build(nrf52): consolidate XIAO QSPI repeater images

.github/workflows/run-unit-tests.yml

@@ -216,6 +216,7 @@ jobs:
           python3 -B test/test_full_logging_resume.py
           python3 -B test/test_firmware_capabilities.py
           bash test/test_build_profiles.sh
+          bash test/test_xiao_qspi_combined.sh
 
       - name: Verify nRF52 UF2-reset CLI coverage
         run: python3 -B test/test_nrf52_uf2reset_cli.py

build.sh

@@ -138,7 +138,7 @@ Options:
   --firmware-version <version>: Firmware version to embed.
   --radio-preset <name|number>: Override the USA Cascadia radio default. Stable names are usa-cascadia and target; legacy menu numbers remain accepted.
   --profile <default|cascade>: Override runtime settings embedded in the firmware (not its feature set).
-  --build-profile <auto|standard|full>: Select feature/partition policy. Auto uses the combined Full MQTT/USB/WiFi recipe when it covers the plain infrastructure target; otherwise it first builds complete LoRa-OTA-capable firmware with a measured-size fallback. Internal-flash nRF52 repeaters and room servers also publish the reduced image for delta-staging headroom. Standard preserves portable images, including the 1.25 MiB slot; full requires the expanded ESP32 recipe.
+  --build-profile <auto|standard|full>: Select feature/partition policy. Auto uses the combined Full MQTT/USB/WiFi recipe when it covers the plain infrastructure target; otherwise it first builds complete LoRa-OTA-capable firmware with a measured-size fallback. Internal-flash nRF52 repeaters and room servers also publish the reduced image for delta-staging headroom; XIAO nRF52 repeaters with external-QSPI staging publish one combined image. Standard preserves portable images, including the 1.25 MiB slot; full requires the expanded ESP32 recipe.
   --auto|--standard|--full: Short forms of --build-profile.
   --skip-kiss|--include-kiss: Exclude (default) or include KISS modem targets in bulk builds.
   --clean|--resume: Clean output or resume existing Option 3/FULL-only artifacts.
@@ -353,12 +353,16 @@ for section, options in data:
         *_repeater|*_repeater_|*_repeatr|*_repeatr_|*_room_server|*_room_server_|*_room_svr|*_room_svr_) ;;
         *) continue ;;
       esac
-      # SolarXiao 30S/33S repeater and room-server roles already use matched
-      # external QSPI staging, so their normal full-sensor image is
-      # install-capable. A second lean no-external-sensors target provides no
-      # additional OTA capability.
+      # XIAO nRF52840 repeaters with raw-QSPI staging and the reserved
+      # bootloader scratch region keep sensors, packet logging, and LoRa OTA
+      # in their normal image. Do not publish a redundant reduced sibling.
+      if is_xiao_qspi_combined_repeater_target "$env_name"; then
+        continue
+      fi
+      # Leave SolarXiao room-server inventory unchanged; these roles are not
+      # part of the XIAO repeater consolidation.
       case "${env_name,,}" in
-        solarxiao_30s_repeater|solarxiao_33s_repeater|solarxiao_30s_room_server|solarxiao_33s_room_server) continue ;;
+        solarxiao_30s_room_server|solarxiao_33s_room_server) continue ;;
       esac
       ota_env="${env_name%_}_lora_ota_no_external_sensors"
       PIO_ENV_COMPLETE_OTA_BASE_BY_NAME["$ota_env"]="$env_name"
@@ -2080,6 +2084,22 @@ is_lora_ota_only_target() {
   [[ "$target_lc" == *lora_ota* ]]
 }
 
+is_xiao_qspi_combined_repeater_target() {
+  local env_name=$1
+
+  [ "${PIO_ENV_PLATFORM_BY_NAME[$env_name]:-}" = "NRF52_PLATFORM" ] \
+    && [ "${PIO_ENV_BOARD_BY_NAME[$env_name]:-}" = "seeed-xiao-afruitnrf52-nrf52840" ] \
+    && [ "${PIO_ENV_QSPI_OTA_BY_NAME[$env_name]:-0}" = "1" ] \
+    && { [[ "${env_name,,}" == *_repeater ]] \
+         || [[ "${env_name,,}" == *_repeater_ ]]; }
+}
+
+is_xiao_qspi_canonical_repeater_build() {
+  is_xiao_qspi_combined_repeater_target "$1" \
+    && [ "$BUILD_PROFILE_FOR_TARGET" = "standard" ] \
+    && [ -z "$FIRMWARE_FILENAME_INFIX" ]
+}
+
 is_lora_ota_no_external_sensors_target() {
   local target_lc=${1,,}
   [[ "$target_lc" == *lora_ota_no_external_sensors ]]
@@ -3138,7 +3158,8 @@ record_application_expectation() {
 declare_full_logging_application_contract() {
   local env_name=$1
   BUILD_APPLICATION_EXPECTATIONS=()
-  if requires_full_usb_packet_logging "$env_name"; then
+  if requires_full_usb_packet_logging "$env_name" \
+      || is_xiao_qspi_canonical_repeater_build "$env_name"; then
     # Inspect the packaged application, not an ELF debug/symbol string. The
     # settings alone can exist in debug-only builds with packet logging absent.
     record_application_expectation "logging.usb.packets" \
@@ -3179,7 +3200,9 @@ declare_build_capability_contract() {
   if [ "$env_platform" = "NRF52_PLATFORM" ] && ! is_kiss_modem_target "$env_name"; then
     # Prove the real DFU service is linked, not merely a generic OTA CLI stub.
     record_build_expectation "ota.update.bluetooth" "_ZN6BLEDfu5beginEv"
-    if is_lora_ota_build "$env_name" && ! is_companion_build "$env_name"; then
+    if { is_lora_ota_build "$env_name" \
+          || is_xiao_qspi_canonical_repeater_build "$env_name"; } \
+        && ! is_companion_build "$env_name"; then
       # nRF52 applies mOTA in its bootloader, so the ESP32 decoder marker is
       # absent. The checker also verifies the packaged app's EndF/storage layout.
       record_build_expectation "ota.update.lora" "invalid in-place patch geometry"
@@ -3209,7 +3232,8 @@ declare_build_capability_contract() {
     fi
   fi
 
-  if is_lora_ota_build "$env_name"; then
+  if is_lora_ota_build "$env_name" \
+      || is_xiao_qspi_canonical_repeater_build "$env_name"; then
     record_build_expectation "ota.cli" "OTA: status"
   fi
 
@@ -4077,7 +4101,8 @@ write_build_capability_manifest() {
   )
   local item
 
-  if requires_wireless_self_update "$env_name"; then
+  if requires_wireless_self_update "$env_name" \
+      || is_xiao_qspi_canonical_repeater_build "$env_name"; then
     checker_args+=(--require-ota)
   fi
   if [ "$env_platform" = "ESP32_PLATFORM" ]; then

test/test_xiao_qspi_combined.sh

@@ -0,0 +1,77 @@
+#!/usr/bin/env bash
+set -euo pipefail
+
+cd "$(dirname "$0")/.."
+source build.sh
+
+fail() { echo "test_xiao_qspi_combined: $*" >&2; exit 1; }
+
+# Use the resolved PlatformIO recipes, not a board-name allowlist: each
+# canonical XIAO repeater must retain the internal bootloader scratch bank,
+# raw external-QSPI OTA staging, and packet logging in one application.
+init_project_context
+BUILD_PROFILE_FOR_TARGET=standard
+BUILD_PROFILE_EFFECTIVE=standard
+FIRMWARE_FILENAME_INFIX=""
+DISABLE_DEBUG=0
+PACKET_LOGGING_OVERRIDE=""
+MESHDEBUG_OVERRIDE=""
+MQTT_BRIDGE_OVERRIDE=""
+
+for target in \
+  Xiao_nrf52_repeater \
+  ikoka_handheld_nrf_e22_30dbm_repeater \
+  ikoka_nano_nrf_22dbm_repeater \
+  ikoka_nano_nrf_30dbm_repeater \
+  ikoka_nano_nrf_33dbm_repeater \
+  ikoka_stick_nrf_22dbm_repeater \
+  ikoka_stick_nrf_30dbm_repeater \
+  ikoka_stick_nrf_33dbm_repeater \
+  solarxiao_30S_repeater \
+  solarxiao_33S_repeater; do
+  is_supported_build_env "$target" || fail "$target is missing"
+  is_xiao_qspi_canonical_repeater_build "$target" \
+    || fail "$target lost its combined-image classification"
+  if is_supported_build_env "${target}_lora_ota_no_external_sensors"; then
+    fail "$target still publishes a redundant lean OTA sibling"
+  fi
+  if get_reduced_lora_ota_target "$target" >/dev/null; then
+    fail "$target still falls back to a reduced OTA sibling"
+  fi
+  pio_env_option_contains "$target" board_build.ldscript \
+    nrf52840_s140_v7_xiao_bootloader_ota.ld \
+    || fail "$target lost its 40 KiB internal bootloader scratch reservation"
+  pio_env_option_contains "$target" board_upload.maximum_size 757760 \
+    || fail "$target lost its internal application size limit"
+  pio_env_option_contains "$target" build_flags OTA_QSPI_BOOTLOADER_UPDATE=1 \
+    || fail "$target lost its OTAFIX bootloader-update layout"
+  pio_env_option_contains "$target" build_flags OTA_QSPI_STORE=1 \
+    || fail "$target lost external-QSPI OTA staging"
+  pio_env_option_contains "$target" build_flags MESH_PACKET_LOGGING=1 \
+    || fail "$target lost packet logging"
+  is_lora_ota_build "$target" || fail "$target lost LoRa OTA"
+
+  BUILD_CAPABILITIES=()
+  BUILD_REDUCTIONS=()
+  BUILD_EXPECTATIONS=()
+  BUILD_APPLICATION_EXPECTATIONS=()
+  declare_build_capability_contract "$target" NRF52_PLATFORM
+  expectations=" ${BUILD_EXPECTATIONS[*]} "
+  application=" ${BUILD_APPLICATION_EXPECTATIONS[*]} "
+  [[ "$expectations" == *"ota.update.lora=invalid in-place patch geometry"* ]] \
+    || fail "$target no longer proves its LoRa OTA receiver"
+  [[ "$expectations" == *"ota.cli=OTA: status"* ]] \
+    || fail "$target no longer proves its OTA CLI"
+  [[ "$application" == *"logging.usb.packets=%s: %s, len=%d (type=%d, route=%s, payload_len=%d)"* ]] \
+    || fail "$target no longer verifies packaged packet logging"
+  [[ "$application" == *"logging.usb.control=OK - USB logging %s (saved)"* ]] \
+    || fail "$target no longer verifies the packaged USB logging control"
+done
+
+# This consolidation is specific to the external-QSPI XIAO repeater layout.
+is_xiao_qspi_combined_repeater_target Xiao_nrf52_room_server \
+  && fail "non-QSPI room server was incorrectly consolidated"
+is_xiao_qspi_combined_repeater_target RAK_4631_repeater \
+  && fail "unrelated repeater was incorrectly consolidated"
+
+echo "test_xiao_qspi_combined: OK"

variants/ikoka_handheld_nrf/platformio.ini

@@ -99,6 +99,7 @@ build_flags = ${ikoka_handheld_nrf.build_flags}
   -D ADMIN_PASSWORD='"password"'
   -D MAX_NEIGHBOURS=50
   -D LORA_TX_POWER=20
+  -D MESH_PACKET_LOGGING=1
 build_src_filter = ${ikoka_handheld_nrf.build_src_filter}
   +<../examples/simple_repeater/*.cpp>
 

variants/ikoka_nano_nrf/platformio.ini

@@ -129,7 +129,7 @@ build_flags =
   -D ADVERT_LON=0.0
   -D ADMIN_PASSWORD='"password"'
   -D MAX_NEIGHBOURS=50
-;  -D MESH_PACKET_LOGGING=1
+  -D MESH_PACKET_LOGGING=1
 ;  -D MESH_DEBUG=1
 build_src_filter = ${ikoka_nano_nrf.build_src_filter}
   +<../examples/simple_repeater/*.cpp>

variants/ikoka_stick_nrf/platformio.ini

@@ -135,7 +135,7 @@ build_flags =
   -D ADVERT_LON=0.0
   -D ADMIN_PASSWORD='"password"'
   -D MAX_NEIGHBOURS=50
-;  -D MESH_PACKET_LOGGING=1
+  -D MESH_PACKET_LOGGING=1
 ;  -D MESH_DEBUG=1
 build_src_filter = ${ikoka_stick_nrf.build_src_filter}
   +<helpers/ui/SSD1306Display.cpp>

variants/xiao_nrf52/platformio.ini

@@ -101,7 +101,7 @@ build_flags =
   -D ADVERT_LON=0.0
   -D ADMIN_PASSWORD='"password"'
   -D MAX_NEIGHBOURS=50
-;  -D MESH_PACKET_LOGGING=1
+  -D MESH_PACKET_LOGGING=1
 ;  -D MESH_DEBUG=1
 build_src_filter = ${Xiao_nrf52.build_src_filter}
   +<../examples/simple_repeater/*.cpp>
@@ -231,6 +231,7 @@ build_flags =
   -D ADVERT_LON=0.0
   -D ADMIN_PASSWORD='"password"'
   -D MAX_NEIGHBOURS=50
+  -D MESH_PACKET_LOGGING=1
   -D WITH_RS232_BRIDGE=Serial1
   -D WITH_RS232_BRIDGE_UART=1
   -D WITH_RS232_BRIDGE_RX=PIN_SERIAL1_RX