@typecad/framework-zephyr 1.0.0-alpha.10

package/src/toolchain/index.ts

@@ -0,0 +1,482 @@
+// ---------------------------------------------------------------------------
+// FrameworkToolchain impl for Zephyr (west / CMake)
+//
+// compile() scaffolds the project (idempotent) then runs `west build -b <board>`.
+// upload() runs `west flash`. monitor() runs a best-effort serial monitor.
+//
+// west resolution goes through westSpawn(), which finds a usable west without
+// requiring the user to have activated the Zephyr Python venv — it prefers
+// `<python> -m west` (robust cross-platform form) and injects ZEPHYR_BASE when
+// a SDK root is discovered. See west-discover.ts / west-spawn.ts.
+//
+// The board target is carried via frameworkData.buildTarget (populated as
+// ToolchainOptions.buildTarget by the cuttlefish CLI), defaulting to the
+// framework's canonical MVP target (xiao_ble).
+//
+// Mirrors framework-esp32/src/toolchain/index.ts structure: projectRoot derived
+// from outputDir, prepare is a no-op (scaffold happens in compile when the
+// target is known), GCC errors parsed via the shared parseCompileErrors helper.
+// ---------------------------------------------------------------------------
+
+import { spawnSync } from 'node:child_process';
+import { basename, dirname, join } from 'node:path';
+import { readdirSync, readFileSync, mkdirSync, rmSync, existsSync } from 'node:fs';
+import type { ToolchainOptions, CompileResult, UploadResult } from '@typecad/cuttlefish/api/shared';
+import { parseCompileErrors } from '@typecad/cuttlefish/api/shared';
+import { scaffoldZephyrProject, writeIfChanged } from './scaffold.js';
+import { westSpawn, buildEnv } from './west-spawn.js';
+import { discoverWest } from './west-discover.js';
+import { writeDebugConfig, resolveDebugLocations } from './debug-config.js';
+import { ZephyrStrategy } from '../strategy.js';
+import { generateOverlay, type DisplayWiring, type TouchWiring } from '../dt-config/overlay.js';
+import { chipForTarget } from '../chips/index.js';
+import { detectZephyrVersion, checkZephyrCompat, resolveBoardTarget } from './compat.js';
+import { DEFAULT_ZEPHYR_DISPLAY_PROFILE } from '../display/profiles.js';
+
+/** Default board target — the framework's MVP canonical board. */
+const DEFAULT_BOARD = 'xiao_ble';
+
+function targetFromOptions(o: ToolchainOptions): string {
+  // The cuttlefish CLI populates ToolchainOptions.buildTarget from
+  // config.frameworkData.buildTarget. Accept frameworkData.target as an alias.
+  const fcTarget = (o.frameworkConfig?.target as string | undefined);
+  return (o.buildTarget as string | undefined) ?? fcTarget ?? DEFAULT_BOARD;
+}
+
+/**
+ * Derive the Zephyr project root from the cuttlefish-emitted source path.
+ *
+ * Cuttlefish emits `src/main.cpp` under the output dir. The CLI passes
+ * `sourcePath` = full path to `main.cpp` and `outputDir` = its parent (`src/`).
+ * For Zephyr, the project root is the parent of `src/` — one level above
+ * `outputDir`. Detect that shape and adjust; otherwise fall back to `outputDir`.
+ */
+export function projectRootFromOptions(o: ToolchainOptions): string {
+  const outDir = o.outputDir;
+  if (basename(outDir) === 'src') {
+    return dirname(outDir);
+  }
+  return outDir;
+}
+
+/**
+ * west build timeout. Zephyr's first build fetches the toolchain modules and
+ * configures CMake/Ninja, which can take several minutes; allow generous headroom.
+ */
+const BUILD_TIMEOUT_MS = 600_000;
+const FLASH_TIMEOUT_MS = 120_000;
+
+/**
+ * Build the `west flash` argument list for a board.
+ *
+ * Runner selection: each board's board.cmake declares a sensible default flash
+ * runner for its hardware (xiao_ble → nrfutil, esp32* → esptool), and `west
+ * flash` resolves it automatically. The framework only intervenes where the
+ * board default needs an argument it can't infer:
+ *   - An explicit `zephyr.runner` (from cuttlefish.config.ts) always wins.
+ *   - ESP32 boards forward the port via `--esp-device` (esptool reads the
+ *     device from it); board.cmake still picks the runner.
+ *   - Every other board trusts the board.cmake default. Previously this forced
+ *     `--runner nrfjprog` for every non-ESP32 target, which broke boards whose
+ *     default is not nrfjprog (xiao_ble defaults to nrfutil) and required
+ *     Nordic J-Link tools that a USB-bootloader board does not have.
+ *
+ * Exported (pure) so the runner-selection contract is unit-testable without
+ * spawning west.
+ */
+export function buildFlashArgs(
+  buildDir: string,
+  board: string,
+  userRunner: string | undefined,
+  port: string | undefined,
+): string[] {
+  const args = ['flash', '-d', buildDir];
+  if (userRunner) {
+    args.push('--runner', userRunner);
+  }
+  if (port && board.startsWith('esp32')) {
+    args.push('--esp-device', port);
+  }
+  return args;
+}
+
+/**
+ * Classify a `west flash` result as success/failure.
+ *
+ * west's exit status is authoritative except for one known race in the uf2
+ * runner on Windows: the UF2 bootloader reboots to run new firmware the instant
+ * the file copy completes, unmounting the USB-MSC drive before `shutil.copy`'s
+ * trailing `copymode`/chmod runs. That raises `OSError: [WinError 433] A
+ * device which does not exist was specified` and makes west exit non-zero —
+ * even though the firmware copied and flashed correctly (the LED blinks).
+ *
+ * The copy starting is logged ("Copying UF2 file to '<drive>'"); WinError 433
+ * during `copymode` after that point proves the data write finished and the
+ * drive only vanished on the metadata step. Treat that exact signature as
+ * success so the upload isn't reported as a failure. Genuine uf2 failures
+ * (no partition found, write errors before the copy) still surface as failures.
+ *
+ * Exported (pure) so the classification is unit-testable without spawning west.
+ */
+export function classifyUploadResult(
+  runner: string | undefined,
+  status: number | null,
+  output: string,
+): boolean {
+  if (status === 0) return true;
+  if (isUf2DriveVanishRace(output)) return runner === 'uf2';
+  return false;
+}
+
+/**
+ * Whether `output` carries the benign UF2 copymode/WinError-433 race signature
+ * (see classifyUploadResult). Centralized so classify + cleanse share one match.
+ */
+function isUf2DriveVanishRace(output: string): boolean {
+  return /Copying UF2 file to/.test(output)
+    && /WinError 433/.test(output)
+    && /copymode/.test(output);
+}
+
+/**
+ * Cleanse the `west flash` output shown to the user.
+ *
+ * When classifyUploadResult has decided a non-zero west exit was the benign UF2
+ * race (firmware copied, drive unmounted on the trailing chmod), the raw output
+ * is a wall of Python traceback that reads like a hard failure. Drop everything
+ * after the "Copying UF2 file to" line — i.e. the entire traceback — so a
+ * successful flash reads as a success (the framework's ✓ Done follows). Non-race
+ * output is returned untouched; genuine errors stay fully visible for diagnosis.
+ *
+ * Exported (pure) so the cleansing is unit-testable without spawning west.
+ */
+export function cleanseUploadOutput(
+  runner: string | undefined,
+  status: number | null,
+  output: string,
+): string {
+  if (status === 0) return output;
+  if (runner === 'uf2' && isUf2DriveVanishRace(output)) {
+    // Keep everything west printed up to and including "Copying UF2 file to",
+    // then stop — everything after that is the drive-vanish traceback.
+    const upto = output.match(/[\s\S]*Copying UF2 file to[^\n]*/);
+    const head = upto ? upto[0] : '-- west flash: using runner uf2';
+    return head;
+  }
+  return output;
+}
+
+
+/**
+ * FrameworkToolchain for Zephyr. Spec §3.5 (mirror of the ESP-IDF toolchain).
+ * The target board is carried via frameworkData.buildTarget; scaffolding
+ * happens at compile time when the target is known.
+ */
+export const Toolchain = {
+  prepare(outputDir: string, entryPoint: string): void {
+    // Write the DT overlay for the default board (the real target is known at
+    // compile time; prepare runs before compile, so use the default board id).
+    // The overlay is additive and idempotent; compile re-runs prepare-equivalent
+    // logic in scaffold via the usage scan. Mirrors how Arduino's library
+    // resolution is a pre-build artifact step.
+    const projectRoot = basename(outputDir) === 'src' ? dirname(outputDir) : outputDir;
+    const board = DEFAULT_BOARD;
+    const chip = chipForTarget(board);
+    // Scan the emitted source for usage tokens (same authoritative signal the
+    // scaffold uses). entryPoint is the path to main.cpp; its dir is src/.
+    const srcDir = dirname(entryPoint);
+    let src = '';
+    try {
+      for (const name of readdirSync(srcDir)) {
+        if (name.endsWith('.cpp') || name.endsWith('.c')) {
+          src += readFileSync(join(srcDir, name), 'utf8');
+        }
+      }
+    } catch { /* src may not exist yet on first prepare */ }
+    const uses = (t: string): boolean => src.includes(t);
+    // Display usage tokens: the minimal GFX runtime (display_write/_fill_rect)
+    // and the UI display adapter (display_init / __tc_display_dev /
+    // DEVICE_DT_GET on the display nodelabel). Both paths need the DT overlay
+    // to enable the display node.
+    const usesDisplay = uses('display_write') || uses('display_init')
+      || uses('display_fill_rect') || uses('__tc_display_dev')
+      || uses('CuttlefishDisplayTarget');
+    // Both registered Zephyr display profiles use dtLabel 'display0', so the
+    // default profile's overlay block (&display0 { status="okay" }) is correct
+    // for either driver. Thread a non-default profile here only if a future
+    // board carries a display node under a different nodelabel.
+    const displayProfile = usesDisplay ? DEFAULT_ZEPHYR_DISPLAY_PROFILE : undefined;
+    const overlay = generateOverlay(chip, {
+      usesI2c: uses('i2c_'),
+      usesSpi: uses('spi_'),
+      usesUart: uses('uart_'),
+      usesDisplay,
+      usesTouch: uses('ft6336u') || uses('touch_'),
+    }, displayProfile);
+    const overlayDir = join(projectRoot, 'boards');
+    mkdirSync(overlayDir, { recursive: true });
+    writeIfChanged(join(overlayDir, `${board}.overlay`), overlay);
+  },
+
+  compile(o: ToolchainOptions): CompileResult {
+    const projectRoot = projectRootFromOptions(o);
+    const rawBoard = targetFromOptions(o);
+
+    // Fail fast on an incompatible Zephyr (clear message vs. a cryptic west/
+    // CMake board error), then normalize the board target for the installed
+    // version — Zephyr 4.3+ rejects bare multi-core board names, so a stale
+    // config (esp32s3_devkitc) is rewritten to the qualified form
+    // (esp32s3_devkitc/esp32s3/procpu). See toolchain/compat.ts.
+    const zephyrVersion = detectZephyrVersion();
+    const compat = checkZephyrCompat(zephyrVersion);
+    if (compat.status === 'out-of-range') {
+      throw new Error(
+        `Zephyr ${zephyrVersion} is outside the supported range (${compat.range}) for @typecad/framework-zephyr. ` +
+        `Set ZEPHYR_BASE to a compatible Zephyr checkout, or install one via '@typecad/zephyr-installer'.`,
+      );
+    }
+    if (compat.status === 'undetectable') {
+      console.warn(
+        `! Could not detect the installed Zephyr version (is ZEPHYR_BASE set?). ` +
+        `Skipping compat check; declared range is ${compat.range}.`,
+      );
+    }
+    const board = resolveBoardTarget(rawBoard, zephyrVersion);
+
+    const debugMode = new ZephyrStrategy().debugMode(board);
+    const isGdbDebug = o.debug === true && debugMode === 'gdb';
+    const zc = o.zephyrConfig as Record<string, unknown> | undefined;
+    const userKconfig = zc?.kconfig as Record<string, string> | undefined;
+    const configChanged = scaffoldZephyrProject(projectRoot, isGdbDebug, userKconfig, o.psram);
+
+    // Regenerate the DT overlay for the ACTUAL target board. prepare() writes
+    // it for the default board (the real target is unknown until compile), so
+    // the <default>.overlay it wrote does not match `west build -b <board>`.
+    // Zephyr auto-detects boards/<board>.overlay under APPLICATION_CONFIG_DIR.
+    try {
+      const chip = chipForTarget(board);
+      const srcDir = join(projectRoot, 'src');
+      let src = '';
+      try {
+        for (const name of readdirSync(srcDir)) {
+          if (name.endsWith('.cpp') || name.endsWith('.c')) {
+            src += readFileSync(join(srcDir, name), 'utf-8');
+          }
+        }
+      } catch { /* src may not exist */ }
+      const uses = (t: string): boolean => src.includes(t);
+      const usesDisplay = uses('display_write') || uses('display_init')
+        || uses('display_fill_rect') || uses('__tc_display_dev')
+        || uses('CuttlefishDisplayTarget');
+      // Derive the display dimensions from the emitted adapter code
+      // (display_width/height return the profile's w/h). This ensures the DT
+      // overlay's width/height match the panel the adapter targets, not the
+      // default profile — critical for drivers like ST7796S that initialize
+      // the panel geometry from the DT node.
+      let displayProfile = usesDisplay ? DEFAULT_ZEPHYR_DISPLAY_PROFILE : undefined;
+      if (usesDisplay) {
+        const wMatch = src.match(/display_width\(\)\s*\{\s*return\s+(\d+)\s*;\s*\}/);
+        const hMatch = src.match(/display_height\(\)\s*\{\s*return\s+(\d+)\s*;\s*\}/);
+        if (wMatch && hMatch) {
+          displayProfile = {
+            ...DEFAULT_ZEPHYR_DISPLAY_PROFILE,
+            width: parseInt(wMatch[1], 10),
+            height: parseInt(hMatch[1], 10),
+          };
+        }
+      }
+      // Extract display pin wiring (cs/dc/rst/spiFrequency/spiPins) from the
+      // config display section so the DT overlay wires the MIPI DBI bridge to
+      // the correct GPIOs + SPI bus pins.
+      const dispCfg = o.display as Record<string, unknown> | undefined;
+      const spiPins = (dispCfg?.spiPins ?? undefined) as
+        { sck?: unknown; mosi?: unknown; miso?: unknown } | undefined;
+      const wiring: DisplayWiring | undefined = dispCfg
+        ? {
+            cs: typeof dispCfg.cs === 'number' ? dispCfg.cs : undefined,
+            dc: typeof dispCfg.dc === 'number' ? dispCfg.dc : undefined,
+            rst: typeof dispCfg.rst === 'number' ? dispCfg.rst : undefined,
+            spiFrequency: typeof dispCfg.spiFrequency === 'number' ? dispCfg.spiFrequency : undefined,
+            sck: typeof spiPins?.sck === 'number' ? spiPins.sck : undefined,
+            mosi: typeof spiPins?.mosi === 'number' ? spiPins.mosi : undefined,
+            miso: typeof spiPins?.miso === 'number' ? spiPins.miso : undefined,
+            backlightPin: typeof dispCfg.backlightPin === 'number' ? dispCfg.backlightPin : undefined,
+          }
+        : undefined;
+      // Extract touch pin wiring (irq/resetPin/sda/scl) from the config
+      // display.touch section so the DT overlay wires the I2C bus + touch node.
+      const touchCfg = dispCfg?.touch as Record<string, unknown> | undefined;
+      const touchWiring: TouchWiring | undefined = touchCfg
+        ? {
+            irq: typeof touchCfg.irq === 'number' ? touchCfg.irq : undefined,
+            resetPin: typeof touchCfg.resetPin === 'number' ? touchCfg.resetPin : undefined,
+            sda: typeof touchCfg.sda === 'number' ? touchCfg.sda : undefined,
+            scl: typeof touchCfg.scl === 'number' ? touchCfg.scl : undefined,
+          }
+        : undefined;
+      const overlay = generateOverlay(chip, {
+        usesI2c: uses('i2c_'),
+        usesSpi: uses('spi_'),
+        usesUart: uses('uart_'),
+        usesDisplay,
+        usesTouch: uses('ft6336u') || uses('touch_'),
+        psram: o.psram,
+      }, displayProfile, wiring, touchWiring);
+      const overlayDir = join(projectRoot, 'boards');
+      mkdirSync(overlayDir, { recursive: true });
+      // Write the board-specific overlay (the one west loads). Zephyr looks for
+      // boards/<board_id>.overlay under APPLICATION_CONFIG_DIR — use the bare
+      // board id (before any hardware-qualifier suffix, e.g. 'esp32_devkitc'
+      // not the full 'esp32_devkitc/esp32/procpu' target string).
+      const boardId = board.split('/')[0];
+      writeIfChanged(join(overlayDir, `${boardId}.overlay`), overlay);
+    } catch { /* best-effort overlay regen; the build surfaces DT errors */ }
+
+    // Use a stable build dir so incremental builds reuse the Ninja graph.
+    // west defaults to <projectRoot>/build.
+    const buildDir = join(projectRoot, 'build');
+
+    // Nuke the build dir whenever a previous build exists. Zephyr's gen_offset
+    // flow (offsets.h is generated FROM offsets.c.obj, while gen_offset.h makes
+    // offsets.c include offsets.h) leaves a permanent `offsets.h ->
+    // offsets.c.obj -> offsets.h` cycle in the .ninja_deps log after the first
+    // incremental pass — ninja then fails every later build with `dependency
+    // cycle` even when nothing changed. This is a known Zephyr-on-Windows
+    // issue; the reliable fix is a pristine build dir per build. Also nukes
+    // when prj.conf/CMakeLists/overlay changed, so Kconfig symbols and
+    // generated headers never diverge from a cached graph.
+    if (configChanged || existsSync(join(buildDir, 'zephyr', 'zephyr.bin'))) {
+      try { rmSync(buildDir, { recursive: true, force: true }); } catch { /* may not exist */ }
+    }
+
+    const buildArgs = ['build', '-b', board, '-d', buildDir, projectRoot];
+    // Explicitly pass the generated DT overlay. Zephyr's auto-detection of
+    // boards/<board>.overlay fails for hardware-qualified targets (e.g.
+    // esp32_devkitc/esp32/procpu) because the FILE_SUFFIX matching doesn't
+    // resolve — passing -DDTC_OVERLAY_FILE forces it unconditionally.
+    const boardId = board.split('/')[0];
+    const overlayPath = join(projectRoot, 'boards', `${boardId}.overlay`);
+    try {
+      if (readFileSync(overlayPath, 'utf-8').length > 0) {
+        // CMake parses backslashes as escapes — use forward slashes so the
+        // Windows path survives the -D argument intact.
+        buildArgs.push('--', `-DDTC_OVERLAY_FILE=${overlayPath.replace(/\\/g, '/')}`);
+      }
+    } catch { /* no overlay — let Zephyr auto-detect or build without one */ }
+    // Append user cmake args from cuttlefish.config.ts zephyr.cmakeArgs.
+    const userCmakeArgs = zc?.cmakeArgs as string[] | undefined;
+    if (userCmakeArgs && userCmakeArgs.length > 0) {
+      if (!buildArgs.includes('--')) buildArgs.push('--');
+      buildArgs.push(...userCmakeArgs);
+    }
+    const inv = westSpawn(
+      buildArgs,
+      { cwd: projectRoot, encoding: 'utf-8', timeout: BUILD_TIMEOUT_MS },
+    );
+    const result = spawnSync(inv.command, inv.args, inv.options);
+
+    const stdout = typeof result.stdout === 'string' ? result.stdout : (result.stdout?.toString() ?? '');
+    const stderr = typeof result.stderr === 'string' ? result.stderr : (result.stderr?.toString() ?? '');
+    const output = stdout + stderr;
+    // Prefix the build log with how west was resolved, for transparency.
+    const header = `Using west via ${inv.install.source}` +
+      (inv.install.zephyrBase ? ` (ZEPHYR_BASE=${inv.install.zephyrBase})` : '') + '\n';
+
+    // After a successful build in gdb mode (--debug on a probe-capable target),
+    // write the VS Code launch.json + tasks.json + gdb-script artifacts so F5
+    // attaches GDB to the chip's debug probe. Non-fatal on failure — a missing
+    // artifact doesn't block the build. Mirrors the deleted framework-esp32
+    // toolchain compile() debug-config wiring.
+    if (result.status === 0 && isGdbDebug) {
+      try {
+        const { workspaceRoot, sketchRel } = resolveDebugLocations(projectRoot);
+        writeDebugConfig({
+          projectRoot,
+          workspaceRoot,
+          sketchRel,
+          target: board,
+          buildDir,
+          sourceMapPath: join(dirname(o.sourcePath), `${basename(o.sourcePath)}.thcppmap.json`),
+        });
+      } catch (e) {
+        console.warn(`[cuttlefish] gdb debug config generation failed: ${(e as Error).message}`);
+      }
+    }
+
+    return {
+      success: result.status === 0,
+      output: header + output,
+      errors: parseCompileErrors(output, o.sourcePath),
+    };
+  },
+
+  upload(o: ToolchainOptions): UploadResult {
+    const projectRoot = projectRootFromOptions(o);
+    const buildDir = join(projectRoot, 'build');
+    const board = targetFromOptions(o);
+    const zc = o.zephyrConfig as Record<string, unknown> | undefined;
+    const runner = zc?.runner as string | undefined;
+    const args = buildFlashArgs(buildDir, board, runner, o.port);
+
+    const inv = westSpawn(args, {
+      cwd: projectRoot,
+      encoding: 'utf-8',
+      timeout: FLASH_TIMEOUT_MS,
+    });
+    const result = spawnSync(inv.command, inv.args, inv.options);
+
+    const fstdout = typeof result.stdout === 'string' ? result.stdout : (result.stdout?.toString() ?? '');
+    const fstderr = typeof result.stderr === 'string' ? result.stderr : (result.stderr?.toString() ?? '');
+    const raw = fstdout + fstderr;
+    return {
+      success: classifyUploadResult(runner, result.status, raw),
+      output: cleanseUploadOutput(runner, result.status, raw),
+    };
+  },
+
+  monitor(o: ToolchainOptions): void {
+    // Serial monitor over USB-CDC. Zephyr does NOT ship a `west serial`
+    // subcommand (it's not a real west command — invoking it errors with
+    // "unknown command"). The discovered west install's venv carries pyserial,
+    // so run its bundled miniterm directly: `python -m serial.tools.miniterm`.
+    // That is the same cross-platform terminal pyserial provides in ESP-IDF's
+    // idf.py monitor, and it inherits stdio so Ctrl+C exits cleanly.
+    if (!o.port) {
+      throw new Error(
+        'A serial port is required to monitor. Pass --port <COMx/ttyX>.',
+      );
+    }
+    // ESP32 USB-CDC console runs at 115200 (the Zephyr ESP32 board default).
+    // The CLI's generic default of 9600 is wrong for this target; honor an
+    // explicit --baud / config.console.baudRate when given, else 115200.
+    const baud = o.baud ?? 115200;
+    const install = discoverWest();
+    const py = install?.pythonExecutable ?? process.env.PYTHON ?? 'python';
+    // Reuse west-spawn's env builder (prepends the venv bin dir to PATH so the
+    // python we spawn resolves pyserial from the same venv). Falls back to the
+    // process env when no install is discovered.
+    const env = install ? buildEnv(install) : process.env;
+    spawnSync(py, ['-m', 'serial.tools.miniterm', o.port, String(baud)], {
+      cwd: projectRootFromOptions(o),
+      env,
+      stdio: 'inherit',
+    });
+  },
+
+  debug(o: ToolchainOptions): void {
+    // Launch an interactive GDB session for the last build. `west debug`
+    // auto-resolves the runner (openocd for esp32s3, nrfjprog/jlink for nRF)
+    // and the GDB binary from the build dir's CMakeCache/board.cmake — no
+    // hand-authored gdbinit needed. Inherits stdio so GDB runs interactively.
+    // (Not invoked by the standard build/compile flow; powers an explicit
+    // debug-attach entry point for terminal-driven debugging without VS Code.)
+    const projectRoot = projectRootFromOptions(o);
+    const buildDir = join(projectRoot, 'build');
+    const inv = westSpawn(['debug', '-d', buildDir], {
+      cwd: projectRoot,
+      encoding: 'utf-8',
+      stdio: 'inherit',
+    });
+    spawnSync(inv.command, inv.args, inv.options);
+  },
+};

package/src/toolchain/scaffold.ts

@@ -0,0 +1,196 @@
+// ---------------------------------------------------------------------------
+// Zephyr project scaffolding
+//
+// Writes the CMakeLists.txt + prj.conf around the cuttlefish-emitted src/main.cpp
+// so `west build` has a valid Zephyr application. Idempotent: overwrites the
+// generated files only when their content changes (avoids invalidating the
+// Ninja incremental build's mtime-based dependency tracking).
+// ---------------------------------------------------------------------------
+
+import { writeFileSync, existsSync, mkdirSync, readFileSync, readdirSync } from 'node:fs';
+import { join } from 'node:path';
+import { resolveKconfigFragments, type KconfigUsage } from '../dt-config/kconfig.js';
+
+/** Write a file only if the content differs from the existing file.
+ *  Returns true when the file was written (content changed or file was new). */
+export function writeIfChanged(filePath: string, content: string): boolean {
+  if (existsSync(filePath)) {
+    try {
+      if (readFileSync(filePath, 'utf8') === content) return false;
+    } catch {
+      // Read failed — fall through to write.
+    }
+  }
+  writeFileSync(filePath, content);
+  return true;
+}
+
+/**
+ * Concatenate all emitted source under src/ so the scaffold can detect which
+ * peripherals the program actually uses. The cuttlefish lowering emits
+ * well-known driver API tokens (adc_read, spi_transceive, bt_*, …), so scanning
+ * the post-transpile source is an authoritative usage signal — and it keeps the
+ * scaffold self-contained (no need to thread analysis through the toolchain
+ * contract). Returns '' when no sources exist yet (first prepare call).
+ */
+function readEmittedSources(srcDir: string): string {
+  if (!existsSync(srcDir)) return '';
+  let out = '';
+  for (const name of readdirSync(srcDir)) {
+    if (name.endsWith('.cpp') || name.endsWith('.c')) {
+      try {
+        out += readFileSync(join(srcDir, name), 'utf8');
+      } catch {
+        // ignore unreadable files
+      }
+    }
+  }
+  return out;
+}
+
+/**
+ * Emit the Zephyr application skeleton around the generated src/main.cpp.
+ *
+ * Layout written:
+ *   <projectRoot>/
+ *     CMakeLists.txt   (find_package(Zephyr), target_sources app ← src/*.cpp)
+ *     prj.conf         (CONFIG_* for GPIO + C++ + libc)
+ *     src/main.cpp     (owned by cuttlefish's emit pipeline — NOT touched here)
+ *
+ * Idempotent. Mirrors scaffoldEspIdfProject's writeIfChanged discipline.
+ */
+export function scaffoldZephyrProject(projectRoot: string, debug = false, userKconfig?: Record<string, string>, psram?: 'opi' | 'quad'): boolean {
+  const srcDir = join(projectRoot, 'src');
+  if (!existsSync(srcDir)) mkdirSync(srcDir, { recursive: true });
+
+  // Detect which peripherals the program actually uses by scanning the emitted
+  // source. The cuttlefish lowering emits well-known driver API tokens, so this
+  // is authoritative. Usage-gating the Kconfig symbols keeps a GPIO-only
+  // program from pulling in (and linking) stacks it doesn't need — notably
+  // NimBLE (CONFIG_BT), whose Espressif prebuilt blobs are not always present
+  // in a workspace. The symbol set itself lives in resolveKconfigFragments
+  // (dt-config/kconfig.ts), unit-tested separately.
+  const src = readEmittedSources(srcDir);
+  // Boundary-anchored token scan: a bare `src.includes('power_')` would match
+  // `tx_power_dbm` (emitted by the WiFi shim) and flip CONFIG_PM on for a
+  // WiFi-only program — on the ESP32-S3 that spins the PM soft-off retry loop
+  // forever and starves the app. Anchor each `<prefix>_` token at a leading
+  // word boundary so it matches the intended driver/HAL symbol, not a suffix.
+  const uses = (token: string): boolean => {
+    if (token.endsWith('_')) {
+      return new RegExp(`\\b${token.replace(/[.*+?^${}()|[\]\\]/g, '\\$&')}`).test(src);
+    }
+    return src.includes(token);
+  };
+  const usage: KconfigUsage = {
+    usesAdc: uses('adc_'),
+    usesPwm: uses('pwm_'),
+    usesI2c: uses('i2c_'),
+    usesSpi: uses('spi_'),
+    usesUart: uses('uart_'),
+    usesWdt: uses('wdt_'),
+    usesBle: uses('bt_') || uses('bt_gatt') || uses('bt_le_'),
+    usesDisplay: uses('display_write') || uses('display_init') || uses('display_fill_rect') || uses('__tc_display_dev') || uses('CuttlefishDisplayTarget'),
+    usesTouch: uses('ft6336u') || uses('touch_'),
+    // Power tokens: k_sleep + pm_state_force / PM_STATE_* (what power.ts emits).
+    // The old `power_` token matched nothing the power HAL emits and collides
+    // with tx_power_dbm — removed.
+    usesPower: uses('pm_') || uses('k_sleep') || uses('PM_STATE_'),
+    usesWifi: uses('wifi_') || uses('net_mgmt') || uses('conn_mgr'),
+    // HTTP: the __tc_http_* shim + http_client_req + getaddrinfo. The '_'-anchored
+    // 'http_' token matches __tc_http_* and http_client_req (the core HTTP lib
+    // symbol), mirroring how wifi_ detects the wifi shim. An http-only program
+    // still pulls the networking stack even without usesWifi.
+    usesHttp: uses('http_') || uses('__tc_http') || uses('http_client_req'),
+    // MQTT: the __tc_mqtt_* shim + mqtt_connect/mqtt_publish/mqtt_subscribe.
+    usesMqtt: uses('mqtt_') || uses('__tc_mqtt') || uses('mqtt_connect'),
+    // Preferences: the __tc_prefs_* shim + the settings_* API the shim calls.
+    // settings_load/save_one/delete + SETTINGS_STATIC_HANDLER_DEFINE all emit
+    // `settings_` symbols; __tc_prefs catches the typed accessors (put_int etc.
+    // template into __tc_prefs_put<...>, which keeps the __tc_prefs token).
+    usesPreferences: uses('settings_') || uses('__tc_prefs'),
+    // Random: the __tc_rand_* shim + the sys_rand_get entropy tap it seeds from.
+    usesRandom: uses('__tc_rand') || uses('sys_rand_get'),
+    psram,
+  };
+
+  let changed = false;
+
+  // ── Root CMakeLists.txt ─────────────────────────────────────────────────
+  // The canonical Zephyr CMake application. GLOB src/*.cpp so future multi-
+  // file emits are picked up automatically; cuttlefish owns the file contents.
+  const cmakeLists = [
+    '# Auto-generated by @typecad/framework-zephyr from cuttlefish.config.ts.',
+    'cmake_minimum_required(VERSION 3.20.0)',
+    '',
+    'find_package(Zephyr REQUIRED HINTS $ENV{ZEPHYR_BASE})',
+    '',
+    'project(zephyr_app)',
+    '',
+    '# Collect cuttlefish-emitted sources.',
+    'file(GLOB app_sources src/*.cpp src/*.c)',
+    '',
+    'target_sources(app PRIVATE ${app_sources})',
+    // When PSRAM is configured, define BOARD_HAS_PSRAM so the UI runtime's
+    // PSRAM canvas allocator (ui_create_canvas_best) is compiled in.
+    ...(psram ? ['', '# PSRAM enabled: activate the runtime PSRAM canvas paths.', 'target_compile_definitions(app PRIVATE BOARD_HAS_PSRAM)', ''] : ['']),
+  ].join('\n');
+  if (writeIfChanged(join(projectRoot, 'CMakeLists.txt'), cmakeLists)) changed = true;
+
+  // ── prj.conf ────────────────────────────────────────────────────────────
+  // Driver Kconfig symbols are usage-gated on the emitted source: only a
+  // peripheral whose driver API the program actually references is enabled.
+  // Zephyr's Kconfig treats an enabled-but-unused driver as harmless, BUT
+  // several driver stacks pull in large/specific dependencies — notably
+  // NimBLE (CONFIG_BT) needs Espressif prebuilt blobs that are not always
+  // fetched (`west blobs fetch hal_espressif`). Usage-gating keeps a GPIO-only
+  // blink from requiring those, and shrinks the link for every program. The
+  // core GPIO driver and C++ support stay unconditional. Symbol selection is
+  // delegated to resolveKconfigFragments (unit-tested in dt-config/kconfig).
+  const symbols = resolveKconfigFragments(usage, debug);
+
+  const prjConf: string[] = [
+    '# Auto-generated by @typecad/framework-zephyr from cuttlefish.config.ts.',
+    '# Edit in cuttlefish.config.ts (frameworkData), not here.',
+    '# Driver symbols are usage-gated on the emitted source — only peripherals',
+    '# the program references are enabled.',
+    '',
+    '# Route printf/stdout to the console UART (needed by the @typecad/expect',
+    '# test runner protocol, which uses printf via __tc_print/__tc_println).',
+    'CONFIG_STDOUT_CONSOLE=y',
+    'CONFIG_PRINTK=y',
+    '',
+  ];
+  // Emit a section header before the BT block when present.
+  let btHeaderEmitted = false;
+  let wifiHeaderEmitted = false;
+  for (const [sym, val] of symbols) {
+    if (sym === 'CONFIG_BT' && !btHeaderEmitted) {
+      prjConf.push('', '# Bluetooth (NimBLE peripheral).');
+      btHeaderEmitted = true;
+    }
+    if (sym === 'CONFIG_WIFI' && !wifiHeaderEmitted) {
+      prjConf.push('', '# WiFi / networking (conn_mgr + esp32 wifi driver).');
+      wifiHeaderEmitted = true;
+    }
+    // Skip auto-detected symbols that the user explicitly overrides
+    // in cuttlefish.config.ts zephyr.kconfig — the user value is
+    // emitted in the User Kconfig section below and takes precedence.
+    if (userKconfig && userKconfig.hasOwnProperty(sym)) continue;
+    prjConf.push(`${sym}=${val}`);
+  }
+  // Emit user-specified Kconfig from cuttlefish.config.ts zephyr.kconfig.
+  // These override any matching auto-detected symbol (skipped above).
+  if (userKconfig) {
+    prjConf.push('', '# User Kconfig (cuttlefish.config.ts → zephyr.kconfig).');
+    for (const [sym, val] of Object.entries(userKconfig)) {
+      prjConf.push(`${sym}=${val}`);
+    }
+  }
+  // CONFIG_BT_DEVICE_NAME is a string value not produced by the resolver — add
+  // it after the BT block when BLE is used (parity with the previous inline form).
+  if (usage.usesBle) prjConf.push('CONFIG_BT_DEVICE_NAME="TypeCAD"');
+  prjConf.push('');
+  if (writeIfChanged(join(projectRoot, 'prj.conf'), prjConf.join('\n'))) changed = true;
+  return changed;
+}