fix: use PlatformIO platform API to locate boot_app0.bin

.github/workflows/build.yml

@@ -70,15 +70,35 @@ jobs:
         WLED_RELEASE: True
         WLED_NIGHTLY_BUILD: ${{ inputs.nightly_build && 'true' || 'false' }}
       run: pio run -e ${{ matrix.environment }}
-    - name: Rename Bin
-      run: mv -v .pio/build/${{ matrix.environment }}/firmware.bin firmware-${{ matrix.environment }}.bin
+    - name: Collect firmware files
+      run: |
+        mkdir -p artifact-${{ matrix.environment }}
+        cp .pio/build/${{ matrix.environment }}/firmware.bin artifact-${{ matrix.environment }}/firmware.bin
+        # partitions.bin is only produced by ESP32 builds (not ESP8266)
+        if [ -f .pio/build/${{ matrix.environment }}/partitions.bin ]; then
+          cp .pio/build/${{ matrix.environment }}/partitions.bin artifact-${{ matrix.environment }}/partitions.bin
+        fi
+        # bootloader.bin is only produced by ESP32 builds using arduino-esp32 >= 2.x (not ESP8266, not old 1.0.x)
+        if [ -f .pio/build/${{ matrix.environment }}/bootloader.bin ]; then
+          cp .pio/build/${{ matrix.environment }}/bootloader.bin artifact-${{ matrix.environment }}/bootloader.bin
+        fi
+        # boot_app0.bin is copied to the build dir by output_bins.py using the PlatformIO platform API (ESP32 only)
+        if [ -f .pio/build/${{ matrix.environment }}/boot_app0.bin ]; then
+          cp .pio/build/${{ matrix.environment }}/boot_app0.bin artifact-${{ matrix.environment }}/boot_app0.bin
+        fi
+        echo "--- Collected files for ${{ matrix.environment }} ---"
+        ls -la artifact-${{ matrix.environment }}/
+        # Create a zip with all collected files for use as a release asset
+        (cd artifact-${{ matrix.environment }} && zip ../firmware-${{ matrix.environment }}.zip *)
     - uses: actions/upload-artifact@v4
       with:
         name: firmware-${{ matrix.environment }}
-        path: firmware-${{ matrix.environment }}.bin
+        path: artifact-${{ matrix.environment }}/
     - uses: actions/upload-artifact@v4
-      if: startsWith(github.ref, 'refs/tags/')
+      if: startsWith(github.ref, 'refs/tags/') || inputs.nightly_build
       with:
         name: firmware-release-${{ matrix.environment }}
-        path: build_output/release/*.bin
+        path: |
+          build_output/release/*.bin
+          firmware-${{ matrix.environment }}.zip
 

.github/workflows/nightly.yml

@@ -20,6 +20,7 @@ jobs:
       - name: Download artifacts
         uses: actions/download-artifact@v4
         with:
+          pattern: firmware-release-*
           merge-multiple: true
       - name: Show Files
         run: ls -la
@@ -44,6 +45,7 @@ jobs:
           files: |
             *.bin
             *.bin.gz
+            *.zip
 #      - name: Repository Dispatch
 #        uses: peter-evans/repository-dispatch@v3
 #        with:

.github/workflows/release.yml

@@ -17,6 +17,7 @@ jobs:
     steps:
     - uses: actions/download-artifact@v4
       with:
+        pattern: firmware-release-*
         merge-multiple: true
     - name: "✏️ Generate release changelog"
       id: changelog
@@ -35,4 +36,5 @@ jobs:
         files: |
           *.bin
           *.bin.gz
+          *.zip
 

pio-scripts/output_bins.py

@@ -150,6 +150,21 @@ def bin_rename_copy(source, target, env):
     if os.path.isfile(source_map):
         print(f"Found linker mapfile {source_map}")
         shutil.copy(source_map, map_file)
+
+    # Copy boot_app0.bin to the build dir if available.
+    # Use the PlatformIO platform API to locate the exact arduino-esp32 framework package used
+    # for this build. ESP8266 builds return None from get_package_dir() and are silently skipped.
+    # Old arduino-esp32 1.0.x builds lack the file under tools/partitions/ and are also skipped.
+    _ARDUINO_ESP32_PACKAGE = "framework-arduinoespressif32"
+    try:
+        framework_dir = env.PioPlatform().get_package_dir(_ARDUINO_ESP32_PACKAGE)
+        if framework_dir:
+            boot_app0_src = os.path.join(str(framework_dir), "tools", "partitions", "boot_app0.bin")
+            if os.path.isfile(boot_app0_src):
+                shutil.copy(boot_app0_src, os.path.join(builddir, "boot_app0.bin"))
+    except Exception as e:
+        print(f"Warning: could not copy boot_app0.bin ({e})")
+
     # Check if this is a release build (CI sets WLED_RELEASE=True)
     is_release_build = os.environ.get('WLED_RELEASE', '').lower() in ('true', '1', 'yes')
     # show build flags summary for github CI builds