Added ESP32 firmware merging

.github/merge.py

@@ -0,0 +1,64 @@
+import os
+import shutil
+import subprocess
+
+root_dir = '.pio/build'
+boot_app0_path = os.path.join(os.path.expanduser("~"),".platformio/packages/framework-arduinoespressif32/tools/partitions/boot_app0.bin")
+
+print("+++ Starting merging... +++")
+
+# Check if the boot_app0.bin file exists
+if not os.path.isfile(boot_app0_path):
+    print(f"boot_app0.bin not found at {boot_app0_path}")
+    exit(1)
+
+# Check if the root directory exists
+if not os.path.isdir(root_dir):
+    print(f"Root directory {root_dir} not found")
+    exit(1)
+
+# Iterate over all items in the root directory
+for item in os.listdir(root_dir):
+    item_path = os.path.join(root_dir, item)
+
+    # Check if the item is a directory and its name starts with "esp32"
+    if os.path.isdir(item_path) and item.lower().startswith("esp32"):
+        print(f"Found an 'esp32' directory: {item_path}")
+
+        # Check if the directory contains a file which begins with "firmware"
+        firmware_path = ""
+        for file in os.listdir(item_path):
+            if file.lower().startswith("firmware") and file.lower().endswith(".bin") and "combined" not in file.lower():
+                firmware_path = os.path.join(item_path, file)
+                directory_path, filename_with_extension = os.path.split(firmware_path)
+                filename, file_extension = os.path.splitext(filename_with_extension)
+                print(f"> Found a 'firmware' file: {firmware_path}")
+
+                # build new filename
+                firmware_combined_path = os.path.join(directory_path, filename + ".combined" + file_extension)
+
+                # copy boot_app0.bin
+                print(f"> Copying boot_app0.bin to {item_path}...")
+                shutil.copy(boot_app0_path, item_path)
+
+                # merge firmware
+                print(f"> Merging firmware to {firmware_combined_path}...")
+                command = f"python -m esptool --chip esp32 merge_bin -o {firmware_combined_path} --flash_mode dio --flash_freq 40m --flash_size 4MB 0x1000 {item_path}/bootloader.bin 0x8000 {item_path}/partitions.bin 0xe000 {item_path}/boot_app0.bin 0x10000 {firmware_path}"
+                return_code  = subprocess.call(command, shell=True, stdout=subprocess.DEVNULL, stderr=subprocess.DEVNULL)
+                if return_code != 0:
+                    print(f"> Merging failed with return code {return_code}.")
+                    break
+                else:
+                    print("> Merging successful")
+
+                # remove unmerged firmware
+                print(f"> Removing unmerged firmware {firmware_path}...")
+                os.remove(firmware_path)
+
+                print("> Done")
+                break
+
+        if firmware_path == "":
+            print("> No firmware file for merging found")
+
+print("+++ Merging done... +++")

.github/workflows/build-and-release.yml

@@ -74,11 +74,15 @@ jobs:
       - name: Install pio and its dependencies 🔧
         run: |
           python -m pip install --upgrade pip
-          pip install --upgrade platformio
+          pip install --upgrade platformio esptool
 
       - name: Run PlatformIO build on selected platforms 🏗️
         run: platformio run -e ESP8266_generic -e ESP8266_nodemcuv2 -e ESP32_generic -e ESP32_d1_mini32 -e ESP8266_d1_mini -e ESP32_ulanzi
 
+      - name: Merge ESP32 firmware to single binaries 🔧
+        run: |
+          python .github/merge.py
+
       - name: Upload build artifacts 💾
         uses: actions/upload-artifact@v3
         with: