I have no experience in the CTF scene so I'm curious - why not lean in and design the puzzles with an AI harness like the one top teams use in the loop and use the(presumably) expert skills of the designers to patch up the holes until the AI can't find them? Do you just end up designing ~perfectly secure systems that no human can break without finding monetizable 0days?

I think that misses the point - it's a little bit like asking why FPS game developers don't lean into aimbot usage. You could, but by default it's a bit boring, and a different type of game.