@yoshicham5267 I think you are overthinking this. First, you have no idea if what you heard is factual and even if it was, I really doubt a chameleon would actually choke to death. They don't breathe a lot and normally have a very low blood oxygen level. That being said, I am sure it could happen but I just really doubt it. Sometimes chameleons have trouble swallowing something because it is too big. That's not the same as choking to death.
Second, a chameleon actually knows the head of an bug from the tail. If you watch, they aim for the head. If you feed them something really big (which I often do) you will see them planning when and where to hit the bug. I've fed my adult wild caughts adult Katydids that are the size of their heads and really big wild stick bugs that take them a long long time to work down into the stomach. They come alive and are very animated as they plan to get the big bug. I think part of their increased interest is that it is a wild bug and they really do know the difference between a wild caught bug than a commercial feeder (and they MUCH prefer wild). Also, spiders and bees are a big part of a wild chameleon's diet. I would not recommend a honey bee as a feeder as English honey bees have a much more venomous sting than any African bee but I have seen my animals hit them and eat them without any issue when outside. I know people who collect wild bugs and put everything into the chameleon cages, including any spiders caught up in the field sweep.
Herbivore caterpillars might pinch but I honestly wouldn't worry about it.