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Root cause: every java launch inlined the whole classpath into one -cp argument with no "Shorten command line", so long classpaths exceeded CreateProcessW's 32767-char limit (os error 206) before the JVM started. Fix (IDEA's auto "Shorten command line"): ide-run rewrites a too-long java command line at spawn time — @argfile on JDK 9+ with ASCII paths, otherwise a MANIFEST pathing jar (percent-encoded file: URLs, 72-byte lines); temp files are removed when the process exits. Debug passes the same choice to java-debug's shortenCommandLine. Siblings covered: Application/Spring Boot, test classpath, Kotlin main, explicit java -cp configs, profiler, PTY launches, Debug. Verified: unit tests, pathing jar loaded by real JDK 8/11/25, ProcessManager integration test with 3000 entries on JDK 8/17/25. Not verified on Windows. Claude-Session: https://claude.ai/code/session_01VUYsdXA2nkF5v6zsC93dpn