I'm getting this error when archiving my Flutter iOS app:

Error (Xcode): unable to spawn process '/bin/sh' (Argument list too long)

Environment:

• Xcode 16.4
• Flutter 3.38.7
• CocoaPods 1.16.2
• macOS (Darwin 24.4.0)

What I've tried:

• Cleaned DerivedData (rm -rf ~/Library/Developer/Xcode/DerivedData)
• Ran flutter clean and flutter pub get
• Removed ios/build and ios/Pods, then ran pod install
• Verified --dart-define-from-file config is small (~1.6KB)
• Verified environment variables are small (~2KB total)

Project details:

• 84 pods installed
• Uses Firebase, Sentry, OneSignal, Mixpanel, and other common SDKs

Build command: fvm flutter build ipa --flavor stage --target lib/main_stage.dart --dart-define-from-file=config_stage.json

Questions:

1. Is this a known Xcode 16.4 issue?
2. Are there workarounds for the ARG_MAX limit in Xcode build phases?
3. Could any specific pod be contributing to this?

Any help appreciated.