diff --git a/packaging/model/project_model.py b/packaging/model/project_model.py
index 2c2b78ba..22fa8bed 100644
--- a/packaging/model/project_model.py
+++ b/packaging/model/project_model.py
@@ -370,10 +370,22 @@ def _create_project_runtime(self, project_dir: str, *, on_status=None) -> None:
             return
 
         # Dev mode: create a classic .venv
+        # Note: --copies is NOT used here. On macOS, venv --copies copies the Python
+        # executable but NOT libpython3.12.dylib, causing "Library not loaded" at runtime.
+        # Using symlinks instead: the python symlink resolves to the original binary,
+        # and @executable_path/../lib/libpython3.12.dylib resolves correctly from there.
         venv_path = os.path.join(project_dir, ".venv")
         if on_status:
             on_status("Creating project virtual environment...")
-        _run_hidden([sys.executable, "-m", "venv", "--copies", venv_path], timeout=600)
+        _run_hidden([sys.executable, "-m", "venv", venv_path], timeout=600)
+
+        # Bootstrap pip into the venv using the host Python (avoids ensurepip issues).
+        venv_lib = os.path.join(venv_path, "lib", f"python{sys.version_info.major}.{sys.version_info.minor}", "site-packages")
+        _run_hidden(
+            [sys.executable, "-m", "pip", "install", "--no-input", "--disable-pip-version-check",
+             "--target", venv_lib, "pip"],
+            timeout=300,
+        )
 
     def _install_infernux_in_runtime(self, project_dir: str, engine_version: str = "", *, on_status=None):
         """Install the Infernux wheel into the project's Python environment.
diff --git a/packaging/stage_bundled_python_runtime.py b/packaging/stage_bundled_python_runtime.py
index 4fd7a5f7..2e66f4f9 100644
--- a/packaging/stage_bundled_python_runtime.py
+++ b/packaging/stage_bundled_python_runtime.py
@@ -304,6 +304,49 @@ def _ensure_pip(python_exe: str) -> None:
     if completed.returncode == 0:
         return
 
+    # ensurepip can fail with SIGABRT on copied Python binaries on macOS.
+    # Try a fallback: copy pip from the original venv that we know works.
+    import shutil as _shutil, os as _os, sys as _sys, subprocess as _subprocess
+    original_python = _sys.executable
+    if original_python and _os.path.dirname(original_python) != _os.path.dirname(python_exe):
+        import site as _site
+        orig_site_packages = next(
+            (p for p in _site.getsitepackages() if _os.path.isdir(p) and "site-packages" in p), None
+        )
+        target_site_packages = next(
+            (p for p in _site.getsitepackages() if _os.path.isdir(p) and "site-packages" in p), None
+        ) if False else None
+        # Try to find target site-packages via python path
+        try:
+            result = _subprocess.run(
+                [python_exe, "-c", "import site; print(site.getsitepackages()[0])"],
+                capture_output=True, text=True, timeout=10
+            )
+            target_site_packages = result.stdout.strip() if result.returncode == 0 else None
+        except Exception:
+            target_site_packages = None
+
+        if orig_site_packages and target_site_packages:
+            pip_src = _os.path.join(orig_site_packages, "pip")
+            if _os.path.isdir(pip_src):
+                pip_dest = _os.path.join(target_site_packages, "pip")
+                try:
+                    _shutil.rmtree(pip_dest, ignore_errors=True)
+                    _shutil.copytree(pip_src, pip_dest)
+                    # Also copy wheel & certifi dependencies if present
+                    for dep in ("wheel", "certifi", "distlib"):
+                        dep_src = _os.path.join(orig_site_packages, dep)
+                        if _os.path.isdir(dep_src):
+                            _shutil.rmtree(_os.path.join(target_site_packages, dep), ignore_errors=True)
+                            _shutil.copytree(dep_src, _os.path.join(target_site_packages, dep))
+                    # Verify it works now
+                    verify = _subprocess.run([python_exe, "-m", "pip", "--version"], capture_output=True, timeout=30)
+                    if verify.returncode == 0:
+                        return
+                except Exception:
+                    pass
+
+    # Last resort: try ensurepip normally
     completed = _run([python_exe, "-m", "ensurepip", "--upgrade"], timeout=600)
     if completed.returncode != 0:
         raise SystemExit(