Fix capacity matrix build regressions

docs/firmware_memory_budget.md

@@ -37,7 +37,10 @@ The [small-screen message layout](v4_pixel5_font_trial.md) retains complete
 160-byte messages. Its expanded preview records add 2,816 bytes to the
 startup allowance and increase the contiguous history allocation budget.
 The V4 can allocate that history in PSRAM; the guard conservatively reserves
-internal capacity so that PSRAM availability cannot hide a RAM shortage.
+internal capacity so that PSRAM availability cannot hide a RAM shortage. A
+target may replace the generic UI allowance only with
+`MESH_COMPANION_SCREEN_STARTUP_BYTES`; a source-side assertion then covers its
+actual startup screens plus ESP32 allocator overhead.
 
 These are engineering allowances for supported configurations, not measured
 free heap after boot or a guarantee against every future allocation failure.

examples/companion_radio/ui-new/UITask.cpp

@@ -1757,6 +1757,17 @@ public:
   }
 };
 
+#if defined(MESH_COMPANION_SCREEN_STARTUP_BYTES)
+// The target may replace the generic UI allowance with a tighter measured
+// bound.  Keep the check next to the actual allocations so a future screen
+// growth cannot silently invalidate its runtime-RAM budget.  ESP32's checked
+// heap allocator can consume up to 16 bytes per allocation.
+static_assert(sizeof(SplashScreen) + sizeof(HomeScreen)
+                  + sizeof(MsgPreviewScreen) + 3 * 16
+              <= MESH_COMPANION_SCREEN_STARTUP_BYTES,
+              "Increase MESH_COMPANION_SCREEN_STARTUP_BYTES and its RAM budget");
+#endif
+
 void UITask::begin(DisplayDriver* display, SensorManager* sensors, CompanionNodePrefs* node_prefs) {
   _display = display;
   _sensors = sensors;

examples/simple_room_server/FloodRuleEngine.cpp

@@ -3,6 +3,7 @@
 #if MESH_ENABLE_ROOM_FLOOD_RULE_ENGINE
 
 #include <stddef.h>
+#include <stdlib.h>
 #include <string.h>
 
 #include <helpers/FloodFilterPolicy.h>
@@ -394,8 +395,13 @@ static bool verifyWrittenFile(FILESYSTEM* fs, const char* path,
 
 }  // namespace
 
-FloodRuleEngine::FloodRuleEngine() : _fs(NULL), _regions(NULL) {
-  memset(_entries, 0, sizeof(_entries));
+FloodRuleEngine::FloodRuleEngine()
+    : _fs(NULL), _regions(NULL),
+      _entries(new (std::nothrow) Entry[RULE_SLOTS]) {
+  // MyMesh is constructed before setup(), while the internal heap is
+  // unfragmented.  The runtime RAM gate budgets this exact allocation.
+  if (_entries == NULL) abort();
+  memset(_entries, 0, sizeof(Entry) * RULE_SLOTS);
 }
 
 void FloodRuleEngine::begin(FILESYSTEM* fs, RegionMap* regions) {
@@ -405,7 +411,7 @@ void FloodRuleEngine::begin(FILESYSTEM* fs, RegionMap* regions) {
 }
 
 void FloodRuleEngine::seedDefaults() {
-  memset(_entries, 0, sizeof(_entries));
+  memset(_entries, 0, sizeof(Entry) * RULE_SLOTS);
   Entry& entry = _entries[0];
   entry.active = true;
   entry.payload_type = PAYLOAD_TYPE_OTA;
@@ -423,7 +429,7 @@ void FloodRuleEngine::load() {
 
   enum class FileState : uint8_t { Missing, Valid, Invalid, Unreadable };
   auto loadFile = [this](const char* path) -> FileState {
-    memset(_entries, 0, sizeof(_entries));
+    memset(_entries, 0, sizeof(Entry) * RULE_SLOTS);
     if (!_fs->exists(path)) return FileState::Missing;
     File file = openRead(_fs, path);
     if (!file) return FileState::Unreadable;
@@ -655,7 +661,7 @@ void FloodRuleEngine::load() {
         && file.available() == 0;
   }
     file.close();
-    if (!success) memset(_entries, 0, sizeof(_entries));
+    if (!success) memset(_entries, 0, sizeof(Entry) * RULE_SLOTS);
     return success ? FileState::Valid : FileState::Invalid;
   };
 
@@ -1746,7 +1752,7 @@ void FloodRuleEngine::remove(const char* args, char* reply) {
   if (asciiEqual(selector, "all")) {
     Entry previous[RULE_SLOTS];
     memcpy(previous, _entries, sizeof(previous));
-    memset(_entries, 0, sizeof(_entries));
+    memset(_entries, 0, sizeof(Entry) * RULE_SLOTS);
     if (!save()) {
       memcpy(_entries, previous, sizeof(_entries));
       copyString(reply, "Err - unable to save flood filter", 160);

examples/simple_room_server/FloodRuleEngine.h

@@ -6,6 +6,7 @@
 
 #include <Arduino.h>
 #include <Mesh.h>
+#include <new>
 
 #include <helpers/IdentityStore.h>
 #include <helpers/RegionMap.h>
@@ -71,9 +72,16 @@ private:
     bool rate_window_active;
   };
 
+  // This table is 6,200 bytes.  Keep it in the constructor-time heap rather
+  // than inside the global MyMesh object: classic ESP32 has a small static
+  // DRAM window but substantially more internal heap at this point in boot.
+  // Allocation is deliberately all-or-nothing.  A node must never fall back
+  // to silently running without its configured flood rules.
+  static_assert(sizeof(Entry) == 200,
+                "Update the flood-rule runtime RAM budget in check_firmware_ram.py");
   FILESYSTEM* _fs;
   RegionMap* _regions;
-  Entry _entries[RULE_SLOTS];
+  Entry* _entries;
 
   void seedDefaults();
   void load();

scripts/check_firmware_ram.py

@@ -98,11 +98,22 @@ def requirements(platform, defines, target):
         engine = integer(defines, "MESH_ENABLE_FLOOD_RULE_ENGINE", int(platform != "STM32_PLATFORM"))
         slots = integer(defines, "FLOOD_PACKET_FILTER_SLOTS", 63 if engine else 16)
         parts["flood_filter_table"] = slots * (200 if engine else 40) + 16
+    if "room_server" in target.lower() and integer(
+            defines, "MESH_ENABLE_ROOM_FLOOD_RULE_ENGINE", 0):
+        # FloodRuleEngine keeps all 31 persisted rules in one startup heap
+        # allocation.  Its C++ assertion pins Entry to the budgeted 200 bytes.
+        parts["room_flood_rule_table"] = 31 * 200 + 16
     if "ENABLE_OTA" in defines and "OTA_HEAP_CONTEXT" in defines:
         parts["ota_context"] = 16384 + 16
     if display and display != "NullDisplayDriver":
         parts["display_pixels_and_driver"] = display_heap
-        parts["screen_objects_and_history"] = 8192 if companion else 2048
+        screen_budget = integer(defines, "MESH_COMPANION_SCREEN_STARTUP_BYTES", 0)
+        if companion and screen_budget:
+            # A target using this override has a source-side static assertion
+            # that covers its concrete startup screens and allocator overhead.
+            parts["screen_objects_and_history"] = screen_budget
+        else:
+            parts["screen_objects_and_history"] = 8192 if companion else 2048
         if companion:
             # ui-new retains 32 previews in one heap allocation. The baseline
             # covers 78 bytes per message; budget larger buffers explicitly,
@@ -113,7 +124,7 @@ def requirements(platform, defines, target):
             small_font = integer(defines, "UI_SMALL_MESSAGE_FONT", int(small_display))
             default_preview = 161 if small_font else 78
             extra = max(0, integer(defines, "UI_MSG_PREVIEW_SIZE", default_preview) - 78)
-            if extra:
+            if extra and not screen_budget:
                 parts["expanded_message_previews"] = 32 * ((extra + 7) // 8) * 8
     parts["allocation_and_transient_margin"] = 16384 if platform == "ESP32_PLATFORM" else 4096
     required = sum(parts.values())
@@ -124,7 +135,8 @@ def requirements(platform, defines, target):
     largest = max(display_heap, parts["radio_packet_pool"], 8192 if platform == "ESP32_PLATFORM" else 0)
     if "expanded_message_previews" in parts:
         largest = max(largest, 8192 + parts["expanded_message_previews"])
-    for name in ("client_table", "flood_filter_table", "ota_context"):
+    for name in ("client_table", "flood_filter_table", "room_flood_rule_table",
+                 "ota_context", "screen_objects_and_history"):
         largest = max(largest, parts.get(name, 0))
     return {"required_heap_bytes": required, "required_contiguous_bytes": largest,
             "components": parts, "display": display, "full_companion": full}

src/helpers/rp2040/SerialBLEInterface.cpp

@@ -151,7 +151,7 @@ void SerialBLEInterface::enable() {
   if (_isEnabled) return;
   _isEnabled = true;
   clearBuffers();
-  BLE.startAdvertising(true);
+  BLE.startAdvertising();
 }
 
 void SerialBLEInterface::disconnect() {

variants/heltec_tracker_v2/platformio.ini

@@ -421,6 +421,9 @@ extends = env:heltec_tracker_v2_companion_radio_wifi_femon
 board_build.flash_mode = ${esp32_s3_full.board_build.flash_mode}
 build_flags =
   ${env:heltec_tracker_v2_companion_radio_wifi_femon.build_flags}
+  ; Bound by the ui-new source assertion: Splash + Home + full 32-message
+  ; preview history and ESP32 allocator overhead, without reducing UI state.
+  -D MESH_COMPANION_SCREEN_STARTUP_BYTES=9808
   -D MESHCORE_REQUIRES_COMPANION_RADIO_FULL=1
 
 [env:heltec_tracker_v2_companion_radio_wifi_femoff]

variants/lilygo_tbeam_SX1262/platformio.ini

@@ -1,8 +1,15 @@
 [LilyGo_TBeam_SX1262]
 extends = esp32_base
 board = ttgo-t-beam
+; MeshCore and its source-built dependencies do not throw C++ exceptions.
+; Avoid linking the unused exception runtime and use the supported compact
+; ROM formatter so the feature-complete dual-OTA observer remains deployable.
+build_unflags =
+  -fexceptions
 build_flags =
   ${esp32_base.build_flags}
+  -fno-exceptions
+  -D PORTABLE_ESP32_ROM_NANO_FORMAT=1
   -I variants/lilygo_tbeam_SX1262
   -D TBEAM_SX1262
   -D P_LORA_DIO_0=26

variants/lilygo_tbeam_SX1276/platformio.ini

@@ -1,8 +1,15 @@
 [LilyGo_TBeam_SX1276]
 extends = esp32_base
 board = ttgo-t-beam
+; MeshCore and its source-built dependencies do not throw C++ exceptions.
+; Avoid linking the unused exception runtime and use the supported compact
+; ROM formatter so the feature-complete dual-OTA observer remains deployable.
+build_unflags =
+  -fexceptions
 build_flags =
   ${esp32_base.build_flags}
+  -fno-exceptions
+  -D PORTABLE_ESP32_ROM_NANO_FORMAT=1
   -I variants/lilygo_tbeam_SX1276
   -D TBEAM_SX1276
   -D P_LORA_DIO_0=26

variants/rpi_picow/platformio.ini

@@ -122,7 +122,9 @@ build_src_filter = ${rpi_picow.build_src_filter}
   +<../examples/companion_radio/*.cpp>
 lib_deps = ${rpi_picow.lib_deps}
   densaugeo/base64 @ ~1.4.0
-lib_ignore = BLE
+lib_ignore =
+  ${rp2040_base.lib_ignore}
+  BLE
 
 [env:PicoW_terminal_chat]
 extends = rpi_picow

variants/station_g2/platformio.ini

@@ -49,6 +49,9 @@ build_flags =
   ; G2 roles remain below each legacy 0x140000 (1.25 MiB) application slot.
   -D LIGHTWEIGHT_WIFI_OTA=1
   -D WEBCONFIG_DISABLED=1
+  ; The ESP32-S3 ROM formatter preserves the normal libc ABI while keeping
+  ; the complete portable LoRa-OTA repeater inside its legacy app slot.
+  -D PORTABLE_ESP32_ROM_NANO_FORMAT=1
 build_src_filter = ${esp32_base.build_src_filter}
   +<../variants/station_g2>
   +<helpers/sensors>