bash bloat / fbuild symbols: no arm-none-eabi path; can't measure LPC845 bloat from FastLED's wrapper #594

Summary

bash bloat <board> (ci/bloat.py) is wired only for ESP32-family chips. Running it on lpc845brk fails immediately because there's no arm-none-eabi entry in BOARD_CHIP_MAP. The underlying fbuild symbols already supports any ELF + matching nm, so the gap is purely in the shim.

This blocks per-symbol bloat analysis on the LPC8xx low-memory bring-up — the very target where every byte matters and where the -DFASTLED_LPC_RX_SCT_WS2812=1 config currently overflows the 64 KB FLASH region by 11,112 bytes.

Reproduction

$ bash bloat lpc845brk
Bloat: board 'lpc845brk' has no nm mapping. Add it to BOARD_CHIP_MAP in
ci/bloat.py — entries are mechanical (arch + chip prefix). Supported
boards today: esp32, esp32c3, esp32c6, esp32h2, esp32s2, esp32s3.

ci/bloat.py:75 only registers Xtensa + RISC-V ESP32 chips:

BOARD_CHIP_MAP = {
    "esp32":   ("xtensa", "esp32"),
    "esp32s2": ("xtensa", "esp32s2"),
    "esp32s3": ("xtensa", "esp32s3"),
    "esp32c3": ("riscv",  "esp32c3"),
    "esp32c6": ("riscv",  "esp32c6"),
    "esp32h2": ("riscv",  "esp32h2"),
}

And PIO_NM_BY_ARCH (above) only knows about toolchain-xtensa-* and toolchain-riscv32-esp-elf PIO packages.

What's missing

Three independent gaps:

1. ci/bloat.py BOARD_CHIP_MAP — no arm-none-eabi entry

Need an "arm" arch family that points at the developer-gnu toolchain. The toolchain lives at:

~/.fbuild/prod/cache/toolchains/developer-gnu/<hash>/15.2.Rel1/bin/arm-none-eabi-nm.exe

That's a fbuild cache path, not a ~/.platformio/packages path, so pio_packages_dir() won't find it. The shim needs to either:

• Query fbuild for the resolved nm path (fbuild symbols already supports --build-info for this — build_info.json carries nm_path), or
• Add an alternate "fbuild-managed" toolchain lookup branch alongside the existing PIO branch.

2. fbuild build has no "emit ELF on overflow" mode

When you want to measure over-budget bloat, the build has to succeed enough to produce an ELF. Today, an LD region overflowed by N bytes error is fatal — no ELF emitted, LTO temp objects deleted on exit. The only workaround is to hand-patch the LD script in the fbuild cache (~/.fbuild/prod/cache/platforms/.../lpc845_flash.ld → bump LENGTH = 64K to 128K), build, then revert. That is the workflow I had to use to gather this report.

Reasonable surfaces:

• fbuild build --no-flash-check / --bloat-analysis that bypasses the LD region check (or auto-patches an INPUT(...) override)
• fbuild symbols --over-budget <env> that orchestrates the build + analyze in one step
• Or simply: keep .lto-tmp/*.ltrans*.ltrans.o after a failed link so external nm can be run on the LTO partitions directly

3. bash bloat doesn't speak fbuild-native builds

The shim looks for ELFs at:

build_root / "pio" / board / ".pio" / "build" / board / "firmware.elf"
build_root / board / "firmware.elf"

fbuild emits to .fbuild/build/<env>/release/firmware.elf — that path isn't in the candidate list, so even on green builds bash bloat lpc845brk would still fail to locate the ELF.

What I actually did to work around it

1. Edited platformio.ini to add -DFASTLED_LPC_RX_SCT_WS2812=1
2. Edited ~/.fbuild/prod/cache/.../lpc845_flash.ld to bump FLASH from 64K → 128K
3. Ran fbuild build -e lpc845brk — got a complete firmware.map even when the first attempt failed at link time
4. Parsed the linker map with a one-off Python script to compute per-symbol sizes via address deltas (LTO partitions merge into 2 giant ltrans*.ltrans.o chunks, but the map's 0x... <demangled> lines are still per-symbol)
5. Reverted everything

This worked but is the wrong shape — there should be a one-command path.

Findings the workaround surfaced (separate from the tooling gap)

For tracking, the symbol-level results of the workaround run:

• Total .text with RX_SCT_WS2812=1: 76,272 bytes vs 65,232 budget → +11,040 bytes over (matches linker's +11,112 report within fixup math)
• Top single symbol: fl::CRGB::computeAdjustment(unsigned char, fl::CRGB const&, fl::CRGB const&) = 9,516 bytes (12.5% of .text)
• libgcc double-precision soft-FP cascade pulled in: __adddf3 2,088 + __muldf3 1,392 + __subsf3 1,172 ≈ 5 KB despite the "no soft-FP" invariant
• fl::string::trim() const = 2,966 bytes
• fl::variant<fl::function<…(fl::json const&)>::…> copy/move/destroy clones across the FreeFunction / InlinedLambda / NonConstMember / ConstMember alternatives ≈ 12 KB combined

These are separate FastLED-side bug-class issues and should be filed against FastLED, not fbuild. This issue is purely about the toolchain gap.

Acceptance criteria

• bash bloat lpc845brk runs end-to-end against a fresh build and prints a per-symbol top-N table
• When the build is over-budget, the bloat command surfaces the overage and still produces an ELF + report (degenerate-case workflow)
• The arm-none-eabi-nm from fbuild's developer-gnu toolchain is auto-resolved (no PIO dependency)

Out of scope

• Fixing the actual FastLED-side bloat (file separate issues against FastLED for CRGB::computeAdjustment, soft-FP cascade in low-memory mode, fl::string::trim, etc.)
• Adding more ESP32 chips / adding non-LPC ARM boards (this issue is about the arch family, LPC845 is the test case)