[nrf52] switch nrf52 builds to native sdk by default (#17319)

Co-authored-by: Jonathan Swoboda <154711427+swoboda1337@users.noreply.github.com>
Co-authored-by: ESPHome Device Builder <device-builder@esphome.io>

esphome/components/nrf52/__init__.py

@@ -117,7 +117,7 @@ def set_core_data(config: ConfigType) -> ConfigType:
 
 def _resolve_toolchain(config: ConfigType) -> ConfigType:
     if CORE.toolchain is None:
-        CORE.toolchain = config.get(CONF_TOOLCHAIN, Toolchain.PLATFORMIO)
+        CORE.toolchain = config.get(CONF_TOOLCHAIN, Toolchain.SDK_NRF)
     return config
 
 
@@ -439,8 +439,8 @@ def get_download_types(storage_json: StorageJSON) -> list[dict[str, str]]:
     types = []
     UF2_PATH = "zephyr/zephyr.uf2"
     DFU_PATH = "firmware.zip"
-    HEX_PATH = "zephyr/zephyr.hex"
+    HEX_PATH = "zephyr/zephyr.hex"  # SDK 2.6.1, only generated when OTA is disabled
-    HEX_MERGED_PATH = "zephyr/merged.hex"
+    HEX_MERGED_PATH = "zephyr/merged.hex"  # SDK 2.9.2, always generated
     APP_IMAGE_PATH = "zephyr/app_update.bin"
     build_dir = Path(storage_json.firmware_bin_path).parent
     if (build_dir / UF2_PATH).is_file():
@@ -777,6 +777,11 @@ def _generate_cmake_lists() -> bool:
     )
 
 
+def _copy_if_exists(src: Path, dst: Path) -> None:
+    if src.is_file():
+        shutil.copy2(src, dst)
+
+
 def run_compile(args, config: ConfigType) -> bool:
     if CORE.using_toolchain_platformio:
         return False
@@ -828,15 +833,18 @@ def run_compile(args, config: ConfigType) -> bool:
     ):
         raise EsphomeError("nRF52 native build failed")
 
-    # Zephyr's cmake places kernel artifacts in build_dir/zephyr/zephyr/ and
-    # merged.hex at build_dir/. Normalize to build_dir/zephyr/ so paths match
-    # get_download_types (which mirrors the platformio build output layout).
     zephyr_dir = build_dir / "zephyr"
-    west_out = zephyr_dir / "zephyr"
+    framework_ver = CORE.data[KEY_CORE][KEY_FRAMEWORK_VERSION]
-    for filename in ["zephyr.uf2"]:
+    # SDK < 2.9.2 places artifacts directly in build_dir/zephyr/.
-        src = west_out / filename
+    # SDK >= 2.9.2 nests them one level deeper (build_dir/zephyr/zephyr/);
-        if src.is_file():
+    # copy files to match get_download_types layout.
-            shutil.copy2(src, zephyr_dir / filename)
+    if framework_ver < cv.Version(2, 9, 2):
+        west_out = zephyr_dir
+    else:
+        west_out = zephyr_dir / "zephyr"
+        _copy_if_exists(west_out / "zephyr.uf2", zephyr_dir / "zephyr.uf2")
+        _copy_if_exists(west_out / "zephyr.signed.bin", zephyr_dir / "app_update.bin")
+        _copy_if_exists(build_dir / "merged.hex", zephyr_dir / "merged.hex")
 
     # (dev_type, sd_req) per bootloader — values from Nordic SoftDevice release notes
     _GENPKG_PARAMS = {

esphome/components/nrf52/framework.py

@@ -2,10 +2,12 @@ import logging
 import os
 from pathlib import Path
 import platform
+import shutil
 import tempfile
 
 import platformdirs
 
+import esphome.config_validation as cv
 from esphome.const import KEY_CORE, KEY_FRAMEWORK_VERSION
 from esphome.core import CORE, EsphomeError
 from esphome.framework_helpers import (
@@ -134,6 +136,23 @@ def get_build_env() -> dict:
     return env
 
 
+def _patch_uf2conv_escape_sequences(framework_path: Path) -> None:
+    # SDK v2.6.1 ships uf2conv.py with '\s+' — an unrecognised escape that
+    # Python 3.12+ flags with SyntaxWarning (a future version will reject it).
+    uf2conv = framework_path / "zephyr" / "scripts" / "build" / "uf2conv.py"
+    if not uf2conv.exists():
+        return
+    content = uf2conv.read_text(encoding="utf-8")
+    patched = content.replace("re.split('\\s+', line)", "re.split('\\\\s+', line)")
+    if patched == content:
+        return
+    # Write atomically so a concurrent build never sees a truncated file
+    tmp = uf2conv.with_suffix(".py.tmp")
+    tmp.write_text(patched, encoding="utf-8")
+    shutil.copymode(uf2conv, tmp)
+    tmp.replace(uf2conv)
+
+
 def check_and_install() -> None:
     version = _get_version_str()
     python_env_path = _get_python_env_path(version)
@@ -195,6 +214,9 @@ def check_and_install() -> None:
         ]
         if not run_command_ok(cmd, cwd=framework_path):
             raise EsphomeError(f"Can't update nRF Connect SDK {version}")
+        framework_ver = CORE.data[KEY_CORE][KEY_FRAMEWORK_VERSION]
+        if framework_ver < cv.Version(2, 9, 2):
+            _patch_uf2conv_escape_sequences(framework_path)
         sentinel.touch()
 
     zephyr_sentinel = python_env_path / ".zephyr_reqs_ready"

esphome/components/zephyr/__init__.py

@@ -18,6 +18,7 @@ from .const import (
     KEY_OVERLAY,
     KEY_PM_STATIC,
     KEY_PRJ_CONF,
+    KEY_SYSBUILD,
     KEY_USER,
     KEY_ZEPHYR,
     zephyr_ns,
@@ -55,6 +56,7 @@ class ZephyrData(TypedDict):
     pm_static: list[Section]
     user: dict[str, list[str]]
     kconfig: str
+    sysbuild: bool
 
 
 def zephyr_set_core_data(config: ConfigType) -> None:
@@ -69,6 +71,10 @@ def zephyr_set_core_data(config: ConfigType) -> None:
         pm_static=[],
         user={},
         kconfig="",
+        # When OTA is disabled, the image is built without a bootloader even if the
+        # config says `bootloader: mcuboot`, so the image can be smaller. This was
+        # the default behaviour in SDK 2.6.1.
+        sysbuild=False,
     )
 
 
@@ -286,6 +292,13 @@ def copy_files() -> None:
         CORE.relative_build_path("zephyr/Kconfig"), kconfig
     )
 
+    sysbuild_conf = ""
+    if zephyr_data()[KEY_SYSBUILD]:
+        sysbuild_conf = "SB_CONFIG_BOOTLOADER_MCUBOOT=y\n"
+    changed |= _write_file_if_changed_or_remove_when_empty(
+        CORE.relative_build_path("zephyr/sysbuild.conf"), sysbuild_conf
+    )
+
     if changed:
         # A configure-time input changed; drop the CMake cache so the build
         # can't reuse stale configure results (the native sdk-nrf toolchain

esphome/components/zephyr/const.py

@@ -13,6 +13,7 @@ KEY_PRJ_CONF: Final = "prj_conf"
 KEY_ZEPHYR = "zephyr"
 KEY_BOARD: Final = "board"
 KEY_USER: Final = "user"
+KEY_SYSBUILD: Final = "sysbuild"
 
 zephyr_ns = cg.esphome_ns.namespace("zephyr")
 CdcAcm = zephyr_ns.class_("CdcAcm", cg.Component)

esphome/components/zephyr_mcumgr/ota/__init__.py

@@ -6,9 +6,19 @@ from esphome.components.zephyr import (
     zephyr_add_prj_conf,
     zephyr_data,
 )
-from esphome.components.zephyr.const import BOOTLOADER_MCUBOOT, KEY_BOOTLOADER
+from esphome.components.zephyr.const import (
+    BOOTLOADER_MCUBOOT,
+    KEY_BOOTLOADER,
+    KEY_SYSBUILD,
+)
 import esphome.config_validation as cv
-from esphome.const import CONF_HARDWARE_UART, CONF_ID, Framework
+from esphome.const import (
+    CONF_HARDWARE_UART,
+    CONF_ID,
+    KEY_CORE,
+    KEY_FRAMEWORK_VERSION,
+    Framework,
+)
 from esphome.core import CORE, coroutine_with_priority
 from esphome.coroutine import CoroPriority
 from esphome.types import ConfigType
@@ -139,3 +149,6 @@ async def to_code(config: ConfigType) -> None:
                 }};
                 """
         )
+    framework_ver = CORE.data[KEY_CORE][KEY_FRAMEWORK_VERSION]
+    if framework_ver >= cv.Version(2, 9, 2):
+        zephyr_data()[KEY_SYSBUILD] = True

script/ci_memory_impact_extract.py

@@ -1,8 +1,8 @@
 #!/usr/bin/env python3
 """Extract memory usage statistics from ESPHome build output.
 
-This script parses the PlatformIO build output to extract RAM and flash
+This script parses the build output to extract RAM and flash usage
-usage statistics for a compiled component. It's used by the CI workflow to
+statistics for a compiled component. It's used by the CI workflow to
 compare memory usage between branches.
 
 The script reads compile output from stdin and looks for the standard
@@ -10,6 +10,13 @@ PlatformIO output format:
     RAM:   [====      ]  36.1% (used 29548 bytes from 81920 bytes)
     Flash: [===       ]  34.0% (used 348511 bytes from 1023984 bytes)
 
+or the linker memory usage table printed by Zephyr native builds
+(e.g. nRF52 with the sdk-nrf toolchain):
+    Memory region         Used Size  Region Size  %age Used
+               FLASH:       90624 B       796 KB     11.12%
+                 RAM:       22432 B       256 KB      8.56%
+            IDT_LIST:          0 GB        32 KB      0.00%
+
 Optionally performs detailed memory analysis if a build directory is provided.
 """
 
@@ -34,20 +41,43 @@ _RAM_PATTERN = re.compile(r"RAM:\s+\[.*?\]\s+\d+\.\d+%\s+\(used\s+(\d+)\s+bytes"
 _FLASH_PATTERN = re.compile(r"Flash:\s+\[.*?\]\s+\d+\.\d+%\s+\(used\s+(\d+)\s+bytes")
 _BUILD_PATH_PATTERN = re.compile(r"Build path: (.+)")
 
+# Zephyr native builds print the GNU ld --print-memory-usage table instead of
+# the PlatformIO summary. Only the FLASH and RAM regions are real memory
+# (IDT_LIST is a build-time pseudo-region discarded from the final image).
+# Each cell is humanized to the largest unit that divides evenly, so used
+# sizes are not always plain bytes (zero prints as "0 GB").
+_ZEPHYR_RAM_PATTERN = re.compile(
+    r"^\s*RAM:\s+(\d+)\s*([KMG]?B)\s+\d+\s*[KMG]?B\s+\d+\.\d+%", re.MULTILINE
+)
+_ZEPHYR_FLASH_PATTERN = re.compile(
+    r"^\s*FLASH:\s+(\d+)\s*([KMG]?B)\s+\d+\s*[KMG]?B\s+\d+\.\d+%", re.MULTILINE
+)
+_ZEPHYR_UNIT_MULTIPLIERS = {"B": 1, "KB": 1024, "MB": 1024**2, "GB": 1024**3}
+
+
+def _zephyr_bytes(matches: list[tuple[str, str]]) -> int:
+    """Sum humanized (value, unit) pairs from the Zephyr memory table."""
+    return sum(int(value) * _ZEPHYR_UNIT_MULTIPLIERS[unit] for value, unit in matches)
+
 
 def extract_from_compile_output(
     output_text: str,
 ) -> tuple[int | None, int | None, str | None]:
-    """Extract memory usage and build directory from PlatformIO compile output.
+    """Extract memory usage and build directory from compile output.
 
     Supports multiple builds (for component groups or isolated components).
     When test_build_components.py creates multiple builds, this sums the
     memory usage across all builds.
 
-    Looks for lines like:
+    Looks for PlatformIO lines like:
         RAM:   [====      ]  36.1% (used 29548 bytes from 81920 bytes)
         Flash: [===       ]  34.0% (used 348511 bytes from 1023984 bytes)
 
+    and Zephyr (native west build) linker table rows like:
+        Memory region         Used Size  Region Size  %age Used
+                   FLASH:       90624 B       796 KB     11.12%
+                     RAM:       22432 B       256 KB      8.56%
+
     Also extracts build directory from lines like:
         INFO Compiling app... Build path: /path/to/build
 
@@ -61,12 +91,20 @@ def extract_from_compile_output(
     ram_matches = _RAM_PATTERN.findall(output_text)
     flash_matches = _FLASH_PATTERN.findall(output_text)
 
-    if not ram_matches or not flash_matches:
+    # Zephyr native builds print the linker memory table instead
+    zephyr_ram_matches = _ZEPHYR_RAM_PATTERN.findall(output_text)
+    zephyr_flash_matches = _ZEPHYR_FLASH_PATTERN.findall(output_text)
+
+    if not (ram_matches or zephyr_ram_matches) or not (
+        flash_matches or zephyr_flash_matches
+    ):
         return None, None, None
 
     # Sum all builds (handles multiple component groups)
     total_ram = sum(int(match) for match in ram_matches)
     total_flash = sum(int(match) for match in flash_matches)
+    total_ram += _zephyr_bytes(zephyr_ram_matches)
+    total_flash += _zephyr_bytes(zephyr_flash_matches)
 
     # Extract build directory from ESPHome's explicit build path output
     # Look for: INFO Compiling app... Build path: /path/to/build
@@ -202,20 +240,23 @@ def main() -> int:
     )
 
     if ram_bytes is None or flash_bytes is None:
-        print("Failed to extract memory usage from compile output", file=sys.stderr)
-        print("Expected lines like:", file=sys.stderr)
         print(
-            "  RAM:   [====      ]  36.1% (used 29548 bytes from 81920 bytes)",
+            "Failed to extract memory usage from compile output\n"
-            file=sys.stderr,
+            "Expected lines like:\n"
-        )
+            "  RAM:   [====      ]  36.1% (used 29548 bytes from 81920 bytes)\n"
-        print(
+            "  Flash: [===       ]  34.0% (used 348511 bytes from 1023984 bytes)\n"
-            "  Flash: [===       ]  34.0% (used 348511 bytes from 1023984 bytes)",
+            "or a Zephyr linker memory usage table like:\n"
+            "  Memory region         Used Size  Region Size  %age Used\n"
+            "             FLASH:       90624 B       796 KB     11.12%\n"
+            "               RAM:       22432 B       256 KB      8.56%",
             file=sys.stderr,
         )
         return 1
 
     # Count how many builds were found
-    num_builds = len(_RAM_PATTERN.findall(compile_output))
+    num_builds = len(_RAM_PATTERN.findall(compile_output)) + len(
+        _ZEPHYR_RAM_PATTERN.findall(compile_output)
+    )
 
     if num_builds > 1:
         print(

tests/components/api/test.nrf52-adafruit.yaml

@@ -1,7 +1,7 @@
+<<: !include common.yaml
+
 network:
   enable_ipv6: true
 
 openthread:
   tlv: 0E080000000000010000
-
-api:

tests/components/nrf52/test.nrf52-adafruit.yaml

@@ -19,5 +19,3 @@ nrf52:
   reg0:
     voltage: 2.1V
     uicr_erase: true
-  framework:
-    version: "2.6.1-b"