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… platformio-build.py patch _patch_platformio_extra_modules monkey-patched the framework package's scripts/platformio/platformio-build.py to append platform-provisioned modules (_pio/modules) to the ZEPHYR_MODULES CMake variable. The patch was needle-based and not reliably idempotent: a stale floating-URL platform install re-inserted its block on every build (14 duplicate copies found on a real machine), and marker drift on a framework package update would silently drop the module instead -- showing up as '1200-bps DFU touch stopped working'. Replace it with Zephyr's own out-of-tree module mechanism: set the ZEPHYR_EXTRA_MODULES environment variable, which Zephyr's CMake reads through zephyr_get()'s ENV scope (cmake/modules/extensions.cmake). _register_xiao_modules_via_env() collects the framework-cache modules (xiao_dfu_reset, sdk-edge-ai, edge-impulse-sdk-zephyr) plus the XIAO_EDGE_AI_DIR / XIAO_EDGE_IMPULSE_DIR developer overrides and registers them after all provisioning. The dead PIO_NCS_MODULES SCons variable is removed with it. Existing installs keep previously injected blocks in their cached platformio-build.py; those are harmless (dedup-guarded) and simply no longer maintained. Known limitation (accepted): ZEPHYR_EXTRA_MODULES is transient. Zephyr's MERGE-mode zephyr_get() never writes the ENV value into CMakeCache.txt, so a cmake/ninja reconfigure started outside a PlatformIO-driven process (fresh shell, IDE CMake integration) silently drops these modules, where the retired -DZEPHYR_MODULES= injection persisted in the cache. Builds driven by 'pio run' always inherit the variable and are unaffected; after editing CMake files, re-run 'pio run'. Documented in _register_xiao_modules_via_env()'s docstring. Also add docs/zephyr-patch-inventory.md (was untracked): A6 marked retired with no upstream destination, zephyr.py line references re-anchored after the deletion, totals adjusted (A 6->5, total 17->16, upstreamable ~11->~10). Validation (local platform tree, framework-zephyr 4.4.0): - 20B zephyr-blink: CONFIG_XIAO_DFU_RESET=y, xiao_dfu_reset symbols in firmware.elf (incl. __init_xiao_dfu_init) - 20B edgeai-classification: CONFIG_NRF_EDGEAI=y, Axon/EdgeAI symbols in firmware.elf -- sdk-edge-ai registered through the env var only - stm32c5 zephyr-blink: cannectivity/uf2_dfu_reset/xiao_dfu_reset all present in build.ninja via the env mechanisms - installed platformio-build.py stayed unpatched across all builds Co-Authored-By: Claude <noreply@anthropic.com>
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Summary
Retire the
_patch_platformio_extra_modulesmonkey-patch (inventory item A6) and replace it with Zephyr's own out-of-tree module mechanism.Why: the patch edited the framework package's
scripts/platformio/platformio-build.py(needle-based) to append platform-provisioned modules toZEPHYR_MODULES. It was not reliably idempotent — a stale floating-URL platform install re-inserted its block on every build (14 duplicate copies found on a real machine), and marker drift on a framework package update would silently drop the module, surfacing as "1200-bps DFU touch stopped working".What:
_register_xiao_modules_via_env(): collects_pio/modulescache modules (xiao_dfu_reset,sdk-edge-ai,edge-impulse-sdk-zephyr) plusXIAO_EDGE_AI_DIR/XIAO_EDGE_IMPULSE_DIRdeveloper overrides, and registers them via theZEPHYR_EXTRA_MODULESenv var — which Zephyr's CMake reads throughzephyr_get()'s ENV scope (cmake/modules/extensions.cmake). Called after all provisioning.PIO_NCS_MODULESSCons variable removed.platformio-build.pyfor module discovery.Existing installs keep previously injected blocks in their cached
platformio-build.py— harmless (dedup-guarded), simply no longer maintained.Validation (local platform tree, framework-zephyr 4.4.0)
zephyr-blinkCONFIG_XIAO_DFU_RESET=y;xiao_dfu_resetsymbols infirmware.elfincl.__init_xiao_dfu_initedgeai-classificationCONFIG_NRF_EDGEAI=y; 118 Axon/EdgeAI symbols infirmware.elf— sdk-edge-ai registered through the env var onlyseeed-xiao-stm32c5zephyr-blinkbuild.ninjavia the env mechanismsplatformio-build.pystayed unpatched across all three buildsnRF54L15 has no example set and uses no XIAO modules (its Kconfig gates on the 20B board symbol), so it is unaffected by construction.
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