Qualify ESP-NOW RAM and Wio Mini release capacity

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

@@ -40,6 +40,12 @@ jobs:
       - name: Compile ordinary STM32 USB Companion with pinned core and RadioLib
         run: pio run -e RAK_3x72_companion_radio_usb
 
+      - name: Qualify Wio-E5 Mini Companion at release version length
+        run: >-
+          bash build.sh build-firmware wio-e5-mini_companion_radio_usb
+          --firmware-version v1.17.1.9-halo-keymind-cascade-dev
+          --radio-preset usa-cascade-fixed --profile cascade --require-ota
+
   bootloader-version:
     runs-on: ubuntu-latest
     steps:

build_legacy.sh

@@ -4191,6 +4191,9 @@ apply_companion_radio_full_profile() {
       record_build_reduction \
         "Wireless Paper Full: 350 contacts; 256 offline frames normally, 128 while mOTA borrows queue storage"
       ;;
+    # ESP-NOW Full also needs the C3 queue limit: 256 frames leave only
+    # 141376 internal heap bytes against the unchanged 142336-byte reserve.
+    generic_espnow_companion_radio_full|\
     heltec_ct62_companion_radio_full|\
     xiao_c3_companion_radio_full|\
     heltec_tracker_v2_companion_radio_full_*)
@@ -4199,7 +4202,6 @@ apply_companion_radio_full_profile() {
       record_build_reduction \
         "companion.capacity limited to 100 contacts for runtime RAM; 224 queued frames and all Full transports retained"
       ;;
-    generic_espnow_companion_radio_full|\
     heltec_v3_companion_radio_full)
       # The 1.17.1.8 matrix exceeds the runtime heap budget at 150 contacts
       # after adding alerts and held DMs. Preserve the 256-frame queue, Full

docs/releases/1.17.1.9.md

@@ -33,7 +33,6 @@ layout before installing an image.
   complete sensor profile with the existing 8 KiB loop stack, 50 neighbors,
   color framebuffer and OTA arena. Their capability manifests record this
   capacity limit; heap qualification margins are unchanged.
-
 - The RAK3401 unified repeater reserves 47 flood-rule entries so its full
   sensor profile, 8 KiB loop stack, 50 neighbors and internal/QSPI OTA stores
   fit the runtime RAM requirement. Full and reduced sensor images use the
@@ -42,6 +41,15 @@ layout before installing an image.
   If active rules exceed an image's capacity, the stored file is preserved and
   policy saves are blocked. The CLI reports the capacity mismatch; install
   firmware with enough rule slots to recover the complete policy.
+- ESP32 filesystem buffer checks cover the pinned Arduino 3 frameworks used
+  by RC32 and C6 targets and continue rejecting unhonored buffer allocations.
+- Generic ESP-NOW Full Companion retains all Full transports and 100 contacts
+  with a 224-frame offline queue to meet the unchanged runtime RAM requirement.
+- Wio-E5 Mini Companion uses smaller generated code while preserving its
+  filesystem allocation, contacts, channels and physical-button controls.
+  CI compiles its actual Cascade release profile with the full version string.
+- Mesh America preserves download-only installation for hardware cards that
+  require it, including their Full and reduced sensor profiles.
 
 ## Installation
 

variants/wio-e5-mini/platformio.ini

@@ -83,6 +83,7 @@ build_flags = ${lora_e5_mini.build_flags}
   -Oz
   -flto
   -fno-inline-small-functions
+  -fno-tree-dominator-opts ; save 160 release bytes while preserving the 32 KiB filesystem
   -fipa-pta
   -fmerge-all-constants
   -fno-ipa-cp-clone