChannelId, ChannelPlugin>;
+  lazyPluginsById: Map<ChannelId, ChannelPlugin | null>;
+  lazySetupPluginsById: Map<ChannelId, ChannelPlugin | null>;
   lazySecretsById: Map<ChannelId, ChannelPlugin["secrets"] | null>;
   lazySetupSecretsById: Map<ChannelId, ChannelPlugin["secrets"] | null>;
   lazyAccountInspectorsById: Map<
@@ -461,9 +461,8 @@ function getBundledChannelPluginForRoot(
   rootScope: BundledChannelRootScope,
   cacheContext: BundledChannelCacheContext,
 ): ChannelPlugin | undefined {
-  const cached = cacheContext.lazyPluginsById.get(id);
-  if (cached) {
-    return cached;
+  if (cacheContext.lazyPluginsById.has(id)) {
+    return cacheContext.lazyPluginsById.get(id) ?? undefined;
   }
   if (cacheContext.pluginLoadInProgressIds.has(id)) {
     return undefined;
@@ -486,6 +485,11 @@ function getBundledChannelPluginForRoot(
     };
     cacheContext.lazyPluginsById.set(id, normalizedPlugin);
     return normalizedPlugin;
+  } catch (error) {
+    const detail = formatErrorMessage(error);
+    log.warn(`[channels] failed to load bundled channel ${id}: ${detail}`);
+    cacheContext.lazyPluginsById.set(id, null);
+    return undefined;
   } finally {
     cacheContext.pluginLoadInProgressIds.delete(id);
   }
@@ -503,11 +507,18 @@ function getBundledChannelSecretsForRoot(
   if (!entry) {
     return undefined;
   }
-  const secrets =
-    entry.loadChannelSecrets?.() ??
-    getBundledChannelPluginForRoot(id, rootScope, cacheContext)?.secrets;
-  cacheContext.lazySecretsById.set(id, secrets ?? null);
-  return secrets;
+  try {
+    const secrets =
+      entry.loadChannelSecrets?.() ??
+      getBundledChannelPluginForRoot(id, rootScope, cacheContext)?.secrets;
+    cacheContext.lazySecretsById.set(id, secrets ?? null);
+    return secrets;
+  } catch (error) {
+    const detail = formatErrorMessage(error);
+    log.warn(`[channels] failed to load bundled channel secrets ${id}: ${detail}`);
+    cacheContext.lazySecretsById.set(id, null);
+    return undefined;
+  }
 }
 
 function getBundledChannelAccountInspectorForRoot(
@@ -523,9 +534,16 @@ function getBundledChannelAccountInspectorForRoot(
     cacheContext.lazyAccountInspectorsById.set(id, null);
     return undefined;
   }
-  const inspector = entry.loadChannelAccountInspector();
-  cacheContext.lazyAccountInspectorsById.set(id, inspector);
-  return inspector;
+  try {
+    const inspector = entry.loadChannelAccountInspector();
+    cacheContext.lazyAccountInspectorsById.set(id, inspector);
+    return inspector;
+  } catch (error) {
+    const detail = formatErrorMessage(error);
+    log.warn(`[channels] failed to load bundled channel account inspector ${id}: ${detail}`);
+    cacheContext.lazyAccountInspectorsById.set(id, null);
+    return undefined;
+  }
 }
 
 function getBundledChannelSetupPluginForRoot(
@@ -533,9 +551,8 @@ function getBundledChannelSetupPluginForRoot(
   rootScope: BundledChannelRootScope,
   cacheContext: BundledChannelCacheContext,
 ): ChannelPlugin | undefined {
-  const cached = cacheContext.lazySetupPluginsById.get(id);
-  if (cached) {
-    return cached;
+  if (cacheContext.lazySetupPluginsById.has(id)) {
+    return cacheContext.lazySetupPluginsById.get(id) ?? undefined;
   }
   if (cacheContext.setupPluginLoadInProgressIds.has(id)) {
     return undefined;
@@ -549,6 +566,11 @@ function getBundledChannelSetupPluginForRoot(
     const plugin = entry.loadSetupPlugin();
     cacheContext.lazySetupPluginsById.set(id, plugin);
     return plugin;
+  } catch (error) {
+    const detail = formatErrorMessage(error);
+    log.warn(`[channels] failed to load bundled channel setup ${id}: ${detail}`);
+    cacheContext.lazySetupPluginsById.set(id, null);
+    return undefined;
   } finally {
     cacheContext.setupPluginLoadInProgressIds.delete(id);
   }
@@ -566,11 +588,18 @@ function getBundledChannelSetupSecretsForRoot(
   if (!entry) {
     return undefined;
   }
-  const secrets =
-    entry.loadSetupSecrets?.() ??
-    getBundledChannelSetupPluginForRoot(id, rootScope, cacheContext)?.secrets;
-  cacheContext.lazySetupSecretsById.set(id, secrets ?? null);
-  return secrets;
+  try {
+    const secrets =
+      entry.loadSetupSecrets?.() ??
+      getBundledChannelSetupPluginForRoot(id, rootScope, cacheContext)?.secrets;
+    cacheContext.lazySetupSecretsById.set(id, secrets ?? null);
+    return secrets;
+  } catch (error) {
+    const detail = formatErrorMessage(error);
+    log.warn(`[channels] failed to load bundled channel setup secrets ${id}: ${detail}`);
+    cacheContext.lazySetupSecretsById.set(id, null);
+    return undefined;
+  }
 }
 
 export function listBundledChannelPlugins(): readonly ChannelPlugin[] {