script to create merged firmware automatically

examples/companion_radio/MyMesh.h

@@ -8,7 +8,7 @@
 #define FIRMWARE_VER_CODE 10
 
 #ifndef FIRMWARE_BUILD_DATE
-#define FIRMWARE_BUILD_DATE "11 March 2026"
+#define FIRMWARE_BUILD_DATE "12 March 2026"
 #endif
 
 #ifndef FIRMWARE_VERSION

merge_firmware.py

@@ -0,0 +1,65 @@
+"""
+PlatformIO post-build script: merge bootloader + partitions + firmware
+into a single flashable binary.
+
+Output: .pio/build/<env>/firmware_merged.bin
+Flash:  esptool.py --chip esp32s3 write_flash 0x0 firmware_merged.bin
+
+Place this file in the project root alongside platformio.ini.
+Add to each environment (or the base section):
+  extra_scripts = post:merge_firmware.py
+"""
+
+Import("env")
+
+def merge_bin(source, target, env):
+    import subprocess, os
+
+    build_dir = env.subst("$BUILD_DIR")
+    env_name = env.subst("$PIOENV")
+
+    bootloader = os.path.join(build_dir, "bootloader.bin")
+    partitions = os.path.join(build_dir, "partitions.bin")
+    firmware   = os.path.join(build_dir, "firmware.bin")
+    output     = os.path.join(build_dir, "firmware_merged.bin")
+
+    # Verify all inputs exist
+    for f in [bootloader, partitions, firmware]:
+        if not os.path.isfile(f):
+            print(f"[merge] WARNING: {f} not found, skipping merge")
+            return
+
+    # Read flash settings from board config
+    flash_mode = env.BoardConfig().get("build.flash_mode", "qio")
+    flash_freq = env.BoardConfig().get("build.f_flash", "80000000L").rstrip("L")
+    flash_size = env.BoardConfig().get("upload.flash_size", "16MB")
+    mcu = env.BoardConfig().get("build.mcu", "esp32s3")
+
+    # Convert numeric frequency to esptool format
+    freq_map = {"80000000": "80m", "40000000": "40m", "26000000": "26m", "20000000": "20m"}
+    flash_freq_str = freq_map.get(flash_freq, "80m")
+
+    cmd = [
+        env.subst("$PYTHONEXE"), "-m", "esptool",
+        "--chip", mcu,
+        "merge_bin",
+        "-o", output,
+        "--flash_mode", flash_mode,
+        "--flash_freq", flash_freq_str,
+        "--flash_size", flash_size,
+        "0x0",     bootloader,
+        "0x8000",  partitions,
+        "0x10000", firmware,
+    ]
+
+    print(f"\n[merge] Creating merged firmware for {env_name}...")
+    print(f"[merge] {' '.join(cmd[-6:])}")
+
+    result = subprocess.run(cmd, capture_output=True, text=True)
+    if result.returncode == 0:
+        size_kb = os.path.getsize(output) / 1024
+        print(f"[merge] OK: {output} ({size_kb:.0f} KB)")
+    else:
+        print(f"[merge] FAILED: {result.stderr}")
+
+env.AddPostAction("$BUILD_DIR/firmware.bin", merge_bin)

variants/lilygo_t5s3_epaper_pro/platformio.ini

@@ -10,6 +10,7 @@
 
 [LilyGo_T5S3_EPaper_Pro]
 extends = esp32_base
+extra_scripts = post:merge_firmware.py
 board = t5s3-epaper-pro
 board_build.flash_mode = qio
 board_build.f_flash = 80000000L

variants/lilygo_tdeck_pro/platformio.ini

@@ -1,5 +1,6 @@
 [LilyGo_TDeck_Pro]
 extends = esp32_base
+extra_scripts = post:merge_firmware.py
 board = t-deck_pro
 board_build.flash_mode = qio
 board_build.f_flash = 80000000L