From 13ec5f27e9df7691fb92202ef83808a95e04fa81 Mon Sep 17 00:00:00 2001
From: clydebarrow <2366188+clydebarrow@users.noreply.github.com>
Date: Sun, 18 Oct 2026 17:56:36 +1100
Subject: [PATCH] [packet_interface] Leave no room, instead of underflowing, on
 a small link

As in the other layers, addressing ports and fragmentation get no room
when max_packet_size is smaller than their header, and fragmentation
fails its setup instead of dividing by zero.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
---
 esphome/components/packet_interface/basic_addressing.cpp | 4 +++-
 .../components/packet_interface/basic_fragmentation.cpp  | 6 ++++++
 .../components/packet_interface/basic_fragmentation.h    | 5 ++++-
 tests/components/packet_interface/basic_addressing.cpp   | 8 ++++++++
 .../components/packet_interface/basic_fragmentation.cpp  | 9 +++++++++
 5 files changed, 30 insertions(+), 2 deletions(-)

diff --git a/esphome/components/packet_interface/basic_addressing.cpp b/esphome/components/packet_interface/basic_addressing.cpp
index 1b5e66196a5..d8a8ebf85cf 100644
--- a/esphome/components/packet_interface/basic_addressing.cpp
+++ b/esphome/components/packet_interface/basic_addressing.cpp
@@ -67,7 +67,9 @@ AddressingPort::AddressingPort(BasicAddressing *addressing, uint16_t destination
   } else {
     this->inherit_from_(addressing->get_link(), CAPABILITY_ADDRESSING);
   }
-  this->max_packet_size_ = addressing->get_link()->get_max_packet_size() - BasicAddressing::HEADER_SIZE;
+  size_t link_size = addressing->get_link()->get_max_packet_size();
+  // A link with no room leaves the layers above none either, so they fail their setup
+  this->max_packet_size_ = link_size > BasicAddressing::HEADER_SIZE ? link_size - BasicAddressing::HEADER_SIZE : 0;
   addressing->add_port(this);
 }
 
diff --git a/esphome/components/packet_interface/basic_fragmentation.cpp b/esphome/components/packet_interface/basic_fragmentation.cpp
index b587d1e3140..2513afbfd74 100644
--- a/esphome/components/packet_interface/basic_fragmentation.cpp
+++ b/esphome/components/packet_interface/basic_fragmentation.cpp
@@ -19,10 +19,16 @@ BasicFragmentation::BasicFragmentation(PacketInterface *lower, size_t max_packet
 
 size_t BasicFragmentation::fragments_for_(size_t size) const {
   size_t fragment_size = this->fragment_size_();
+  if (fragment_size == 0)
+    return SIZE_MAX;
   return std::max<size_t>(1, (size + fragment_size - 1) / fragment_size);
 }
 
 void BasicFragmentation::setup() {
+  if (this->fragment_size_() == 0) {
+    this->mark_failed(LOG_STR("max_packet_size too small for the configured layers"));
+    return;
+  }
   if (this->fragments_for_(this->max_packet_size_) > MAX_FRAGMENTS) {
     this->mark_failed(LOG_STR("max_packet_size needs more than 128 fragments"));
     return;
diff --git a/esphome/components/packet_interface/basic_fragmentation.h b/esphome/components/packet_interface/basic_fragmentation.h
index 4cc3ee3c952..a3c0652eba7 100644
--- a/esphome/components/packet_interface/basic_fragmentation.h
+++ b/esphome/components/packet_interface/basic_fragmentation.h
@@ -36,7 +36,10 @@ class BasicFragmentation : public PacketInterface {
 
  protected:
   void receive_(const PacketBuffer &data, const PacketMetaData &meta_data);
-  size_t fragment_size_() const { return this->lower_->get_max_packet_size() - HEADER_SIZE; }
+  size_t fragment_size_() const {
+    size_t lower_size = this->lower_->get_max_packet_size();
+    return lower_size > HEADER_SIZE ? lower_size - HEADER_SIZE : 0;
+  }
   size_t fragments_for_(size_t size) const;
 
   PacketInterface *lower_;
diff --git a/tests/components/packet_interface/basic_addressing.cpp b/tests/components/packet_interface/basic_addressing.cpp
index 252fc92e594..13726622907 100644
--- a/tests/components/packet_interface/basic_addressing.cpp
+++ b/tests/components/packet_interface/basic_addressing.cpp
@@ -80,6 +80,14 @@ TEST(BasicAddressingTest, HeaderAndCapability) {
   EXPECT_EQ(a.link.sent, (std::vector<Packet>{{0x78, 0x56, 0x34, 0x12, 0xAA}, {0x42, 0x00, 0x34, 0x12, 0xBB}}));
 }
 
+TEST(BasicAddressingTest, LinkTooSmallLeavesNoRoom) {
+  MockLink link;
+  link.set_max_packet_size(BasicAddressing::HEADER_SIZE);
+  BasicAddressing addressing(&link, 0x0001);
+  AddressingPort port(&addressing, 0x0002, true);
+  EXPECT_EQ(port.get_max_packet_size(), 0);
+}
+
 TEST(BasicAddressingTest, BroadcastReachesEveryoneButSender) {
   Device a(1), b(2), c(3);
   a.port().send({0x10});
diff --git a/tests/components/packet_interface/basic_fragmentation.cpp b/tests/components/packet_interface/basic_fragmentation.cpp
index 88d833d8e4f..2feab7ac2f0 100644
--- a/tests/components/packet_interface/basic_fragmentation.cpp
+++ b/tests/components/packet_interface/basic_fragmentation.cpp
@@ -191,4 +191,13 @@ TEST_F(BasicFragmentationTest, OversizedSingleFragmentDropped) {
   EXPECT_EQ(received, std::vector<Packet>{Packet({1, 2, 3, 4})});
 }
 
+TEST_F(BasicFragmentationTest, LinkTooSmallFailsSetup) {
+  this->link_a.set_max_packet_size(BasicFragmentation::HEADER_SIZE);
+  BasicFragmentation fragmentation(&this->link_a, 100);
+  fragmentation.setup();
+  EXPECT_TRUE(fragmentation.is_failed());
+  Packet packet{1};
+  EXPECT_FALSE(fragmentation.send_to_interface(PacketBuffer(packet), {}));
+}
+
 }  // namespace esphome::packet_interface::fragmentation_testing