refactor: replace firmware.zip extraction with script for DFU file normalization

.github/workflows/custom_build.yml

@@ -214,12 +214,8 @@ jobs:
           ROOT=$(cat /tmp/fw-src-root.txt)
           BUILD_DIR="$ROOT/.pio/build/${{ inputs.target_env }}"
 
-          # Path 1: MeshCore produces firmware.zip (Nordic DFU package) when adafruit-nrfutil
-          # is available during pio run. Unzip it to get bin/dat/manifest.json at build root.
-          if [ -f "$BUILD_DIR/firmware.zip" ]; then
-            echo "Found firmware.zip; extracting Nordic DFU files to build root"
-            unzip -j "$BUILD_DIR/firmware.zip" "*.bin" "*.dat" "manifest.json" -d "$BUILD_DIR/" || true
-          fi
+          # Path 1: unpack any DFU-shaped *.zip from the PIO build dir, normalize to firmware.bin/dat.
+          bash "${{ github.workspace }}/scripts/stage-nrf52-dfu-from-build.sh" "$BUILD_DIR"
 
           # Path 2: firmware/ subdirectory fallback (local builds or alternate PIO layouts).
           if [ -d "$BUILD_DIR/firmware" ] && ! ls "$BUILD_DIR"/*.dat >/dev/null 2>&1; then

.github/workflows/custom_build_test.yml

@@ -214,12 +214,8 @@ jobs:
           ROOT=$(cat /tmp/fw-src-root.txt)
           BUILD_DIR="$ROOT/.pio/build/${{ inputs.target_env }}"
 
-          # Path 1: MeshCore produces firmware.zip (Nordic DFU package) when adafruit-nrfutil
-          # is available during pio run. Unzip it to get bin/dat/manifest.json at build root.
-          if [ -f "$BUILD_DIR/firmware.zip" ]; then
-            echo "Found firmware.zip; extracting Nordic DFU files to build root"
-            unzip -j "$BUILD_DIR/firmware.zip" "*.bin" "*.dat" "manifest.json" -d "$BUILD_DIR/" || true
-          fi
+          # Path 1: unpack any DFU-shaped *.zip from the PIO build dir, normalize to firmware.bin/dat.
+          bash "${{ github.workspace }}/scripts/stage-nrf52-dfu-from-build.sh" "$BUILD_DIR"
 
           # Path 2: firmware/ subdirectory fallback (local builds or alternate PIO layouts).
           if [ -d "$BUILD_DIR/firmware" ] && ! ls "$BUILD_DIR"/*.dat >/dev/null 2>&1; then

scripts/stage-nrf52-dfu-from-build.sh

@@ -0,0 +1,79 @@
+#!/usr/bin/env bash
+# Unpack PlatformIO nRF52 DFU archives from the build directory (any *.zip name),
+# then normalize application + init packet to firmware.bin / firmware.dat and align
+# manifest.json when present. Typical layout is one zip per environment; multiple
+# zips are processed in glob order (same member names are last-wins).
+#
+# Usage: stage-nrf52-dfu-from-build.sh BUILD_DIR
+set -euo pipefail
+
+BUILD_DIR="${1:?usage: stage-nrf52-dfu-from-build.sh BUILD_DIR}"
+
+zip_looks_like_dfu() {
+  # Heuristic: DFU package includes a .dat init packet (member path ends in .dat).
+  unzip -l "$1" 2>/dev/null | grep -qE '[.]dat$'
+}
+
+normalize_pair() {
+  local src_bin="$1"
+  local src_dat="$2"
+
+  if [ -z "$src_bin" ] || [ -z "$src_dat" ]; then
+    return 0
+  fi
+  if [ "$src_bin" = 'firmware.bin' ] && [ "$src_dat" = 'firmware.dat' ]; then
+    echo "DFU application already firmware.bin / firmware.dat"
+    return 0
+  fi
+  if [ ! -f "$BUILD_DIR/$src_bin" ] || [ ! -f "$BUILD_DIR/$src_dat" ]; then
+    return 0
+  fi
+
+  echo "Normalizing DFU payload: $src_bin + $src_dat -> firmware.bin + firmware.dat"
+  cp -a "$BUILD_DIR/$src_bin" "$BUILD_DIR/firmware.bin"
+  cp -a "$BUILD_DIR/$src_dat" "$BUILD_DIR/firmware.dat"
+
+  if [ -f "$BUILD_DIR/manifest.json" ] && command -v jq >/dev/null 2>&1; then
+    local tmp
+    tmp="$(mktemp)"
+    jq '.manifest.application.bin_file = "firmware.bin" | .manifest.application.dat_file = "firmware.dat"' \
+      "$BUILD_DIR/manifest.json" >"$tmp" && mv "$tmp" "$BUILD_DIR/manifest.json"
+  fi
+}
+
+shopt -s nullglob
+for z in "$BUILD_DIR"/*.zip; do
+  [ -f "$z" ] || continue
+  if ! zip_looks_like_dfu "$z"; then
+    echo "Skipping zip (no .dat member): $z"
+    continue
+  fi
+  echo "Extracting DFU zip: $z"
+  unzip -jo "$z" '*.bin' '*.dat' 'manifest.json' -d "$BUILD_DIR/" || true
+done
+shopt -u nullglob
+
+src_bin=""
+src_dat=""
+
+if [ -f "$BUILD_DIR/manifest.json" ] && command -v jq >/dev/null 2>&1; then
+  src_bin="$(jq -r '.manifest.application.bin_file // empty' "$BUILD_DIR/manifest.json" 2>/dev/null || true)"
+  src_dat="$(jq -r '.manifest.application.dat_file // empty' "$BUILD_DIR/manifest.json" 2>/dev/null || true)"
+fi
+
+if [ -n "$src_bin" ] && [ -n "$src_dat" ] && [ -f "$BUILD_DIR/$src_bin" ] && [ -f "$BUILD_DIR/$src_dat" ]; then
+  normalize_pair "$src_bin" "$src_dat"
+elif [ -f "$BUILD_DIR/firmware.bin" ] && [ -f "$BUILD_DIR/firmware.dat" ]; then
+  echo "DFU payload already firmware.bin / firmware.dat"
+else
+  shopt -s nullglob
+  dats=("$BUILD_DIR"/*.dat)
+  shopt -u nullglob
+  if [ "${#dats[@]}" -eq 1 ]; then
+    dat="${dats[0]}"
+    base="$(basename "$dat" .dat)"
+    if [ -f "$BUILD_DIR/${base}.bin" ]; then
+      normalize_pair "${base}.bin" "$(basename "$dat")"
+    fi
+  fi
+fi