fix(synapse): surface layer processing errors

.aiox-core/core/synapse/engine.js

@@ -180,6 +180,24 @@ const PIPELINE_TIMEOUT_MS = 100;
 const DEFAULT_ACTIVE_LAYERS = [0, 1, 2];
 const LEGACY_MODE = process.env.SYNAPSE_LEGACY_MODE === 'true';
 
+/**
+ * Safely read the last processing error exposed by a layer.
+ *
+ * @param {object} layer - Synapse layer instance.
+ * @returns {Error|null} Last layer error, or the accessor failure as an Error.
+ */
+function getLayerError(layer) {
+  if (!layer) return null;
+  if (typeof layer.getLastError === 'function') {
+    try {
+      return layer.getLastError();
+    } catch (error) {
+      return error instanceof Error ? error : new Error(String(error));
+    }
+  }
+  return null;
+}
+
 /**
  * Orchestrates the 8-layer SYNAPSE context injection pipeline.
  *
@@ -298,14 +316,25 @@ class SynapseEngine {
         previousLayers,
       });
 
-      const result = layer._safeProcess(context);
+      let result;
+      try {
+        result = layer._safeProcess(context);
+      } catch (error) {
+        metrics.errorLayer(layer.name, error);
+        continue;
+      }
 
       if (result && Array.isArray(result.rules)) {
         metrics.endLayer(layer.name, result.rules.length);
         results.push(result);
         previousLayers.push(result);
       } else if (result === null || result === undefined) {
-        metrics.skipLayer(layer.name, 'Returned null');
+        const layerError = getLayerError(layer);
+        if (layerError) {
+          metrics.errorLayer(layer.name, layerError);
+        } else {
+          metrics.skipLayer(layer.name, 'Returned null');
+        }
       } else {
         metrics.skipLayer(layer.name, 'Invalid result format');
       }

.aiox-core/core/synapse/layers/layer-processor.js

@@ -34,6 +34,7 @@ class LayerProcessor {
     this.name = name;
     this.layer = layer;
     this.timeout = timeout;
+    this._lastError = null;
   }
 
   /**
@@ -65,6 +66,7 @@ class LayerProcessor {
    */
   _safeProcess(context) {
     const start = Date.now();
+    this._lastError = null;
     try {
       const result = this.process(context);
       const elapsed = Date.now() - start;
@@ -73,10 +75,20 @@ class LayerProcessor {
       }
       return result;
     } catch (error) {
-      console.warn(`[synapse:${this.name}] Error: ${error.message}`);
+      this._lastError = error instanceof Error ? error : new Error(String(error));
+      console.warn(`[synapse:${this.name}] Error: ${this._lastError.message}`);
       return null;
     }
   }
+
+  /**
+   * Return the last error captured by _safeProcess(), if any.
+   *
+   * @returns {Error|null} Last captured processing error.
+   */
+  getLastError() {
+    return this._lastError;
+  }
 }
 
 module.exports = LayerProcessor;

.aiox-core/install-manifest.yaml

@@ -8,7 +8,7 @@
 # - File types for categorization
 #
 version: 5.1.15
-generated_at: "2026-05-08T06:26:53.273Z"
+generated_at: "2026-05-08T06:49:15.800Z"
 generator: scripts/generate-install-manifest.js
 file_count: 1111
 files:
@@ -1129,9 +1129,9 @@ files:
     type: core
     size: 8122
   - path: core/synapse/engine.js
-    hash: sha256:47bab93a2144edce875ee68cc2717fee1bd824c9affdd5964454f5141310b8e0
+    hash: sha256:cd26f9a88527744fa4984fc006c428563d6a1ef023a9feb2dd8da073b4e70b9f
     type: core
-    size: 13602
+    size: 14362
   - path: core/synapse/layers/l0-constitution.js
     hash: sha256:2123a6a44915aaac2a6bbd26c67c285c9d1e12b50fe42a8ada668306b07d1c4a
     type: core
@@ -1165,9 +1165,9 @@ files:
     type: core
     size: 4672
   - path: core/synapse/layers/layer-processor.js
-    hash: sha256:15f9e4c1525d3fa2186170705a26191ad87d94ffd7fa7d61f373b07b6fb3d874
+    hash: sha256:9cdb5efb2e95780373dd0ce8dcb64791dd1471128fc6914d274c6744036842a3
     type: core
-    size: 2882
+    size: 3222
   - path: core/synapse/memory/memory-bridge.js
     hash: sha256:820875f97ceea80fc6402c0dab1706cfe58de527897b22dea68db40b0d6ec368
     type: core

tests/synapse/engine.test.js

@@ -395,6 +395,51 @@ describe('SynapseEngine', () => {
         expect(calls[i].prevCount).toBeGreaterThanOrEqual(calls[i - 1].prevCount);
       }
     });
+
+    test('should record captured layer processing errors in metrics', async () => {
+      const layer = engine.layers[0];
+      layer._safeProcess = jest.fn(() => null);
+      layer.getLastError = jest.fn(() => new Error('Layer processing failed'));
+
+      const result = await engine.process('test', {});
+
+      expect(result.metrics.per_layer[layer.name]).toEqual(expect.objectContaining({
+        status: 'error',
+        error: 'Layer processing failed',
+      }));
+      expect(result.metrics.layers_errored).toBeGreaterThanOrEqual(1);
+    });
+
+    test('should record direct _safeProcess exceptions in metrics', async () => {
+      const layer = engine.layers[0];
+      layer._safeProcess = jest.fn(() => {
+        throw new Error('Unsafe layer crash');
+      });
+
+      const result = await engine.process('test', {});
+
+      expect(result.metrics.per_layer[layer.name]).toEqual(expect.objectContaining({
+        status: 'error',
+        error: 'Unsafe layer crash',
+      }));
+      expect(result.metrics.layers_errored).toBeGreaterThanOrEqual(1);
+    });
+
+    test('should record getLastError accessor failures in metrics', async () => {
+      const layer = engine.layers[0];
+      layer._safeProcess = jest.fn(() => null);
+      layer.getLastError = jest.fn(() => {
+        throw new Error('Last error unavailable');
+      });
+
+      const result = await engine.process('test', {});
+
+      expect(result.metrics.per_layer[layer.name]).toEqual(expect.objectContaining({
+        status: 'error',
+        error: 'Last error unavailable',
+      }));
+      expect(result.metrics.layers_errored).toBeGreaterThanOrEqual(1);
+    });
   });
 
   describe('process() — metrics', () => {

tests/synapse/layer-processor.test.js

@@ -104,12 +104,43 @@ describe('LayerProcessor', () => {
       const result = processor._safeProcess({});
 
       expect(result).toBeNull();
+      expect(processor.getLastError()).toBeInstanceOf(Error);
+      expect(processor.getLastError().message).toBe('Something went wrong');
       expect(warnSpy).toHaveBeenCalledWith(
         '[synapse:error-test] Error: Something went wrong',
       );
       warnSpy.mockRestore();
     });
 
+    test('should clear last error after a successful retry', () => {
+      class FlakyProcessor extends LayerProcessor {
+        constructor() {
+          super({ name: 'flaky', layer: 0 });
+          this.shouldFail = true;
+        }
+        process() {
+          if (this.shouldFail) {
+            this.shouldFail = false;
+            throw new Error('First attempt failed');
+          }
+          return { rules: ['recovered'], metadata: { layer: 0 } };
+        }
+      }
+
+      const warnSpy = jest.spyOn(console, 'warn').mockImplementation();
+      const processor = new FlakyProcessor();
+
+      try {
+        expect(processor._safeProcess({})).toBeNull();
+        expect(processor.getLastError().message).toBe('First attempt failed');
+
+        expect(processor._safeProcess({})).toEqual({ rules: ['recovered'], metadata: { layer: 0 } });
+        expect(processor.getLastError()).toBeNull();
+      } finally {
+        warnSpy.mockRestore();
+      }
+    });
+
     test('should warn when timeout exceeded but still return result', () => {
       class SlowProcessor extends LayerProcessor {
         constructor() {