image: slot-sized release rootfs, ext4 artifact, fwup, mkfw.sh

The release image now targets the 200 MiB factory eMMC slot: content
plus 40 MiB working space, hard build failure past the slot size. The
raw ext4 is deployed alongside the wic; scripts/mkfw.sh packs it into
a signed .fw with factory-pattern upgrade.a/upgrade.b tasks. fwup
1.16.0 recipe (applies ForgeFIRM and Glowforge-signed archives on
device) is installed in both images. Dev images stay SD-sized with a
256 MiB working margin and no ceiling.

Verified on the 20260808153331 build: release ext4 180.8 MiB; signed
.fw applies byte-exact with fwup 1.16.0 and with the factory's 0.14.2
(raw-format pubkey), and 0.14.2 -V verifies the signature.

docs/BRINGUP.md

@@ -113,6 +113,15 @@ motion constants were extracted from the `_RESOURCES` pulse files
   kas/forgefirm-glowforge.yml -c 'bitbake forgefirm-image
   forgefirm-image-dev'`. Artifacts:
   `forgefirm/build/tmp/deploy/images/glowforge/`.
+- **fwup lab (host)**: `~/fwup-lab/bin/` holds host-built `fwup-0.14.2`
+  (factory-era) and `fwup-v1.16.0`; `~/fwup-lab/devkeys/fwup-key.{priv,pub}`
+  is the DEV signing keypair (`fwup-key-raw.pub` = raw 32-byte form —
+  what fwup 0.14.2 expects; 1.x reads both). Cross-version compat is
+  proven both ways (modern-packed signed archives apply with 0.14.2;
+  modern fwup verifies+applies the factory .fw — signer key
+  2017-05-001.pub). The production release key does not exist yet —
+  generation/custody is an operator ceremony (UPDATE-SYSTEM.md gate 3).
+  Pack releases with `scripts/mkfw.sh`.
 - **Shell gotchas** (cost real time): PowerShell mangles embedded double
   quotes in git-commit here-strings (avoid `"` in messages); `wsl -- bash
   -c '...'` eats `$VAR` expansions (use script files run via PowerShell,

meta-forgefirm/recipes-extended/fwup/fwup_1.16.0.bb

@@ -0,0 +1,14 @@
+SUMMARY = "Configurable embedded Linux firmware update creator and runner"
+DESCRIPTION = "Applies and creates signed .fw firmware archives. ForgeFIRM \
+uses the factory's own update format: fwup applies ForgeFIRM upgrades and \
+Glowforge factory-restore archives to the inactive rootfs slot."
+HOMEPAGE = "https://github.com/fwup-home/fwup"
+LICENSE = "Apache-2.0"
+LIC_FILES_CHKSUM = "file://LICENSE;md5=3b83ef96387f14655fc854ddc3c6bd57"
+
+DEPENDS = "libconfuse libarchive libsodium"
+
+SRC_URI = "https://github.com/fwup-home/fwup/releases/download/v${PV}/fwup-${PV}.tar.gz"
+SRC_URI[sha256sum] = "a07b79268247ecee134a916ab928914be2a4ecbac0bc5e5f19212ec36ecb5c21"
+
+inherit autotools pkgconfig bash-completion

meta-forgefirm/recipes-forgefirm/images/forgefirm-image-dev.bb

@@ -12,6 +12,11 @@ IMAGE_FEATURES += " \
   tools-debug \
 "
 
+# Dev images boot from SD, never from a 200 MiB eMMC slot: lift the slot
+# ceiling and give the filesystem generous working space instead.
+IMAGE_ROOTFS_MAXSIZE = ""
+IMAGE_ROOTFS_EXTRA_SPACE = "262144"
+
 # Dev builds identify by build timestamp (matches the artifact name),
 # tagged so a bench machine is never mistaken for a release.
 FORGEFIRM_VERSION_STRING = "${DATETIME} (dev)"

meta-forgefirm/recipes-forgefirm/images/forgefirm-image.bb

@@ -16,7 +16,19 @@ IMAGE_INSTALL:remove = "gfui-client"
 # for $H when homing_mode = gfcloud (/data/forgefirm.conf).
 # v4l-utils provides media-ctl / v4l2-ctl for the imx-media pipeline (also a
 # forgectrl runtime dependency, kept explicit here for bring-up use).
-IMAGE_INSTALL:append = " grblhal-glowforge forgectrl gfhome v4l-utils"
+# fwup: applies signed .fw archives (ForgeFIRM upgrades + factory restore)
+# to the inactive rootfs slot.
+IMAGE_INSTALL:append = " grblhal-glowforge forgectrl gfhome v4l-utils fwup"
+
+# The release rootfs must fit a 200 MiB factory eMMC slot (409600 blocks).
+# Sizing: content + 40 MiB working space, hard-capped at the slot size —
+# the build fails rather than emit an unflashable image. The raw ext4 is
+# deployed alongside the wic; scripts/mkfw.sh packs it into the signed
+# .fw release artifact.
+IMAGE_FSTYPES:append = " ext4"
+IMAGE_OVERHEAD_FACTOR = "1.0"
+IMAGE_ROOTFS_EXTRA_SPACE = "40960"
+IMAGE_ROOTFS_MAXSIZE = "204800"
 
 # Version stamp: /etc/forgefirm-version (machine-readable), echoed on the
 # serial-console login prompt (/etc/issue) and at SSH login (motd).

scripts/mkfw.sh

@@ -0,0 +1,85 @@
+#!/bin/sh
+# (C) Copyright 2020-2026
+# Scott Wiederhold, s.e.wiederhold@gmail.com
+# https://community.openglow.org
+# SPDX-License-Identifier:    MIT
+#
+# Packs a ForgeFIRM rootfs.ext4 into a fwup .fw archive with the factory
+# update task layout: upgrade.a / upgrade.b raw-write the rootfs into eMMC
+# slot p1 / p2 (fwup is invoked with -d /dev/mmcblk2p<N>, so offsets are
+# partition-relative, exactly like the factory updater).
+#
+# Usage: mkfw.sh <rootfs.ext4> <version> <output.fw> [private-key]
+#   FWUP=<path> overrides the fwup binary (any 1.x; archives verified to
+#   apply with the factory's fwup 0.14.2).
+#   Unsigned output (no key) is for dev only: release and updater paths
+#   require a signature.
+
+set -e
+
+FWUP="${FWUP:-fwup}"
+ROOTFS="$1"
+VERSION="$2"
+OUT="$3"
+KEY="$4"
+
+usage () {
+  echo "usage: mkfw.sh <rootfs.ext4> <version> <output.fw> [private-key]" >&2
+  exit 2
+}
+
+[ -n "$ROOTFS" ] && [ -n "$VERSION" ] && [ -n "$OUT" ] || usage
+[ -f "$ROOTFS" ] || { echo "ERROR: rootfs '$ROOTFS' not found" >&2; exit 1; }
+command -v "$FWUP" >/dev/null || { echo "ERROR: fwup not found (set FWUP=)" >&2; exit 1; }
+
+# The rootfs must fit the 200 MiB factory slot (409600 x 512-byte blocks).
+SLOT_BYTES=209715200
+SIZE=$(wc -c < "$ROOTFS")
+[ "$SIZE" -le "$SLOT_BYTES" ] || {
+  echo "ERROR: rootfs is $SIZE bytes; slot holds $SLOT_BYTES" >&2; exit 1; }
+
+WORK=$(mktemp -d)
+trap 'rm -rf "$WORK"' EXIT
+cp "$ROOTFS" "$WORK/rootfs.ext4"
+
+cat > "$WORK/fwup.conf" <<EOF
+meta-product = "ForgeFIRM firmware"
+meta-description = "ForgeFIRM firmware for Glowforge brand CNC lasers"
+meta-version = "${VERSION}"
+meta-platform = "glowforge"
+meta-architecture = "arm"
+meta-author = "OpenGlow"
+
+file-resource rootfs.ext4 {
+    host-path = "${WORK}/rootfs.ext4"
+}
+
+task upgrade.a {
+    require-unmounted-destination = true
+    verify-on-the-fly = true
+    on-resource rootfs.ext4 { raw_write(0) }
+}
+
+task upgrade.b {
+    require-unmounted-destination = true
+    verify-on-the-fly = true
+    on-resource rootfs.ext4 { raw_write(0) }
+}
+EOF
+
+"$FWUP" -c -f "$WORK/fwup.conf" -o "$WORK/unsigned.fw"
+
+if [ -n "$KEY" ]; then
+  [ -f "$KEY" ] || { echo "ERROR: key '$KEY' not found" >&2; exit 1; }
+  "$FWUP" -S -s "$KEY" -i "$WORK/unsigned.fw" -o "$OUT"
+  PUB="${KEY%.priv}.pub"
+  if [ -f "$PUB" ]; then
+    "$FWUP" -V -i "$OUT" -p "$PUB" || { echo "ERROR: signature self-check failed" >&2; exit 1; }
+  fi
+  echo "signed: $OUT"
+else
+  cp "$WORK/unsigned.fw" "$OUT"
+  echo "UNSIGNED (dev only): $OUT"
+fi
+
+"$FWUP" -m -i "$OUT" | head -4