sysbuild: mcuboot: direct_xip: enable custom overlay for secondary slot #24561

kapi-no · 2025-09-16T14:38:30Z

Added a dedicated Kconfig option to sysbuild that allows the user to set a custom overlay file for their secondary slot build configuration. If used, the custom file replaces the default DTS overlay.

Added a dedicated Kconfig option to sysbuild that allows the user to set a custom overlay file for their secondary slot build configuration. If used, the custom file replaces the default DTS overlay. Signed-off-by: Kamil Piszczek <[email protected]>

NordicBuilder · 2025-09-16T14:39:56Z

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Build number: 1

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sdk-nrf: PR head: 978548904de2fced3065960569e57defa6b9c9bb

more details

sdk-nrf:

PR head: 978548904de2fced3065960569e57defa6b9c9bb
merge base: fe0a8f648e4d4d1f0890f8fc22706f28ca288324
target head (main): e50881920d7be8132024e1732dee3960fcac9829
Diff

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Enabled	Name	Description
	ci-disabled	Disable the ci execution
	ci-all-test	Run all of ci, no test spec filtering will be done
	ci-force-downstream	Force execution of downstream even if twister fails
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List of changed files detected by CI (2)

sysbuild
│  ├── Kconfig.mcuboot
│  │ mcuboot.cmake

Outputs:

Toolchain

Version: 2b2cd9579a
Build docker image: docker-dtr.nordicsemi.no/sw-production/ncs-build:2b2cd9579a_bba2ea5f2e

Test Spec & Results: ✅ Success; ❌ Failure; 🟠 Queued; 🟡 Progress; ◻️ Skipped; ⚠️ Quarantine

◻️ Toolchain - Skipped: existing toolchain is used
✅ Build twister
❌ Integration tests
- ✅ test-sdk-audio
- ✅ desktop52_verification
- ✅ test-fw-nrfconnect-apps
- ✅ test_ble_nrf_config
- ✅ test-fw-nrfconnect-ble_mesh
- ✅ test-fw-nrfconnect-ble_samples
- ✅ test-fw-nrfconnect-chip
- ✅ test-fw-nrfconnect-nfc
- ❌ test-fw-nrfconnect-nrf-iot_libmodem-nrf
- ✅ test-fw-nrfconnect-nrf-iot_serial_lte_modem
- ✅ test-fw-nrfconnect-nrf-iot_zephyr_lwm2m
- ✅ test-fw-nrfconnect-nrf-iot_samples
- ✅ test-fw-nrfconnect-nrf-iot_lwm2m
- ✅ doc-internal
- ✅ test-fw-nrfconnect-nrf-iot_thingy91
- ✅ test-fw-nrfconnect-nrf_crypto
- ✅ test-fw-nrfconnect-proprietary_esb
- ✅ test-fw-nrfconnect-rpc
- ✅ test-fw-nrfconnect-rs
- ✅ test-fw-nrfconnect-fem
- ✅ test-fw-nrfconnect-tfm
- ✅ test-fw-nrfconnect-thread-main
- ✅ test-sdk-find-my
- ✅ test-fw-nrfconnect-nrf_lrcs_mosh
- ✅ test-fw-nrfconnect-nrf_lrcs_positioning
- ✅ test-sdk-wifi
- ✅ test-low-level
- ✅ test-sdk-pmic-samples
- ✅ test-sdk-mcuboot
- ✅ test-sdk-dfu
- ✅ test-fw-nrfconnect-ps-main
- ✅ test-secdom-samples-public

Note: This message is automatically posted and updated by the CI

NordicBuilder · 2025-09-16T16:23:53Z

Memory footprint analysis revealed the following potential issues

applications.hpf.gpio.icbmsg[nrf54l15dk/nrf54l15/cpuflpr]: High RAM usage: 12430[B] - link (cc: @nrfconnect/ncs-ll-ursus)
applications.hpf.gpio.icbmsg[nrf54l15dk/nrf54l15/cpuflpr]: High ROM usage: 9178[B] - link (cc: @nrfconnect/ncs-ll-ursus)
applications.hpf.gpio.icmsg[nrf54l15dk/nrf54l15/cpuflpr]: High RAM usage: 9090[B] - link (cc: @nrfconnect/ncs-ll-ursus)
applications.hpf.gpio.icmsg[nrf54l15dk/nrf54l15/cpuflpr]: High ROM usage: 5846[B] - link (cc: @nrfconnect/ncs-ll-ursus)
sample.smp_svr_mini_boot[nrf54l15dk/nrf54l15/cpuapp]: RAM size increased by 952[B] in comparison to the main[fe0a8f6] branch. - link (cc: @nrfconnect/ncs-pluto @robertstypa @maciejpietras)

Note: This message is automatically posted and updated by the CI (latest/sdk-nrf/PR-24561/1)

nordicjm · 2025-09-17T06:45:24Z

sysbuild/Kconfig.mcuboot

+config MCUBOOT_BUILD_DIRECT_XIP_VARIANT_CUSTOM_OVERLAY
+	string "Use a custom DTS overlay for the secondary slot image"
+	depends on MCUBOOT_BUILD_DIRECT_XIP_VARIANT || !PARTITION_MANAGER
+	help
+	  When this value is not populated, the default DTS overlay is used for the secondary slot.
+	  Use this Kconfig option when you want to set a custom overlay file for the secondary slot
+	  image.


this is not acceptable. If you want to append a new file then doing that should work via command line

We don't want to use a CLI parameter to override the DTS overlay file because the build command becomes complex (actually, you need to replace overlays for two secondary variants of the following images: the default application image and IPC radio).

west build -p -b nrf54h20dk/nrf54h20/cpuapp -- -Dmcuboot_secondary_app_DTC_OVERLAY_FILE=secondary.overlay -Dipc_radio_secondary_app_DTC_OVERLAY_FILE=secondary.overlay

There is also a guideline/requirement from PMT to make the default build command work in a given project. So the following command should work without any extra params:

west build -p -b nrf54h20dk/nrf54h20/cpuapp

Since there is already a mechanism that injects the overlay file from an arbitrary location ( nrf/subsys/mcuboot/mcuboot_secondary_app.overlay), can't we simply introduce the possibility to change the path and pass your own DTS overlay?

Also, right now, you can't remove the nrf/subsys/mcuboot/mcuboot_secondary_app.overlay overlay, which is added to your secondary images automatically.

@kapi-no but the sample already builds out-of-the-box, correct ?

afaict the mcuboot_secondary_app.overlay is always applied, so what you're tryin (correct me if i'm wrong) is for users to choose their own overlay.

For this, as @nordicjm points out, sysbuild already supports the use of -D<image>_DTC_OVERLAY_FILE=<user-custom-file>.overlay, so why not change the code into dropping add_overlay_dts(${image} "${secondary_overlay}") if custom overlay for image is set ?

Instead of inventing Kconfig setting for this.

@kapi-no but the sample already builds out-of-the-box, correct ?

In the simple MCUboot direct-xip use case scenario, where we have a default application image (built for slot0) and its secondary counterpart (built for slot1) -> yes.

However, when each slot holds two images (merged binary configuration for the nRF54H20): the default application image and the IPC radio image -> the default overlay configuration from the nrf/subsys/mcuboot/mcuboot_secondary_app.overlay is broken.

See the following comment for more context: #24494 (comment)

afaict the mcuboot_secondary_app.overlay is always applied, so what you're tryin (correct me if i'm wrong) is for users to choose their own overlay.

Yes

For this, as @nordicjm points out, sysbuild already supports the use of -D<image>_DTC_OVERLAY_FILE=<user-custom-file>.overlay, so why not change the code into dropping add_overlay_dts(${image} "${secondary_overlay}") if custom overlay for image is set ?

Instead of inventing Kconfig setting for this.

We always strive to have the default build command working for each supported target. Requiring extra parameters breaks this requirement.

There is also a guideline/requirement from PMT to make the default build command work in a given project. So the following command should work without any extra params:

west build -p -b nrf54h20dk/nrf54h20/cpuapp

afaict the mcuboot_secondary_app.overlay is always applied, so what you're tryin (correct me if i'm wrong) is for users to choose their own overlay.

Yes

For this, as @nordicjm points out, sysbuild already supports the use of -D_DTC_OVERLAY_FILE=.overlay, so why not change the code into dropping add_overlay_dts(${image} "${secondary_overlay}") if custom overlay for image is set ?

Instead of inventing Kconfig setting for this.

We always strive to have the default build command working for each supported target. Requiring extra parameters breaks this requirement.

but ensuring that a default build command for a given target always work is not necessarily the same as supporting custom user provided files.

Is the nrf54h20dk/nrf54h20/cpuapp not working with the currently used / default applied mcuboot_secondary_app.overlay file ?

In short, does west build -p -b nrf54h20dk/nrf54h20/cpuapp --sysbuild fail today ?

There is no Jira task reference provided, so I'm a bit unsure exactly what you're trying to solve here.

Working sample out-of-the-box for west build -p -b nrf54h20dk/nrf54h20/cpuapp --sysbuild ?
If this is not working, then we should have an issue describe what and why this is not working.

Ability for our downstream users / customers to provide their own overlays.
Of course a user wanting to provide their own overlay must be expected to do some work of their own.
Even with the use if a Kconfig proposol in this PR they would need to set the value somehow, for example:
-DMCUBOOT_BUILD_DIRECT_XIP_VARIANT_CUSTOM_OVERLAY=<file>.overlay

Generally, the ROM footprint statistics for the nRF54H20 images in the merged binary approach are incorrect. More details can be found in the following ticket:

NCSDK-35489

The code partition for the application image is defined in such a way that it also contains the radio partition.

If I understand NCSDK-35489 then the issue exists for all samples building for nRF54h20dk, so isn't it simply the original mcuboot_secondary_app.overlay intended for the nrf54h20dk which is wrong and should be fixed ?
ef85447

Secondly, if a sample wants to provide custom overlays for images and have those applied per default, then that is also possible. Can even be board specific: https://docs.zephyrproject.org/latest/build/sysbuild/index.html#zephyr-application-configuration

If none of the existing solutions are suitable, then I believe it will be more efficient if you set up a meeting and invite relevant parties.

If I understand NCSDK-35489 then the issue exists for all samples building for nRF54h20dk, so isn't it simply the original mcuboot_secondary_app.overlay intended for the nrf54h20dk which is wrong and should be fixed ?

Yes, at least with the merged binary approach. I haven't tested the DFU solution with isolated binaries, as we want to use one version number for the image set (application + radio image) to minimize complexity in our project.

Secondly, if a sample wants to provide custom overlays for images and have those applied per default, then that is also possible. Can even be board specific: https://docs.zephyrproject.org/latest/build/sysbuild/index.html#zephyr-application-configuration

If none of the existing solutions are suitable, then I believe it will be more efficient if you set up a meeting and invite relevant parties.

Well, I am aware of the application configuration directory solution. We use it in the nRF Desktop app where I initially want to use the suggested change in this PR. I know I can create the configuration from scratch for both the mcuboot_secondary_app and the ipc_radio_secondary_app images. However, this requires copying over 1000 lines of configuration files (at least for the mcuboot_secondary_app) to change one DTS node. And even then, the default file - nrf/subsys/mcuboot/mcuboot_secondary_app.overlay - will be applied.

kapi-no requested a review from a team as a code owner September 16, 2025 14:38

NordicBuilder added the changelog-entry-required Update changelog before merge. Remove label if entry is not needed or already added. label Sep 16, 2025

kapi-no mentioned this pull request Sep 16, 2025

applications: nrf_desktop: nrf54h20: migrate to ironside se #24494

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nordicjm requested changes Sep 17, 2025

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sysbuild: mcuboot: direct_xip: enable custom overlay for secondary slot #24561

sysbuild: mcuboot: direct_xip: enable custom overlay for secondary slot #24561

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CI Information

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Test Spec & Results: ✅ Success; ❌ Failure; 🟠 Queued; 🟡 Progress; ◻️ Skipped; ⚠️ Quarantine

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NordicBuilder commented Sep 16, 2025

Memory footprint analysis revealed the following potential issues

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NordicBuilder commented Sep 16, 2025 •

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