fix: preserve complete companion build profiles

build.sh

@@ -2448,9 +2448,19 @@ declare_build_capability_contract() {
   if is_companion_radio_full_target "$env_name"; then
     record_build_expectation "companion.temp_radio" "tempradio"
     record_build_expectation "companion.ota_cli" "ota folder"
+    record_build_expectation "companion.usb" "+++MESHCORE-TERM-START"
+    record_build_expectation "companion.bluetooth" \
+      "Companion: starting Bluetooth"
+    if is_nrf52_companion_radio_full_target "$env_name" \
+        || is_esp32_dual_cdc_companion_radio_full_target "$env_name"; then
+      record_build_expectation "companion.dedicated_usb_logging" \
+        "get usb.logging"
+    fi
     if [ "$env_platform" = "ESP32_PLATFORM" ]; then
       record_build_expectation "companion.network_terminal" \
-        "Full Companion terminal listening"
+        "USB currently owns the Full Companion terminal"
+      record_build_expectation "companion.wifi_ota_seeder" \
+        "OTA seeder listening on :"
       record_build_expectation "web.webconfig" "start webconfig"
     else
       record_build_expectation "companion.usb_mota_source" "ota folder on"
@@ -2729,6 +2739,29 @@ append_platformio_extra_script() {
   export PLATFORMIO_EXTRA_SCRIPTS
 }
 
+apply_lora_ota_flag_order_fix() {
+  local env_name=$1
+  local pio_env_name=$2
+
+  if ! is_lora_ota_build "$env_name" \
+      && ! is_companion_radio_full_target "$env_name"; then
+    unset MESHCORE_FORCE_LORA_OTA
+    return 0
+  fi
+
+  # A few legacy recipes deliberately finish with -UENABLE_OTA. PlatformIO
+  # retains that raw undefine after externally supplied definitions, so an OTA
+  # overlay can otherwise advertise its controls while compiling out the
+  # protocol implementation. Remove the legacy undefine before flags are
+  # parsed for every OTA overlay, not just for one platform or role.
+  if pio_env_option_contains "$pio_env_name" build_flags "-UENABLE_OTA"; then
+    export MESHCORE_FORCE_LORA_OTA=1
+    append_platformio_extra_script "pre:scripts/force_lora_ota.py"
+  else
+    unset MESHCORE_FORCE_LORA_OTA
+  fi
+}
+
 apply_nrf52_lora_ota_build_recipe() {
   local env_name=$1
   local pio_env_name=$2
@@ -2753,17 +2786,6 @@ apply_nrf52_lora_ota_build_recipe() {
     append_platformio_extra_script "post:tools/mota/pio_endf.py"
   fi
 
-  # A few feature-rich legacy environments deliberately end their own flags
-  # with -UENABLE_OTA. PlatformIO build_unflags cannot remove a trailing -U,
-  # so a pre-script must make the intentional OTA overlay authoritative for
-  # both compilation and the EndF geometry hook.
-  if pio_env_option_contains "$pio_env_name" build_flags "-UENABLE_OTA"; then
-    export MESHCORE_FORCE_LORA_OTA=1
-    append_platformio_extra_script "pre:scripts/force_lora_ota.py"
-  else
-    unset MESHCORE_FORCE_LORA_OTA
-  fi
-
   if supports_nrf52_internal_bootloader_update "$env_name"; then
     export MESHCORE_NRF52_INTERNAL_BOOTLOADER_UPDATE=1
   else
@@ -2904,6 +2926,8 @@ apply_companion_radio_full_profile() {
   if requires_esp32_companion_full_ota_fallback "$pio_env_name"; then
     append_platformio_build_unflags "-DMAX_CONTACTS=350 -DMAX_CONTACTS=160 -DMAX_GROUP_CHANNELS=40 -DOFFLINE_QUEUE_SIZE=512 -DOFFLINE_QUEUE_SIZE=256 -DOFFLINE_QUEUE_SIZE=128"
     export PLATFORMIO_BUILD_FLAGS="${PLATFORMIO_BUILD_FLAGS} -DMAX_CONTACTS=100 -DMAX_GROUP_CHANNELS=8 -DOFFLINE_QUEUE_SIZE=16"
+    record_build_reduction \
+      "companion.capacity limited to 100 contacts, 8 channels, and 16 queued frames by measured internal DRAM"
   fi
 
   # A few WiFi recipes list only their WiFi implementation instead of the
@@ -3354,6 +3378,7 @@ build_firmware() {
   apply_lora_ota_override "$env_name"
   apply_logical_ota_tuning_flags "$env_name" "$pio_env_name"
   apply_companion_radio_full_profile "$env_name" "$pio_env_name"
+  apply_lora_ota_flag_order_fix "$env_name" "$pio_env_name"
   apply_nrf52_lora_ota_build_recipe "$env_name" "$pio_env_name"
   apply_esp32_lora_ota_size_profile "$env_name"
   apply_esp32_constrained_companion_size_profile "$env_name"

docs/cli_build_matrix.md

@@ -104,6 +104,11 @@ available from a canonical image:
   interface `02` for plaintext logs.
   Its LoRa OTA support is source-only: it can serve a host file to another node
   but has no staging store and cannot update itself over LoRa.
+  Installing an ESP32 Full Companion may require one merged-image erase/flash
+  to adopt its expanded partition table. Once migrated, later Full Companion
+  releases use normal app updates. The transport-specific non-Full images stay
+  available as explicit build targets, but are not canonical release artifacts
+  when the qualified Full image fits.
 
 The old aliases still work with `build-firmware` and
 `build-matching-firmwares`. Dedicated repeater LoRa OTA receiver images are not

docs/companion_radio_full.md

@@ -163,8 +163,11 @@ target recipes, but application behavior no longer uses that umbrella as an
 unrelated compile guard. In particular, ESP32 WiFi/WebConfig terminal controls
 are compiled from their actual WiFi/WebConfig capability, and BLE is always
 started before WiFi on any combined ESP32 WiFi+BLE Companion to avoid heap
-fragmentation. The build's capability sidecar verifies the Full controls after
-linking.
+fragmentation. Compile-time prerequisite checks reject inconsistent feature
+flags. After linking, the capability sidecar verifies USB, BLE, the OTA CLI,
+TempRadio, and each platform's host-folder transport; it also verifies the TCP
+terminal, WebConfig, and WiFi seeder on ESP32, plus dedicated logging whenever
+the board uses dual CDC.
 
 On 4 MB ESP32 boards, the full target uses a single 3 MB application partition
 so WiFi, BLE, WebConfig, and source-only mOTA fit together. The T-Beam 1W Full

examples/companion_radio/CompanionFeatures.h

@@ -11,11 +11,13 @@
   #ifndef COMPANION_FEATURE_OTA_CLI
     #define COMPANION_FEATURE_OTA_CLI 1
   #endif
-  #ifndef COMPANION_FEATURE_NETWORK_TERMINAL
-    #define COMPANION_FEATURE_NETWORK_TERMINAL 1
-  #endif
-  #ifndef COMPANION_FEATURE_MEMORY_DIAGNOSTICS
-    #define COMPANION_FEATURE_MEMORY_DIAGNOSTICS 1
+  #if defined(ESP32_PLATFORM)
+    #ifndef COMPANION_FEATURE_NETWORK_TERMINAL
+      #define COMPANION_FEATURE_NETWORK_TERMINAL 1
+    #endif
+    #ifndef COMPANION_FEATURE_MEMORY_DIAGNOSTICS
+      #define COMPANION_FEATURE_MEMORY_DIAGNOSTICS 1
+    #endif
   #endif
   #if defined(MESH_DUAL_CDC_LOGGING)
     #ifndef COMPANION_FEATURE_DEDICATED_USB_LOGGING
@@ -48,12 +50,36 @@
   #define COMPANION_FEATURE_DEDICATED_USB_LOGGING 0
 #endif
 
+#if COMPANION_FEATURE_OTA_CLI && !defined(ENABLE_OTA)
+  #error "COMPANION_FEATURE_OTA_CLI requires ENABLE_OTA"
+#endif
+
 #if COMPANION_FEATURE_NETWORK_TERMINAL && !defined(ENABLE_USB_INTERFACE)
   #error "COMPANION_FEATURE_NETWORK_TERMINAL requires ENABLE_USB_INTERFACE"
 #endif
 
+#if COMPANION_FEATURE_NETWORK_TERMINAL \
+    && !(defined(ESP32_PLATFORM) && defined(WIFI_SSID) \
+         && defined(ENABLE_OTA))
+  #error "COMPANION_FEATURE_NETWORK_TERMINAL requires ESP32 WiFi and the OTA source overlay"
+#endif
+
 #if COMPANION_FEATURE_USB_MOTA_SOURCE \
     && !(defined(NRF52_PLATFORM) && defined(OTA_FOLDER_SERIAL) \
-         && defined(ENABLE_USB_INTERFACE))
+         && defined(ENABLE_USB_INTERFACE) && defined(ENABLE_OTA))
   #error "COMPANION_FEATURE_USB_MOTA_SOURCE requires nRF52 USB folder seeding"
 #endif
+
+#if COMPANION_FEATURE_MEMORY_DIAGNOSTICS && !defined(ESP32_PLATFORM)
+  #error "COMPANION_FEATURE_MEMORY_DIAGNOSTICS requires ESP32"
+#endif
+
+#if COMPANION_FEATURE_DEDICATED_USB_LOGGING \
+    && !(defined(MESH_DUAL_CDC_LOGGING) \
+         && defined(ENABLE_USB_INTERFACE))
+  #error "COMPANION_FEATURE_DEDICATED_USB_LOGGING requires dual-CDC USB"
+#endif
+
+#if defined(COMPANION_RADIO_FULL) && !defined(BLE_PIN_CODE)
+  #error "COMPANION_RADIO_FULL requires the Bluetooth Companion transport"
+#endif

test/test_build_profiles.sh

@@ -149,4 +149,84 @@ verify_reduced_sensor_flags \
 verify_reduced_sensor_flags \
   Heltec_t114_repeater_lora_ota_no_external_sensors 0
 
+# A qualified Full Companion is the one canonical release artifact for its
+# board. The individual USB/BLE transports remain explicitly buildable, but
+# must not be republished beside the Full image.
+SUPPORTED_PIO_ENVS=(
+  Station_G2_companion_radio_usb
+  Station_G2_companion_radio_ble
+  Station_G2_companion_radio_wifi
+  Station_G2_companion_radio_full
+)
+for env_name in "${SUPPORTED_PIO_ENVS[@]}"; do
+  PIO_ENV_PLATFORM_BY_NAME[$env_name]=ESP32_PLATFORM
+  PIO_ENV_BOARD_BY_NAME[$env_name]=station-g2
+done
+mapfile -t companion_release_targets < <(
+  print_release_firmware_targets get-companion-firmwares-to-build
+)
+[ "${#companion_release_targets[@]}" -eq 1 ] \
+  || fail "Station G2 release did not collapse transports to one Full Companion"
+[ "${companion_release_targets[0]}" = Station_G2_companion_radio_full ] \
+  || fail "Station G2 release selected a non-Full Companion artifact"
+
+# A WiFi base's final -UENABLE_OTA must not win over the Full Companion's
+# source-only OTA overlay. That mismatch compiles out both the TCP terminal and
+# seeder while still leaving a superficially valid binary.
+pio_env_option_contains() {
+  [ "$2" = build_flags ] && [ "$3" = -UENABLE_OTA ]
+}
+PLATFORMIO_BUILD_FLAGS=""
+PLATFORMIO_BUILD_UNFLAGS=""
+PLATFORMIO_EXTRA_SCRIPTS=""
+unset MESHCORE_FORCE_LORA_OTA
+apply_companion_radio_full_profile \
+  Station_G2_companion_radio_full Station_G2_companion_radio_wifi
+apply_lora_ota_flag_order_fix \
+  Station_G2_companion_radio_full Station_G2_companion_radio_wifi
+[ "${MESHCORE_FORCE_LORA_OTA:-}" = 1 ] \
+  || fail "ESP32 Full Companion did not force its OTA source overlay"
+[[ "$PLATFORMIO_EXTRA_SCRIPTS" == *"pre:scripts/force_lora_ota.py"* ]] \
+  || fail "ESP32 Full Companion did not install the OTA flag-order fix"
+
+# The same protection applies to explicitly requested standalone OTA
+# transports even though the canonical release publishes the Full replacement.
+PIO_ENV_OTA_BY_NAME[Station_G2_companion_radio_wifi]=1
+PLATFORMIO_EXTRA_SCRIPTS=""
+unset MESHCORE_FORCE_LORA_OTA
+apply_lora_ota_flag_order_fix \
+  Station_G2_companion_radio_wifi Station_G2_companion_radio_wifi
+[ "${MESHCORE_FORCE_LORA_OTA:-}" = 1 ] \
+  || fail "standalone ESP32 OTA Companion did not force its OTA overlay"
+[[ "$PLATFORMIO_EXTRA_SCRIPTS" == *"pre:scripts/force_lora_ota.py"* ]] \
+  || fail "standalone ESP32 OTA Companion omitted the OTA flag-order fix"
+
+# Full capability contracts must use functional strings that survive release
+# builds with optional debug logging disabled.
+BUILD_PROFILE_FOR_TARGET=full
+BUILD_CAPABILITIES=()
+BUILD_REDUCTIONS=()
+BUILD_EXPECTATIONS=()
+declare_build_capability_contract \
+  Station_G2_companion_radio_full ESP32_PLATFORM
+expectations=" ${BUILD_EXPECTATIONS[*]} "
+[[ "$expectations" == *"companion.network_terminal=USB currently owns the Full Companion terminal"* ]] \
+  || fail "ESP32 Full contract uses no stable network-terminal evidence"
+[[ "$expectations" == *"companion.wifi_ota_seeder=OTA seeder listening on :"* ]] \
+  || fail "ESP32 Full contract omitted the WiFi seeder"
+[[ "$expectations" != *"Full Companion terminal listening"* ]] \
+  || fail "ESP32 Full contract still depends on optional debug logging"
+
+PIO_ENV_PLATFORM_BY_NAME[RAK_3401_companion_radio_full]=NRF52_PLATFORM
+BUILD_CAPABILITIES=()
+BUILD_REDUCTIONS=()
+BUILD_EXPECTATIONS=()
+declare_build_capability_contract \
+  RAK_3401_companion_radio_full NRF52_PLATFORM
+expectations=" ${BUILD_EXPECTATIONS[*]} "
+[[ "$expectations" == *"companion.usb_mota_source=ota folder on"* ]] \
+  || fail "nRF52 Full contract omitted USB folder seeding"
+[[ "$expectations" != *"companion.network_terminal="* ]] \
+  || fail "nRF52 Full contract promised an ESP32-only network terminal"
+
 echo "test_build_profiles: OK"

variants/station_g2/platformio.ini

@@ -1,6 +1,12 @@
 [Station_G2]
 extends = esp32_base
 board = station-g2
+; MeshCore and the Station G2's source-built dependencies do not throw C++
+; exceptions. Removing the otherwise forced exception runtime saves about
+; 67 KiB, keeping the complete ordinary repeater inside the deployed 1.25 MiB
+; app slot without removing sensors, LoRa OTA, the browser updater, or CLI.
+build_unflags =
+  -fexceptions
 ; Preserve the original 0x10000/0x150000 dual-OTA layout so app-only updates do
 ; not require replacing the partition table or erasing an installed G2.
 board_build.partitions = default.csv
@@ -11,6 +17,7 @@ board_build.flash_mode = dio
 build_flags =
   ${esp32_base.build_flags}
   ${sensor_base.build_flags}
+  -fno-exceptions
   -I variants/station_g2
   -I src/helpers/ui
   -D STATION_G2
@@ -326,7 +333,9 @@ lib_deps =
 extends = env:Station_G2_companion_radio_wifi
 platform = ${esp32_s3_dual_cdc_full.platform}
 board_build.flash_mode = ${esp32_s3_full.board_build.flash_mode}
-build_unflags = ${esp32_s3_dual_cdc_full.build_unflags}
+build_unflags =
+  ${Station_G2.build_unflags}
+  ${esp32_s3_dual_cdc_full.build_unflags}
 build_flags =
   ${env:Station_G2_companion_radio_wifi.build_flags}
   ${esp32_s3_dual_cdc_full.build_flags}