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PyInstaller frozen executables buffer stdout when piped to a subprocess (no TTY). Even with flush=True in Python, the OS-level pipe buffer can delay output. This prevented the ready event from reaching the Tauri app, causing the "Starting sidecar..." hang. Fix: set PYTHONUNBUFFERED=1 env var on both prod and dev sidecar commands, plus -u flag for dev mode Python. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>