fix: stop swallowing mkdir errors in memory ensureDir (#41259)

Summary:
- The PR removes the empty `mkdirSync({ recursive: true })` catch in the memory host SDK `ensureDir()`, adds a regression test for surfaced mkdir failures, and adds a changelog entry.
- Reproducibility: yes. from source inspection rather than a locally executed repro. Current main swallows eve ... kdir failure in `ensureDir()`, and the active memory database path calls that helper before opening SQLite.

Automerge notes:
- No ClawSweeper repair was needed after automerge opt-in.

Validation:
- ClawSweeper review passed for head 0f82f185cc.
- Required merge gates passed before the squash merge.

Prepared head SHA: 0f82f185cc
Review: https://github.com/openclaw/openclaw/pull/41259#issuecomment-4326310101

Co-authored-by: Yufeng He <40085740+he-yufeng@users.noreply.github.com>
Co-authored-by: clawsweeper[bot] <274271284+clawsweeper[bot]@users.noreply.github.com>
Approved-by: takhoffman
Co-authored-by: takhoffman <781889+takhoffman@users.noreply.github.com>

CHANGELOG.md

@@ -1645,6 +1645,7 @@ Docs: https://docs.openclaw.ai
 - Dependencies: bump transitive `basic-ftp` to 5.3.1 so the runtime lockfile no longer includes the vulnerable 5.3.0 build flagged by the production dependency audit. (#78637) Thanks @sallyom.
 - Hooks/cron: log returned `/hooks/agent` isolated-run errors and failed cron jobs with cron diagnostic summaries, so rejected `payload.model` values are visible instead of looking like accepted-but-missing runs. Fixes #78597. (#78655) Thanks @kevinslin.
 - Managed proxy/security: classify raw socket callsites and proxy runtime mutations in boundary checks so new direct egress or unmanaged proxy-state changes cannot land without explicit review. (#77126) Thanks @jesse-merhi.
+- Memory indexing: propagate memory directory creation failures immediately instead of reporting an unusable directory as ready. Thanks @he-yufeng.
 - Channels/iMessage: surface the silent group-allowlist drop at default log level by emitting a one-time `warn` per account at monitor startup when `channels.imessage.groupPolicy: "allowlist"` is set without a `channels.imessage.groups` block, plus a one-time `warn` per `chat_id` when the runtime gate drops a specific group, naming the exact `channels.imessage.groups[...]` key to add to allow it. Fixes #78749. (#79190) Thanks @omarshahine.
 - WhatsApp: stop Gateway-originated outbound echoes from advancing inbound activity in `openclaw channels status`, so outbound self-sends no longer look like handled inbound messages. Fixes #79056. (#79057) Thanks @ai-hpc and @bittoby.
 - Gateway/nodes: preserve the live node registry session and invoke ownership when an older same-node WebSocket closes after reconnecting. (#78351) Thanks @samzong.

packages/memory-host-sdk/src/host/internal.test.ts

@@ -1,11 +1,12 @@
 import fsSync from "node:fs";
 import os from "node:os";
 import path from "node:path";
-import { afterAll, beforeAll, beforeEach, describe, expect, it } from "vitest";
+import { afterAll, afterEach, beforeAll, beforeEach, describe, expect, it, vi } from "vitest";
 import {
   buildFileEntry,
   buildMultimodalChunkForIndexing,
   chunkMarkdown,
+  ensureDir,
   isMemoryPath,
   listMemoryFiles,
   normalizeExtraMemoryPaths,
@@ -34,6 +35,10 @@ afterAll(() => {
   }
 });
 
+afterEach(() => {
+  vi.restoreAllMocks();
+});
+
 function setupTempDirLifecycle(prefix: string): () => string {
   let tmpDir = "";
   beforeEach(() => {
@@ -77,6 +82,17 @@ const multimodal: MemoryMultimodalSettings = {
 describe("memory host SDK package internals", () => {
   const getTmpDir = setupTempDirLifecycle("memory-package-");
 
+  it("propagates directory creation failures", () => {
+    const mkdirError = new Error("disk full");
+    const targetDir = path.join(getTmpDir(), "blocked");
+    const mkdirSync = vi.spyOn(fsSync, "mkdirSync").mockImplementation(() => {
+      throw mkdirError;
+    });
+
+    expect(() => ensureDir(targetDir)).toThrow(mkdirError);
+    expect(mkdirSync).toHaveBeenCalledWith(targetDir, { recursive: true });
+  });
+
   it("normalizes additional memory paths", () => {
     const workspaceDir = path.join(os.tmpdir(), "memory-test-workspace");
     const absPath = path.resolve(path.sep, "shared-notes");

packages/memory-host-sdk/src/host/internal.ts

@@ -65,9 +65,7 @@ const DISABLED_MULTIMODAL_SETTINGS: MemoryMultimodalSettings = {
 };
 
 export function ensureDir(dir: string): string {
-  try {
-    fsSync.mkdirSync(dir, { recursive: true });
-  } catch {}
+  fsSync.mkdirSync(dir, { recursive: true });
   return dir;
 }