fix: Make bloat analysis optional and fix CI workflows

- Make bloat analysis optional in precommit to avoid CI failures
- Update size-analysis.yml to use cargo bloat directly instead of xtask
- Fix workflow to handle cases where xtask bloat command is unavailable
- Add proper error handling for missing cargo-bloat installation
- Only upload bloat reports if they exist (conditional artifact upload)

This ensures CI workflows work on branches without bloat functionality
while still providing size analysis when available.

Author: rusty1968

.github/workflows/build-test.yml

@@ -47,7 +47,7 @@ jobs:
 
       - name: Upload binary size reports
         uses: actions/upload-artifact@v4
-        if: always()
+        if: always() && hashFiles('target/bloat-reports/*') != ''
         with:
           name: bloat-reports
           path: target/bloat-reports/

.github/workflows/size-analysis.yml

@@ -39,7 +39,8 @@ jobs:
 
       - name: Analyze current branch size
         run: |
-          cargo xtask bloat --release --report --output-dir target/pr-bloat-reports
+          # Use cargo bloat directly since xtask bloat may not be available
+          cargo bloat --release --target thumbv7em-none-eabihf > target/pr-bloat-report.txt || echo "Bloat analysis failed"
           
       - name: Checkout main branch
         run: |
@@ -51,7 +52,8 @@ jobs:
           
       - name: Analyze main branch size
         run: |
-          cargo xtask bloat --release --report --output-dir target/main-bloat-reports
+          # Use cargo bloat directly since xtask bloat may not be available  
+          cargo bloat --release --target thumbv7em-none-eabihf > target/main-bloat-report.txt || echo "Bloat analysis failed"
 
       - name: Generate size comparison report
         id: size-comparison
@@ -86,7 +88,7 @@ jobs:
           echo "" >> size_report.md
           echo "### Top Functions (Current PR)" >> size_report.md
           echo '```' >> size_report.md
-          head -20 target/pr-bloat-reports/bloat_functions.txt >> size_report.md 2>/dev/null || echo "No function data available" >> size_report.md
+          head -20 target/pr-bloat-report.txt >> size_report.md 2>/dev/null || echo "No function data available" >> size_report.md
           echo '```' >> size_report.md
 
       - name: Comment PR with size analysis
@@ -100,7 +102,7 @@ jobs:
         with:
           name: size-analysis-detailed
           path: |
-            target/pr-bloat-reports/
-            target/main-bloat-reports/
+            target/pr-bloat-report.txt
+            target/main-bloat-report.txt
             size_report.md
           retention-days: 7

xtask/src/main.rs

@@ -164,9 +164,15 @@ fn precommit() -> anyhow::Result<()> {
     // Run tests
     test::test(false, false)?;
 
-    // Generate size analysis report
+    // Generate size analysis report (optional - skip if cargo-bloat not available)
     println!("Generating binary size report...");
-    bloat::generate_report(true, "thumbv7em-none-eabihf", "target/bloat-reports")?;
+    match bloat::generate_report(true, "thumbv7em-none-eabihf", "target/bloat-reports") {
+        Ok(_) => println!("📊 Size analysis report generated"),
+        Err(e) => {
+            println!("⚠️  Size analysis skipped: {}", e);
+            println!("   Install cargo-bloat with: cargo install cargo-bloat");
+        }
+    }
 
     println!("✅ All pre-commit checks passed!");
     Ok(())