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arunkumar-mourougappanearunkumar-mourougappane
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🔧 Fix GitHub Actions firmware file handling for releases
🚀 Enhanced Automated Release Workflow: - Added comprehensive firmware file verification before release creation - Enhanced build process with proper error handling and file size validation - Added detailed logging to troubleshoot firmware file issues - Verify all required files exist and have reasonable sizes before proceeding 🏗️ Improved Build Workflow: - Added Feather ESP32-S3 TFT to build matrix for complete CI coverage - Separate artifact uploads for each board type for better organization - Enhanced build reporting for both hardware platforms - Better artifact naming and retention management 🛠️ Updated Manual Release Workflow: - Build firmware for both ESP32dev and Feather ESP32-S3 TFT environments - Comprehensive firmware file verification before release creation - Enhanced release with firmware binaries for both supported boards - Proper file naming convention for easy identification 🔍 Added Verification Steps: - File existence checks with clear error messages - File size validation (>100KB for .bin, >1MB for .elf) - Detailed logging of file locations and sizes - Graceful failure with diagnostic information This resolves the "HTTP 404: Not Found" error by ensuring firmware files are built, verified, and exist before attempting to attach them to releases.
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‎.github/workflows/automated-release.yml‎

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- name: Build release firmware
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run: |
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echo "🔨 Building firmware for version ${{ needs.check-version-bump.outputs.new-version }}"
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# Build ESP32dev environment
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echo "Building ESP32dev environment..."
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pio run --environment esp32dev
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# Build Feather ESP32-S3 TFT environment
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echo "Building Feather ESP32-S3 TFT environment..."
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pio run --environment adafruit_feather_esp32s3_tft
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# Verify firmware files exist
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echo "🔍 Verifying firmware files..."
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ESP32_BIN=".pio/build/esp32dev/firmware.bin"
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ESP32_ELF=".pio/build/esp32dev/firmware.elf"
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FEATHER_BIN=".pio/build/adafruit_feather_esp32s3_tft/firmware.bin"
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FEATHER_ELF=".pio/build/adafruit_feather_esp32s3_tft/firmware.elf"
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if [ ! -f "$ESP32_BIN" ]; then
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echo "❌ ESP32dev firmware.bin not found at $ESP32_BIN"
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exit 1
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fi
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if [ ! -f "$ESP32_ELF" ]; then
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echo "❌ ESP32dev firmware.elf not found at $ESP32_ELF"
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exit 1
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fi
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if [ ! -f "$FEATHER_BIN" ]; then
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echo "❌ Feather firmware.bin not found at $FEATHER_BIN"
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exit 1
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fi
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if [ ! -f "$FEATHER_ELF" ]; then
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echo "❌ Feather firmware.elf not found at $FEATHER_ELF"
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exit 1
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fi
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# Show file sizes for verification
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echo "✅ All firmware files built successfully:"
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echo " ESP32dev firmware.bin: $(ls -lh $ESP32_BIN | awk '{print $5}')"
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echo " ESP32dev firmware.elf: $(ls -lh $ESP32_ELF | awk '{print $5}')"
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echo " Feather firmware.bin: $(ls -lh $FEATHER_BIN | awk '{print $5}')"
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echo " Feather firmware.elf: $(ls -lh $FEATHER_ELF | awk '{print $5}')"
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- name: Generate automated release notes
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run: |
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echo "exists=false" >> $GITHUB_OUTPUT
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fi
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- name: Verify firmware files before release
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if: steps.tag-check.outputs.exists == 'false'
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run: |
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echo "🔍 Final firmware file verification before release..."
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# Define file paths
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ESP32_BIN=".pio/build/esp32dev/firmware.bin"
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ESP32_ELF=".pio/build/esp32dev/firmware.elf"
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FEATHER_BIN=".pio/build/adafruit_feather_esp32s3_tft/firmware.bin"
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FEATHER_ELF=".pio/build/adafruit_feather_esp32s3_tft/firmware.elf"
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# Check all files exist and have reasonable size
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for file in "$ESP32_BIN" "$ESP32_ELF" "$FEATHER_BIN" "$FEATHER_ELF"; do
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if [ ! -f "$file" ]; then
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echo "❌ Required firmware file missing: $file"
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echo "Available files in .pio/build/:"
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find .pio/build/ -type f -name "*.bin" -o -name "*.elf" | sort
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exit 1
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fi
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# Check file size (should be > 100KB for .bin, > 1MB for .elf)
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size=$(stat -c%s "$file")
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if [[ "$file" == *.bin ]] && [ "$size" -lt 102400 ]; then
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echo "❌ Firmware binary $file too small: ${size} bytes (expected > 100KB)"
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exit 1
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fi
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if [[ "$file" == *.elf ]] && [ "$size" -lt 1048576 ]; then
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echo "❌ Firmware ELF $file too small: ${size} bytes (expected > 1MB)"
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exit 1
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fi
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echo "✅ $file: $(ls -lh "$file" | awk '{print $5}')"
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done
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- name: Create Release
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if: steps.tag-check.outputs.exists == 'false'
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env:

‎.github/workflows/build.yml‎

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strategy:
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matrix:
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environment: [esp32dev, test]
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environment: [esp32dev, adafruit_feather_esp32s3_tft, test]
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steps:
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- name: Checkout code
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continue-on-error: true
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- name: Generate build report
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if: matrix.environment == 'esp32dev'
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if: matrix.environment != 'test'
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run: |
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echo "## Build Report 📊" >> $GITHUB_STEP_SUMMARY
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echo "### Environment: ${{ matrix.environment }}" >> $GITHUB_STEP_SUMMARY
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echo "\`\`\`" >> $GITHUB_STEP_SUMMARY
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pio run --environment ${{ matrix.environment }} --verbose | grep -E "(RAM|Flash|Memory)" || echo "Memory usage information not available"
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echo "\`\`\`" >> $GITHUB_STEP_SUMMARY
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- name: Upload build artifacts
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- name: Upload ESP32dev artifacts
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if: matrix.environment == 'esp32dev'
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uses: actions/upload-artifact@v4
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with:
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name: esp32-firmware
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name: esp32dev-firmware
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path: |
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.pio/build/esp32dev/firmware.bin
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.pio/build/esp32dev/firmware.elf
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retention-days: 30
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- name: Upload Feather ESP32-S3 artifacts
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if: matrix.environment == 'adafruit_feather_esp32s3_tft'
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uses: actions/upload-artifact@v4
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with:
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name: feather-esp32s3-firmware
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path: |
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.pio/build/adafruit_feather_esp32s3_tft/firmware.bin
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.pio/build/adafruit_feather_esp32s3_tft/firmware.elf
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retention-days: 30
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documentation-check:
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runs-on: ubuntu-latest
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‎.github/workflows/manual-release.yml‎

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name: Manual Release
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on:
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workflow_dispatch:
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inputs:
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version:
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description: 'Release version (e.g., 2.0.1)'
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required: true
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type: string
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prerelease:
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description: 'Mark as pre-release'
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required: false
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default: false
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type: boolean
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permissions:
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contents: write
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jobs:
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manual-release:
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runs-on: ubuntu-latest
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steps:
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- name: Checkout code
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uses: actions/checkout@v4
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with:
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fetch-depth: 0
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- name: Set up Python
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uses: actions/setup-python@v4
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with:
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python-version: '3.9'
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- name: Install PlatformIO
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run: |
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python -m pip install --upgrade pip
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pip install --upgrade platformio
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- name: Update version in platformio.ini
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run: |
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sed -i 's/-DVERSION="[^"]*"/-DVERSION="${{ inputs.version }}"/' platformio.ini
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git config --local user.email "[email protected]"
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git config --local user.name "GitHub Action"
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git add platformio.ini
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git commit -m "chore: bump version to ${{ inputs.version }}"
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git push
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- name: Build release firmware
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run: |
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echo "🔨 Building firmware for manual release v${{ inputs.version }}"
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# Build ESP32dev environment
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echo "Building ESP32dev environment..."
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pio run --environment esp32dev
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# Build Feather ESP32-S3 TFT environment
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echo "Building Feather ESP32-S3 TFT environment..."
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pio run --environment adafruit_feather_esp32s3_tft
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# Verify firmware files exist
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echo "🔍 Verifying firmware files..."
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ESP32_BIN=".pio/build/esp32dev/firmware.bin"
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ESP32_ELF=".pio/build/esp32dev/firmware.elf"
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FEATHER_BIN=".pio/build/adafruit_feather_esp32s3_tft/firmware.bin"
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FEATHER_ELF=".pio/build/adafruit_feather_esp32s3_tft/firmware.elf"
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for file in "$ESP32_BIN" "$ESP32_ELF" "$FEATHER_BIN" "$FEATHER_ELF"; do
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if [ ! -f "$file" ]; then
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echo "❌ Required firmware file missing: $file"
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exit 1
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fi
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echo "✅ $file: $(ls -lh "$file" | awk '{print $5}')"
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done
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- name: Generate release notes
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run: |
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BUILD_DATE=$(date -u +"%Y-%m-%d %H:%M:%S UTC")
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cat > release_notes.md << EOF
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## ESP32 WiFi Utility v${{ inputs.version }}
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### 🚀 Features
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- ✅ Enhanced WiFi scanning with visual indicators and signal quality analysis
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- ✅ Complete iPerf network performance testing (TCP/UDP client/server modes)
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- ✅ Access Point management with QR code generation for easy mobile connection
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- ✅ Interactive command interface with real-time feedback and status indicators
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- ✅ Comprehensive documentation and 17+ unit tests for quality assurance
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### 📊 Technical Specifications
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- **Flash Usage**: 61.4% (805KB) - Optimized for ESP32 with room for expansion
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- **RAM Usage**: 13.9% (45KB) - Efficient memory utilization
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- **Build System**: PlatformIO with automated CI/CD pipeline
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- **Testing**: Comprehensive unit test suite with hardware-in-loop validation
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### 🔧 Build Information
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- **Version**: ${{ inputs.version }}
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- **Commit**: ${{ github.sha }}
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- **Build Date**: ${BUILD_DATE}
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- **Workflow**: Manual Release
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### 📦 Installation Instructions
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1. **Download**: Get the firmware binary file below
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2. **Flash**: Use esptool, Arduino IDE, or your preferred ESP32 flashing method
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3. **Connect**: Serial connection at 115200 baud rate
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4. **Start**: Type \`help\` for complete command reference
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### 🎯 Quick Start Commands
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\`\`\`bash
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mode station # Switch to WiFi scanning mode
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scan now # Perform enhanced network scan with analysis
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scan info 1 # Get detailed info for specific network
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mode ap # Start access point with QR code
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iperf status # Check network performance testing status
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help # Show all available commands
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\`\`\`
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### 📚 Complete Documentation
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- [README.md](README.md) - Main project documentation
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- [ENHANCED_SCANNING.md](ENHANCED_SCANNING.md) - Advanced scanning features
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- [IPERF_GUIDE.md](IPERF_GUIDE.md) - Network performance testing
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- [GITHUB_ACTIONS.md](GITHUB_ACTIONS.md) - CI/CD pipeline documentation
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**Manual release created for version ${{ inputs.version }}**
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EOF
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- name: Create Release
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env:
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GITHUB_TOKEN: ${{ secrets.GITHUB_TOKEN }}
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run: |
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TAG_NAME="v${{ inputs.version }}"
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RELEASE_NAME="ESP32 WiFi Utility v${{ inputs.version }}"
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PRERELEASE_FLAG=""
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if [ "${{ inputs.prerelease }}" = "true" ]; then
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PRERELEASE_FLAG="--prerelease"
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else
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PRERELEASE_FLAG="--latest"
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fi
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# Create release with firmware attachments for both boards
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gh release create "$TAG_NAME" \
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--title "$RELEASE_NAME" \
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--notes-file release_notes.md \
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$PRERELEASE_FLAG \
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.pio/build/esp32dev/firmware.bin#esp32-wifi-utility-esp32dev-v${{ inputs.version }}.bin \
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.pio/build/esp32dev/firmware.elf#esp32-wifi-utility-esp32dev-debug-v${{ inputs.version }}.elf \
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.pio/build/adafruit_feather_esp32s3_tft/firmware.bin#esp32-wifi-utility-feather-s3-tft-v${{ inputs.version }}.bin \
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.pio/build/adafruit_feather_esp32s3_tft/firmware.elf#esp32-wifi-utility-feather-s3-tft-debug-v${{ inputs.version }}.elf
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echo "✅ Manual release created successfully: $TAG_NAME"

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