feat: complete vendor integration, edge modules, ADR-042 CHCI

.github/workflows/firmware-ci.yml

@@ -0,0 +1,100 @@
+name: Firmware CI
+
+on:
+  push:
+    paths:
+      - 'firmware/**'
+      - '.github/workflows/firmware-ci.yml'
+  pull_request:
+    paths:
+      - 'firmware/**'
+      - '.github/workflows/firmware-ci.yml'
+
+jobs:
+  build:
+    name: Build ESP32-S3 Firmware
+    runs-on: ubuntu-latest
+    container:
+      image: espressif/idf:v5.2
+
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Build firmware
+        working-directory: firmware/esp32-csi-node
+        run: |
+          . $IDF_PATH/export.sh
+          idf.py set-target esp32s3
+          idf.py build
+
+      - name: Verify binary size (< 950 KB gate)
+        working-directory: firmware/esp32-csi-node
+        run: |
+          BIN=build/esp32-csi-node.bin
+          SIZE=$(stat -c%s "$BIN")
+          MAX=$((950 * 1024))
+          echo "Binary size: $SIZE bytes ($(( SIZE / 1024 )) KB)"
+          echo "Size limit:  $MAX bytes (950 KB — includes Tier 3 WASM runtime)"
+          if [ "$SIZE" -gt "$MAX" ]; then
+            echo "::error::Firmware binary exceeds 950 KB size gate ($SIZE > $MAX)"
+            exit 1
+          fi
+          echo "Binary size OK: $SIZE <= $MAX"
+
+      - name: Verify flash image integrity
+        working-directory: firmware/esp32-csi-node
+        run: |
+          ERRORS=0
+          BIN=build/esp32-csi-node.bin
+
+          # Check binary exists and is non-empty.
+          if [ ! -s "$BIN" ]; then
+            echo "::error::Binary not found or empty"
+            exit 1
+          fi
+
+          # Check partition table magic (0xAA50 at offset 0).
+          PT=build/partition_table/partition-table.bin
+          if [ -f "$PT" ]; then
+            MAGIC=$(xxd -l2 -p "$PT")
+            if [ "$MAGIC" != "aa50" ]; then
+              echo "::warning::Partition table magic mismatch: $MAGIC (expected aa50)"
+              ERRORS=$((ERRORS + 1))
+            fi
+          fi
+
+          # Check bootloader exists.
+          BL=build/bootloader/bootloader.bin
+          if [ ! -s "$BL" ]; then
+            echo "::warning::Bootloader binary missing or empty"
+            ERRORS=$((ERRORS + 1))
+          fi
+
+          # Verify non-zero data in binary (not all 0xFF padding).
+          NONZERO=$(xxd -l 1024 -p "$BIN" | tr -d 'f' | wc -c)
+          if [ "$NONZERO" -lt 100 ]; then
+            echo "::error::Binary appears to be mostly padding (non-zero chars: $NONZERO)"
+            ERRORS=$((ERRORS + 1))
+          fi
+
+          if [ "$ERRORS" -gt 0 ]; then
+            echo "::warning::Flash image verification completed with $ERRORS warning(s)"
+          else
+            echo "Flash image integrity verified"
+          fi
+
+      - name: Check QEMU ESP32-S3 support status
+        run: |
+          echo "::notice::ESP32-S3 QEMU support is experimental in ESP-IDF v5.4. "
+          echo "Full smoke testing requires QEMU 8.2+ with xtensa-esp32s3 target."
+          echo "See: https://github.com/espressif/qemu/wiki"
+
+      - name: Upload firmware artifact
+        uses: actions/upload-artifact@v4
+        with:
+          name: esp32-csi-node-firmware
+          path: |
+            firmware/esp32-csi-node/build/esp32-csi-node.bin
+            firmware/esp32-csi-node/build/bootloader/bootloader.bin
+            firmware/esp32-csi-node/build/partition_table/partition-table.bin
+          retention-days: 30

.gitignore

@@ -1,11 +1,23 @@
-# Local machine configuration (not shared)
+# Local Claude config (contains WiFi credentials and machine-specific paths)
 CLAUDE.local.md
 
 # ESP32 firmware build artifacts and local config (contains WiFi credentials)
 firmware/esp32-csi-node/build/
 firmware/esp32-csi-node/sdkconfig
 firmware/esp32-csi-node/sdkconfig.defaults
 firmware/esp32-csi-node/sdkconfig.old
+# Downloaded WASM3 source (fetched at configure time)
+firmware/esp32-csi-node/components/wasm3/wasm3-src/
+
+# NVS partition images and CSVs (contain WiFi credentials)
+nvs.bin
+nvs_config.csv
+nvs_provision.bin
+
+# Working artifacts that should not land in root
+/*.wasm
+/esp32_*.txt
+/serial_error.txt
 
 # Byte-compiled / optimized / DLL files
 __pycache__/