fix(build): clear matrix failures while preserving features

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

@@ -233,6 +233,8 @@ jobs:
         run: |
           bash test/test_build_size_detection.sh
           python3 -B test/test_firmware_ram.py
+          python3 -B test/test_neighbor_scope_storage.py
+          python3 -B test/test_ed25519_compact.py
           python3 -B test/test_cascade_release_package.py
           python3 -B test/test_t096_full_memory.py
           python3 -B test/test_nrf52_ble_startup.py

build.sh

@@ -4384,7 +4384,7 @@ run_pio_with_size_detection() {
     build_status=1
   elif [ "$build_status" -ne 0 ] \
       && grep -Eiq \
-        'will not fit in region|region .+ overflowed by|section .+ will not fit|sketch too big|program size is greater than maximum|exceed(s|ing).*(flash|partition|app)' \
+        'will not fit in region|region .+ overflowed by|section .+ will not fit|sketch too big|program size.*is greater than maximum|exceed(s|ing).*(flash|partition|app)' \
         "$build_output_log"; then
     build_status=42
   fi
@@ -5066,6 +5066,13 @@ is_runtime_setting_alias_target() {
 }
 
 is_redundant_bulk_build_target() {
+  # Bench fixtures and migration utilities use their dedicated PlatformIO
+  # recipes; they are not node firmware for the release/OTA packaging matrix.
+  case "${1,,}" in
+    profile_switch_*|*_partition_migrator|*_partition_migrator_test_*|*_partition_legacy_seed|*_sim)
+      return 0
+      ;;
+  esac
   # Keep every legacy name available to `build-firmware` and
   # `build-matching-firmwares`, but do not republish binaries that differ only
   # by a saved/default setting, or roles already supplied by Full Companion.

examples/companion_radio/main.cpp

@@ -2285,7 +2285,11 @@ void halt() {
                                    clear_bonds, stealth_pair_once,
                                    bonded_only_peer_ptr)) {
       strncpy(companion_bluetooth_start_failure,
+#if defined(NRF52_PLATFORM)
               bluetooth_interface.beginFailure(),
+#else
+              "Bluetooth initialization failed",
+#endif
               sizeof(companion_bluetooth_start_failure) - 1);
       companion_bluetooth_start_failure[
           sizeof(companion_bluetooth_start_failure) - 1] = 0;

examples/simple_repeater/MyMesh.cpp

@@ -3662,7 +3662,7 @@ void MyMesh::begin(FILESYSTEM *fs) {
   loadTelemetryHistoryTxPrefs();
 #endif
 
-#ifdef SIM_WIFI_SSID
+#if defined(SIM_WIFI_SSID) && defined(WITH_MQTT_BRIDGE)
   // Emulator builds (Wokwi) boot with fresh NVS every run. Seed WiFi so the
   // observer auto-joins the simulator's network and brings the MQTT bridge up
   // (WiFi is driven by the bridge task), instead of raising the setup AP that
@@ -12842,7 +12842,7 @@ bool MyMesh::completeNeighborDiscoverEntry() {
     pubkey_hex,
     entry.snr / 4.0f,
     UINT32_MAX,
-    entry.scopes,
+    neighbor_discover_scopes[neighbor_discover_next],
     entry.status == ND_RESPONDED ? "responded"
       : (entry.status == ND_SEND_FAILED ? "send_failed" : "timeout")
   };
@@ -12868,7 +12868,8 @@ bool MyMesh::completeNeighborDiscoverEntry() {
 bool MyMesh::handleNeighborDiscoverResponse(int overlay_idx,
                                             const uint8_t* data, size_t len,
                                             float snr, int16_t rssi) {
-  if (overlay_idx < 0 || overlay_idx >= neighbor_discover_count) return false;
+  if (overlay_idx < 0 || overlay_idx >= neighbor_discover_count
+      || (size_t)overlay_idx >= NEIGHBOR_SCOPE_RESULTS) return false;
   NeighborDiscoverEntry& entry = neighbor_discover[overlay_idx];
   if (entry.status != ND_PENDING || len < 8) return false;
 
@@ -12877,11 +12878,12 @@ bool MyMesh::handleNeighborDiscoverResponse(int overlay_idx,
   if (tag != entry.tag) return false;
 
   size_t scope_len = len - 8;
-  if (scope_len >= sizeof(entry.scopes)) {
-    scope_len = sizeof(entry.scopes) - 1;
+  auto& scopes = neighbor_discover_scopes[overlay_idx];
+  if (scope_len >= sizeof(scopes)) {
+    scope_len = sizeof(scopes) - 1;
   }
-  memcpy(entry.scopes, &data[8], scope_len);
-  entry.scopes[scope_len] = 0;
+  memcpy(scopes, &data[8], scope_len);
+  scopes[scope_len] = 0;
   entry.status = ND_RESPONDED;
   // A zero-hop reply is proof we heard this neighbour now, so re-stamp both the
   // snapshot and live table with this packet's measurements. A stamp taken
@@ -13028,7 +13030,7 @@ void MyMesh::finishNeighborDiscover() {
       bool heard_known = neighborHeardAgeUsable(entry.heard_timestamp, now_secs);
       entries[i].heard_unknown = !heard_known;
       entries[i].heard_secs_ago = heard_known ? (now_secs - entry.heard_timestamp) : 0;
-      entries[i].scopes = entry.scopes;
+      entries[i].scopes = neighbor_discover_scopes[i];
       switch (entry.status) {
         case ND_RESPONDED:   entries[i].status = "responded"; break;
         case ND_SEND_FAILED: entries[i].status = "send_failed"; break;
@@ -13169,7 +13171,6 @@ bool MyMesh::startNeighborDiscover(char* reply) {
       entry.heard_timestamp = neighbours[i].heard_timestamp;
       entry.snr = neighbours[i].snr;
       entry.rssi = neighbours[i].rssi;
-      entry.scopes[0] = 0;
       entry.tag = 0;
       entry.status = ND_UNSENT;
       neighbor_discover_count++;
@@ -13193,6 +13194,7 @@ bool MyMesh::startNeighborDiscover(char* reply) {
     neighbor_discover[j] = entry;
   }
 
+  memset(neighbor_discover_scopes, 0, sizeof(neighbor_discover_scopes));
   neighbor_discover_next = 0;
   resetNeighborDiscoverJsonBudget();
   neighbor_discover_active = true;

examples/simple_repeater/MyMesh.h

@@ -644,10 +644,16 @@ class MyMesh : public mesh::Mesh, public CommonCLICallbacks
     int8_t snr;              // multiplied by 4
     int16_t rssi;            // dBm from the last packet heard from this neighbour
     uint32_t tag;            // anon-regions request tag we're waiting on
-    char scopes[96];         // scope names from the response
     uint8_t status;          // NeighborDiscoverStatus
   };
   NeighborDiscoverEntry neighbor_discover[MAX_NEIGHBOURS];
+  // Only the publishable prefix (plus the result that detects truncation)
+  // receives scope queries. Keep every neighbor snapshot, without reserving
+  // 96 response bytes for each entry that will never be queried.
+  static constexpr size_t NEIGHBOR_SCOPE_RESULTS =
+      MAX_NEIGHBOURS < MQTTBridge::NEIGHBORS_MAX_PUBLISH_ENTRIES + 1
+          ? MAX_NEIGHBOURS : MQTTBridge::NEIGHBORS_MAX_PUBLISH_ENTRIES + 1;
+  char neighbor_discover_scopes[NEIGHBOR_SCOPE_RESULTS][96];
   uint8_t neighbor_discover_count;
   uint8_t neighbor_discover_next;            // newest-first entry currently being queried
   uint8_t neighbor_discover_publish_count;    // completed prefix that fits the JSON buffer

lib/ed25519/sha512.c

@@ -115,6 +115,19 @@ static int sha512_compress(sha512_context *md, unsigned char *buf)
     d += t0; \
     h  = t0 + t1;
 
+#if defined(ED25519_COMPACT_SHA512)
+    /* Same 80 rounds, with a fixed state rotation instead of eight copies of
+       the round body. Small STM32 images trade loop overhead for flash space;
+       neither the loop bounds nor memory indexes depend on secret data. */
+    for (i = 0; i < 80; ++i) {
+       int j;
+       uint64_t next;
+       RND(S[0],S[1],S[2],S[3],S[4],S[5],S[6],S[7],i);
+       next = S[7];
+       for (j = 7; j > 0; --j) S[j] = S[j - 1];
+       S[0] = next;
+    }
+#else
     for (i = 0; i < 80; i += 8) {
        RND(S[0],S[1],S[2],S[3],S[4],S[5],S[6],S[7],i+0);
        RND(S[7],S[0],S[1],S[2],S[3],S[4],S[5],S[6],i+1);
@@ -125,6 +138,7 @@ static int sha512_compress(sha512_context *md, unsigned char *buf)
        RND(S[2],S[3],S[4],S[5],S[6],S[7],S[0],S[1],i+6);
        RND(S[1],S[2],S[3],S[4],S[5],S[6],S[7],S[0],i+7);
    }
+#endif
 
    #undef RND
 

test/test_build_profiles.sh

@@ -12,6 +12,13 @@ fail() {
 [ "$OPTION3_BUILD_WORKERS" -eq 1 ] \
   || fail "logging matrix permits concurrent PlatformIO target builds"
 
+for utility in profile_switch_t096_sx1262 xiao_s3_partition_migrator \
+    heltec_v4_partition_migrator_test_hold xiao_s3_partition_legacy_seed \
+    Heltec_v3_repeater_observer_mqtt_sim; do
+  is_redundant_bulk_build_target "$utility" \
+    || fail "release matrix includes development utility $utility"
+done
+
 # Reduced RAK profiles all retain the compact INA set, but GPS depends on
 # whether the bridge already owns Serial1. Keep those independent contracts so
 # a valid Serial1 image cannot fail release qualification for an absent GPS

test/test_build_size_detection.sh

@@ -38,7 +38,8 @@ pio_result=1
 for pio_message in \
   "firmware.elf section .text will not fit in region FLASH" \
   "region FLASH overflowed by 43080 bytes" \
-  "Error: The program size is greater than maximum allowed"; do
+  "Error: The program size is greater than maximum allowed" \
+  "Error: The program size (1314113 bytes) is greater than maximum allowed (1310720 bytes)"; do
   check_status 42
   grep -Fq "$pio_message" "$test_root/output" || fail "compiler output was lost"
 done

test/test_ed25519_compact.py

@@ -1,3 +1,5 @@
+import ctypes
+import hashlib
 import subprocess
 import tempfile
 import unittest
@@ -22,6 +24,22 @@ SOURCES = [
 
 
 class Ed25519CompactTest(unittest.TestCase):
+    def test_compact_sha512_matches_hashlib_at_block_boundaries(self):
+        with tempfile.TemporaryDirectory() as temp_dir:
+            library = Path(temp_dir) / "sha512.so"
+            subprocess.run(["cc", "-std=c99", "-O2", "-shared", "-fPIC",
+                            "-DED25519_COMPACT_SHA512=1", str(ED25519 / "sha512.c"),
+                            "-o", str(library)], check=True)
+            sha = ctypes.CDLL(str(library)).sha512
+            sha.argtypes = [ctypes.c_void_p, ctypes.c_size_t, ctypes.c_void_p]
+            sha.restype = ctypes.c_int
+            for length in (0, 1, 63, 64, 111, 112, 127, 128, 129, 255, 256, 1024, 4097):
+                data = bytes((i * 73 + 19) % 256 for i in range(length))
+                output = ctypes.create_string_buffer(64)
+                with self.subTest(length=length):
+                    self.assertEqual(sha(data, len(data), output), 0)
+                    self.assertEqual(output.raw, hashlib.sha512(data).digest())
+
     def test_stm32_builds_enable_compact_base_table(self):
         platformio = (ROOT / "platformio.ini").read_text()
         stm32_base = platformio.split("[stm32_base]", 1)[1].split("\n[", 1)[0]
@@ -32,6 +50,8 @@ class Ed25519CompactTest(unittest.TestCase):
             for label, extra_flags in (
                 ("standard", []),
                 ("compact", ["-DED25519_COMPACT_BASE=1"]),
+                ("compact_sha512", ["-DED25519_COMPACT_BASE=1",
+                                    "-DED25519_COMPACT_SHA512=1"]),
             ):
                 executable = Path(temp_dir) / label
                 subprocess.run(

test/test_neighbor_scope_storage.py

@@ -0,0 +1,91 @@
+"""Exercise production scope storage and truncation with 254 neighbors."""
+from pathlib import Path
+import subprocess
+import tempfile
+import unittest
+
+from test_replay_reset_integration import extract_braced
+
+ROOT = Path(__file__).resolve().parents[1]
+
+
+class NeighborScopeStorageTest(unittest.TestCase):
+    def test_response_bounds_and_publish_prefix(self):
+        header = (ROOT / "examples/simple_repeater/MyMesh.h").read_text()
+        source = (ROOT / "examples/simple_repeater/MyMesh.cpp").read_text()
+        layout = header[header.index("  struct NeighborDiscoverEntry {"):
+                        header.index("  uint8_t neighbor_discover_count;")]
+        methods = "\n".join(extract_braced(source, signature) for signature in (
+            "bool MyMesh::completeNeighborDiscoverEntry()",
+            "bool MyMesh::handleNeighborDiscoverResponse("))
+        code = r'''
+#include <cassert>
+#include <cstdint>
+#include <cstring>
+#include <cstddef>
+#define MAX_NEIGHBOURS 254
+#define PUB_KEY_SIZE 32
+namespace mesh {
+struct Identity { uint8_t pub_key[32]; };
+struct Utils { static void toHex(char* out, const uint8_t*, size_t) { out[0] = 0; } };
+}
+struct MQTTBridge {
+  static constexpr int NEIGHBORS_MAX_PUBLISH_ENTRIES = 20;
+  static constexpr size_t NEIGHBORS_JSON_BUFFER_SIZE = 8192;
+};
+struct MQTTMessageBuilder {
+  struct NeighborsMessageEntry {
+    const char* key; float snr; uint32_t age; const char* scopes;
+    const char* status; int16_t rssi;
+  };
+  static size_t measureNeighborsMessageEntry(const NeighborsMessageEntry&) { return 100; }
+};
+struct Clock { uint32_t getCurrentTime() { return 100; } };
+struct MyMesh {
+  enum { ND_UNSENT, ND_QUEUED, ND_PENDING, ND_RESPONDED, ND_TIMEOUT, ND_SEND_FAILED };
+''' + layout + r'''
+  unsigned neighbor_discover_next = 0, neighbor_discover_count = 254;
+  unsigned neighbor_discover_publish_count = 0;
+  size_t neighbor_discover_json_size = 0;
+  bool neighbor_discover_truncated = false, finished = false;
+  Clock clock;
+  Clock* getRTCClock() { return &clock; }
+  void touchNeighbourHeard(const mesh::Identity&, uint32_t, float, int16_t) {}
+  void finishNeighborDiscover() { finished = true; }
+  bool completeNeighborDiscoverEntry();
+  bool handleNeighborDiscoverResponse(int, const uint8_t*, size_t, float, int16_t);
+};
+''' + methods + r'''
+int main() {
+  MyMesh m = {};
+  static_assert(sizeof(m.neighbor_discover_scopes) == 21 * 96, "bounded scope storage");
+  static_assert(sizeof(m.neighbor_discover) / sizeof(m.neighbor_discover[0]) == 254,
+                "retain every neighbor snapshot");
+  uint8_t response[200] = {};
+  uint32_t tag = 123;
+  memcpy(response, &tag, 4);
+  memset(response + 8, 'x', sizeof(response) - 8);
+  for (int i = 0; i <= 20; ++i) {
+    auto& entry = m.neighbor_discover[i];
+    entry.status = MyMesh::ND_PENDING;
+    entry.tag = tag;
+    assert(m.handleNeighborDiscoverResponse(i, response, sizeof(response), 5, -100));
+    assert(strlen(m.neighbor_discover_scopes[i]) == 95);
+    assert(m.completeNeighborDiscoverEntry() == (i < 20));
+  }
+  assert(m.finished && m.neighbor_discover_truncated);
+  assert(m.neighbor_discover_publish_count == 20);
+  assert(!m.handleNeighborDiscoverResponse(21, response, sizeof(response), 5, -100));
+  assert(!m.handleNeighborDiscoverResponse(-1, response, sizeof(response), 5, -100));
+}
+'''
+        with tempfile.TemporaryDirectory() as directory:
+            path = Path(directory)
+            (path / "test.cpp").write_text(code)
+            subprocess.run(["g++", "-std=c++17", "-fsanitize=address,undefined",
+                            str(path / "test.cpp"), "-o", str(path / "test")], check=True)
+            subprocess.run([str(path / "test")], check=True)
+
+
+if __name__ == "__main__":
+    unittest.main()

variants/rak3x72/platformio.ini

@@ -66,6 +66,7 @@ extends = rak3x72
 platform_packages = platformio/toolchain-gccarmnoneeabi@^1.140201.0
 build_unflags = -Os
 build_flags = ${rak3x72.build_flags}
+  -D ED25519_COMPACT_SHA512=1 ; same hash rounds, compact loop preserves the filesystem boundary
   -Oz
   -flto
   -fno-inline-small-functions

variants/tiny_relay/platformio.ini

@@ -72,6 +72,7 @@ extends = Tiny_Relay
 platform_packages = platformio/toolchain-gccarmnoneeabi@^1.140201.0
 build_unflags = -Os
 build_flags = ${Tiny_Relay.build_flags}
+  -D ED25519_COMPACT_SHA512=1 ; same hash rounds, compact loop preserves the filesystem boundary
   -Oz
   -flto
   -fno-inline-small-functions

variants/wio-e5-dev/platformio.ini

@@ -90,6 +90,7 @@ extends = lora_e5
 platform_packages = platformio/toolchain-gccarmnoneeabi@^1.140201.0
 build_unflags = -Os
 build_flags = ${lora_e5.build_flags}
+  -D ED25519_COMPACT_SHA512=1 ; same hash rounds, compact loop preserves the filesystem boundary
   -Oz
   -flto
   -fno-inline-small-functions

variants/wio-e5-mini/platformio.ini

@@ -79,6 +79,7 @@ platform_packages = platformio/toolchain-gccarmnoneeabi@^1.140201.0
 build_unflags =
   -Os
 build_flags = ${lora_e5_mini.build_flags}
+  -D ED25519_COMPACT_SHA512=1 ; same hash rounds, compact loop preserves the filesystem boundary
   -Oz
   -flto
   -fno-inline-small-functions