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NCSDK-35612: Fix offsets in merged slot builds #24707

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@tomchy tomchy commented Sep 25, 2025

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@NordicBuilder NordicBuilder added manifest changelog-entry-required Update changelog before merge. Remove label if entry is not needed or already added. labels Sep 25, 2025
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NordicBuilder commented Sep 25, 2025 •
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The following west manifest projects have changed revision in this Pull Request:

Name Old Revision New Revision Diff
mcuboot nrfconnect/sdk-mcuboot@8534953 nrfconnect/sdk-mcuboot#538 nrfconnect/sdk-mcuboot#538/files
zephyr nrfconnect/sdk-zephyr@69ad052 nrfconnect/sdk-zephyr#3310 nrfconnect/sdk-zephyr#3310/files

⛔ DNM label due to: 2 projects with PR revision

Note: This message is automatically posted and updated by the Manifest GitHub Action.

@tomchy tomchy force-pushed the bugfix/mcuboot/NCSDK-35612_Fix_merged_slot_offsets branch from 4beedbb to 1ae7694 Compare September 25, 2025 14:35
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NordicBuilder commented Sep 25, 2025 •
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CI Information

To view the history of this post, clich the 'edited' button above
Build number: 18

Inputs:

Sources:

sdk-nrf: PR head: 6250267b286db6c7d272cea192c3d7d1772ee434
mcuboot: PR head: dbb9506e257a9725de470b333d8616a364b0140e
zephyr: PR head: 6f16451ed926692c3ac6b11eb07bf75eebfb01a4

more details

sdk-nrf:

PR head: 6250267b286db6c7d272cea192c3d7d1772ee434
merge base: 4e22864b021abf415324514b79e79a189f950e06
target head (main): 4e22864b021abf415324514b79e79a189f950e06
Diff

mcuboot:

PR head: dbb9506e257a9725de470b333d8616a364b0140e
merge base: 85349537b3bc4e8e9e7542abd0303adf28177dcb
target head (main): 7c44ed0191a633efc4c50e18bd0c71c5d839bcb9
Diff

zephyr:

PR head: 6f16451ed926692c3ac6b11eb07bf75eebfb01a4
merge base: 69ad0523f95f13d1de356c19575301ce3de4959e
target head (main): 1fe09df625206d83c43debb8651098dbac1641b0
Diff

Github labels

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
ci-run-twister Force run twister
ci-run-zephyr-twister Force run zephyr twister
List of changed files detected by CI (33) 
applications
│  ├── nrf_desktop
│  │  ├── configuration
│  │  │  ├── nrf54h20dk_nrf54h20_cpuapp
│  │  │  │  ├── app_common.dtsi
│  │  │  │  ├── images
│  │  │  │  │  ├── mcuboot
│  │  │  │  │  │  │ app.overlay
│  │  │  │  │ memory_map.dtsi
│  │  │  ├── nrf54h20dk_nrf54h20_cpurad
│  │  │  │  ├── images
│  │  │  │  │  ├── ipc_radio
│  │  │  │  │  │  │ app.overlay
bootloader
│  ├── mcuboot
│  │  ├── boot
│  │  │  ├── bootutil
│  │  │  │  ├── src
│  │  │  │  │  │ bootutil_priv.h
│  │  │  ├── zephyr
│  │  │  │  ├── sysbuild
│  │  │  │  │  │ CMakeLists.txt
cmake
│  ├── sysbuild
│  │  ├── mcuboot_nrf54h20.cmake
│  │  │ sign_nrf54h20.cmake
samples
│  ├── dfu
│  │  ├── ab
│  │  │  ├── boards
│  │  │  │  │ nrf54h20dk_nrf54h20_cpuapp.overlay
│  │  │  ├── src
│  │  │  │  │ ab_utils.c
│  │  │  ├── sysbuild
│  │  │  │  ├── ipc_radio.overlay
│  │  │  │  │ nrf54h20dk_nrf54h20_memory_map.dtsi
│  ├── zephyr
│  │  ├── smp_svr_mini_boot
│  │  │  ├── boards
│  │  │  │  │ nrf54h20dk_nrf54h20_cpuapp_direct_xip.overlay
│  │  │  ├── sample.yaml
│  │  │  ├── sysbuild
│  │  │  │  ├── ipc_radio_direct_xip.overlay
│  │  │  │  ├── mcuboot
│  │  │  │  │  ├── boards
│  │  │  │  │  │  │ nrf54h20dk_nrf54h20_cpuapp_direct_xip.overlay
│  │  │  │  ├── nrf54h20dk_nrf54h20_memory_map_direct_xip.dtsi
│  │  │  │  │ nrf54h20dk_nrf54h20_memory_map_merged_slot.dtsi
│  │  ├── subsys
│  │  │  ├── mgmt
│  │  │  │  ├── mcumgr
│  │  │  │  │  ├── smp_svr
│  │  │  │  │  │  ├── boards
│  │  │  │  │  │  │  ├── nrf54h20dk_nrf54h20_cpuapp_merged_slot.overlay
│  │  │  │  │  │  │  │ nrf54h20dk_nrf54h20_cpuapp_requests.overlay
│  │  │  │  │  │  ├── sysbuild
│  │  │  │  │  │  │  ├── ipc_radio_merged_slot.overlay
│  │  │  │  │  │  │  ├── ipc_radio_requests.overlay
│  │  │  │  │  │  │  ├── nrf54h20dk_nrf54h20_memory_map_merged_slot.dtsi
│  │  │  │  │  │  │  │ nrf54h20dk_nrf54h20_memory_map_requests.dtsi
subsys
│  ├── bootloader
│  │  │ Kconfig
sysbuild
│  │ CMakeLists.txt
west.yml
zephyr
│  ├── boards
│  │  ├── nordic
│  │  │  ├── nrf54h20dk
│  │  │  │  │ Kconfig.defconfig
│  ├── scripts
│  │  ├── ci
│  │  │  │ check_compliance.py
│  ├── soc
│  │  ├── nordic
│  │  │  ├── nrf54h
│  │  │  │  │ soc.c
│  ├── subsys
│  │  ├── dfu
│  │  │  ├── img_util
│  │  │  │  │ flash_img.c
│  │  ├── mgmt
│  │  │  ├── mcumgr
│  │  │  │  ├── grp
│  │  │  │  │  ├── img_mgmt
│  │  │  │  │  │  ├── src
│  │  │  │  │  │  │  │ img_mgmt.c
│  ├── tests
│  │  ├── subsys
│  │  │  ├── dfu
│  │  │  │  ├── img_util
│  │  │  │  │  ├── src
│  │  │  │  │  │  │ main.c

Outputs:

Toolchain

Version: a7529a11f4
Build docker image: docker-dtr.nordicsemi.no/sw-production/ncs-build:a7529a11f4_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-fw-nrfconnect-ble_mesh
    • ✅ test-fw-nrfconnect-ble_samples
    • ✅ test-fw-nrfconnect-chip
    • ✅ test-fw-nrfconnect-nfc
    • ✅ test-fw-nrfconnect-nrf-iot_cloud
    • ✅ 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
    • ✅ 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

@tomchy tomchy force-pushed the bugfix/mcuboot/NCSDK-35612_Fix_merged_slot_offsets branch from 1ae7694 to d106054 Compare September 25, 2025 15:14
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@tomchy tomchy force-pushed the bugfix/mcuboot/NCSDK-35612_Fix_merged_slot_offsets branch 2 times, most recently from 20f72d8 to 55dd942 Compare September 26, 2025 09:43
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NordicBuilder commented Sep 26, 2025 •
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Memory footprint analysis revealed the following potential issues

applications.hpf.gpio.icmsg[nrf54l15dk/nrf54l15/cpuflpr]: High RAM usage: 9102[B] - link (cc: @nrfconnect/ncs-ll-ursus)
applications.hpf.gpio.icmsg[nrf54l15dk/nrf54l15/cpuflpr]: High ROM usage: 5858[B] - link (cc: @nrfconnect/ncs-ll-ursus)
applications.hpf.gpio.icbmsg[nrf54l15dk/nrf54l15/cpuflpr]: High RAM usage: 12744[B] - link (cc: @nrfconnect/ncs-ll-ursus)
applications.hpf.gpio.icbmsg[nrf54l15dk/nrf54l15/cpuflpr]: High ROM usage: 9492[B] - link (cc: @nrfconnect/ncs-ll-ursus)

Note: This message is automatically posted and updated by the CI (latest/sdk-nrf/PR-24707/18)

@tomchy tomchy force-pushed the bugfix/mcuboot/NCSDK-35612_Fix_merged_slot_offsets branch 2 times, most recently from da2df88 to c95e856 Compare September 29, 2025 14:41
tomchy added 3 commits October 2, 2025 17:21
@tomchy
sysbuild: Allow to use imgtool-based headers
3a0b110 
It is possible to add MCUboot header through --pad-header option.
In such cases, the FLASH_LOAD_OFFSET does not point to the begining of
the slot, but to the beginning of the executable area, thus the check
for the active slot should use ranges instead of exact values.

Signed-off-by: Tomasz Chyrowicz <[email protected]>
@tomchy
cmake: Check image boundaries in merged slot
c7a6512 
Add routine that checks if all merged images are configured within the
boundary of the merged partition.

Ref: NCSDK-35612

Signed-off-by: Tomasz Chyrowicz <[email protected]>
@tomchy
sysbuild: Remove offsets from merged slots
6250267 
Adjust logic, so the merged slots do not include gaps between images.

Ref: NCSDK-25612

Signed-off-by: Tomasz Chyrowicz <[email protected]>
@tomchy tomchy force-pushed the bugfix/mcuboot/NCSDK-35612_Fix_merged_slot_offsets branch from c95e856 to 6250267 Compare October 2, 2025 15:26
@tomchy tomchy marked this pull request as ready for review October 2, 2025 15:30
@tomchy tomchy requested review from a team as code owners October 2, 2025 15:30
kapi-no
kapi-no approved these changes Oct 7, 2025
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Reviewed and tested the nRF Desktop part

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