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perf(esp32): cut SDK -I fan-out from 385 dirs to PlatformIO's curated list - #1543

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perf/esp32-include-fanout
Sep 28, 2026
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zackees merged 3 commits into
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perf/esp32-include-fanout

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@zackees

@zackees zackees commented Sep 28, 2026 •

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Problem

Part of #1537 (cause 1). ESP32-S3 cold builds pass 385 -I directories; PlatformIO passes 199 for the same framework, same toolchain, same flags — fbuild even omits pio's -ggdb, which should make it faster.

Reproduced locally on bench/blink -e esp32s3 (16-core Linux, espressif32@6.13.0, framework 3.20017.241212+sha.dcc1105b):

command -I count time (min of 3)
fbuild flags + fbuild includes 385 0.652s
same invocation, PlatformIO's include list 201 0.462s

~41% per translation unit, paid by all 47 TUs.

Root cause

get_sdk_include_dirs reads flags/includes when the SDK has one. The arduino-esp32 2.x layout used by this fixture has no such file (its SDK is tools/sdk/<mcu>, not tools/esp32-arduino-libs/<mcu>), so it falls back to reconstructing the list by scanning include/ to a fixed depth. That scan is wrong in both directions:

  • Too shallow — it misses leaves PlatformIO passes. bt/common/api/include/api, bt/host/bluedroid/api/include/api and lwip/port/esp32/include/arch are absent today, so any header reached through them does not resolve. This is a latent correctness bug, not only a perf one.
  • Too greedy — it emits ~220 dirs PlatformIO never passes: per-chip dirs for other chips (soc/esp32, esp_system/port/soc/esp32c3, esp_hw_pm/include/esp32s2, idf_test/include/esp32h2), component test dirs (json/cJSON/tests), and an esp-dsp fan-out.

Every extra -I costs a failed path lookup on every unresolved #include, and these SDK paths are deep, so the cost is real per TU.

Fix

Those framework layouts do ship an authoritative list: the SCons builder PlatformIO itself uses for that exact framework version, tools/platformio-build-<mcu>.py. Its CPPPATH block is the include list, in PlatformIO's order — every entry a literal join(FRAMEWORK_DIR, "...").

Parse it and use it, keeping the existing flags/includes path for the newer layout and the tree scan as the last resort. Entries computed from env.BoardConfig() (the flash/PSRAM variant dir, the core dir) are skipped, since the caller already supplies those.

A parse yielding fewer than 20 entries is treated as a failure, not trusted, so an upstream format change degrades to today's behaviour rather than silently truncating the include path.

Verification

  • bench/blink -e esp32s3: 385 → 200 -I (PlatformIO: 199), with the previously-missing deep leaves now present, and the cold build compiles and links to the same firmware.
  • Two new tests: the builder-script list wins over the tree scan (including that the scan's decoy is not included, and that script order is preserved), and an unparseable script falls back to the tree scan.
  • soldr cargo test -p fbuild-library esp32_framework — 36 passed.
  • Full unit suite: 3118 passed; the only failure is the pre-existing fbuild-python libpython3.13.so.1.0 loader error on this box (system Python is 3.14), unrelated to this change.
  • soldr cargo clippy --workspace --all-targets clean; soldr cargo fmt --all applied.

Refs #1537

Summary by CodeRabbit

  • Bug Fixes
    • Improved ESP32-S3 SDK include-directory discovery for older PlatformIO layouts, including deeply nested include paths that may be missed by a directory scan.
    • When the builder script does not provide enough usable paths, discovery continues to fall back to scanning the SDK directories. Existing memory-variant include paths are also retained when available.

… list

ESP32-S3 cold builds pass 385 `-I` directories where PlatformIO passes 199.
Same toolchain, same flags — fbuild even omits pio's `-ggdb`. Swapping only
the include list moves a single translation unit ~41% (0.652s -> 0.462s,
min of 3, one TU, same g++ invocation both sides), and the whole 47-TU
build pays it, so this is the largest single term in the cold-build gap
reported in #1537.

The fan-out comes from `get_sdk_include_dirs`'s fallback: when the SDK has
no `flags/includes` (every arduino-esp32 2.x layout, e.g. the
`espressif32@6.13.0` fixture, whose SDK lives at `tools/sdk/<mcu>`), it
reconstructs the list by scanning `include/` to a fixed depth. That scan is
wrong in both directions:

  - too shallow: it misses leaves PlatformIO passes, so
    `bt/common/api/include/api`, `bt/host/bluedroid/api/include/api` and
    `lwip/port/esp32/include/arch` are absent and any header reached through
    them fails to resolve;
  - too greedy: it emits ~220 dirs PlatformIO never passes, including
    per-chip dirs for *other* chips (`soc/esp32`, `port/soc/esp32c3`,
    `esp_hw_pm/include/esp32s2`), component test dirs (`json/cJSON/tests`)
    and an `esp-dsp` fan-out.

Every extra `-I` costs a failed path lookup on every unresolved `#include`,
and these paths are deep, so the cost is real per TU.

Those framework layouts do ship an authoritative list: the SCons builder
PlatformIO itself uses for that exact framework version,
`tools/platformio-build-<mcu>.py`, whose `CPPPATH` block is the include list
in PlatformIO's order. Parse it and use it, keeping the existing
`flags/includes` path for the newer layout and the tree scan as the last
resort.

A parse that yields fewer than 20 entries is treated as a failure rather than
trusted, so an upstream format change degrades to today's behaviour instead
of silently truncating the include path. Entries computed from
`env.BoardConfig()` (the flash/PSRAM variant dir, the core dir) are skipped;
the caller already supplies those.

Measured on bench/blink -e esp32s3: 385 -> 200 `-I` (PlatformIO: 199), with
the previously-missing deep leaves now present, and the cold build compiles
and links to the same firmware.

Refs #1537
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📒 Files selected for processing (2)
  • crates/fbuild-library/src/library/esp32_framework/sdk_paths.rs
  • crates/fbuild-library/src/library/esp32_framework/tests.rs
📝 Walkthrough

Walkthrough

SDK include discovery now parses existing include paths from the PlatformIO builder script when the usual include data is unavailable. If the parsed list does not meet the minimum entry count, discovery retains the recursive tree-scan fallback.

Changes

ESP32 SDK include discovery

Layer / File(s) Summary
Parse builder CPPPATH entries
crates/fbuild-library/src/library/esp32_framework/sdk_paths.rs
Helpers extract literal paths from the builder script’s CPPPATH block, keep existing paths, and deduplicate them. The parser returns no paths when fewer than 20 entries qualify.
Use parsed paths and validate fallback
crates/fbuild-library/src/library/esp32_framework/sdk_paths.rs, crates/fbuild-library/src/library/esp32_framework/tests.rs
SDK include discovery uses parsed paths when available and appends the selected existing memory-variant directory if it is absent. Tests cover script order, nested paths, decoy exclusion, and tree-scan fallback when too few paths qualify.

Priority: ➖ Normal

Estimated code review effort: 2 (Simple) | ~15 minutes

Change: Bug fix

Merge Risk: 🟡 Moderate · up to 55d63

Repeated builder paths could leave required SDK headers undiscovered and break an ESP32 build. Apply the threshold after deduplication before merging.

Security Architecture Review

Security architecture risk: 🟡 Moderate · up to 55d63

The new include discovery can accept paths outside the installed framework and pass them to ESP32 compilation. This warrants checking the trust placed in framework packages and overrides; the available evidence does not establish an exploitable build or a compromised package.

Retained concerns

  • Medium · security · inferred: Builder-script literals can select existing include directories outside the framework root and propagate them to ESP32 compiler invocations. The security consequence is conditional on who can influence the installed framework; package trust and an intended containment exception remain unverified.
Security review details

Security Blast Radius

  • inferred — An accepted include path can affect header resolution across ESP32 translation-unit categories using the shared compiler inputs; the evidence does not show an effect on other targets or deployment environments.

Security Findings and Attack Paths

  • inferred — If an actor can alter an otherwise-used framework builder script, adding an existing outside-root path to a qualifying CPPPATH list can influence compiler header search. No evidence establishes that an actor lacking prior control of framework contents can do so.

Trust Boundaries and Controls

  • observed — The parser requires an installed script, skips lines containing env., requires existing paths and a minimum entry count, and does not execute script code. Those checks do not verify that a selected path stays beneath the framework root.

Resilience and Maintainability Implications

  • observed — Tests cover script order, exclusion of a scan-only decoy, and fallback for too few entries; they do not establish behavior for an existing path outside the framework root.

Hardening Proposals

  • proposed — Establish the intended trust and path-containment contract for framework packages and overrides; if outside-root includes are not intentional, validate parsed paths against the resolved framework root while preserving documented exceptions.
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✅ Passed checks (5 passed)
Check name Status Explanation
Description Check ✅ Passed Check skipped - CodeRabbit’s high-level summary is enabled.
Title check ✅ Passed The title clearly summarizes the main change: reducing ESP32 SDK include-path fan-out by using PlatformIO's curated list. It is specific, concise, and related to the changeset.
Docstring Coverage ✅ Passed Docstring coverage is 100.00% which is sufficient. The required threshold is 80.00%. Docstring coverage is scoped to functions touched by this diff. Analyzed 6 functions across 2 files.
Linked Issues check ✅ Passed Check skipped because no linked issues were found for this pull request.
Out of Scope Changes check ✅ Passed Check skipped because no linked issues were found for this pull request.
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Actionable comments posted: 1


  • 🪄 Fix CodeRabbit comments on this PR
🤖 Prompt to fix review comments
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Inline comments:
Review comments at
@crates/fbuild-library/src/library/esp32_framework/sdk_paths.rs:
- Around line 83-88: In the directory-listing function, deduplicate `dirs` with
the existing `seen` set before checking `MIN_PIO_CPPPATH_ENTRIES`; apply the
threshold to the distinct paths so undersized results use the existing fallback.

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Comment thread crates/fbuild-library/src/library/esp32_framework/sdk_paths.rs Outdated
@zackees

zackees commented Sep 28, 2026

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Effect on compiled output (disclosed deliberately)

This changes which headers a few #includes resolve to, so the firmware is not byte-identical to main. I checked what actually moves, and it is narrower than "the include list changed":

Preprocessing Esp.cpp under the old 385-dir list vs the new 199-dir list (fbuild's framework root, identical compiler, -E -P) gives 31,455 vs 31,456 lines with 10/12 differing lines — all of them assert-related:

old (385) new (199)
__assert_func decl extern void __assert_func(const char *, int, const char *, const char *); same, plus __attribute__((__noreturn__))
__assert absent void __assert(const char *, int, const char *) __attribute__((__noreturn__));

Both lists resolve the standard assert.h to the same file (tools/sdk/esp32s3/include/newlib/platform_include/assert.h) and the assert() expansion is identical in both. The only difference is that the new list reaches the toolchain's own xtensa-esp32s3-elf/sys-include/assert.h, which declares __assert_func as __noreturn__, where the old list reached hal/platform_port/include/hal/assert.h.

So the behavioural delta is: one extra __noreturn__ attribute the compiler is entitled to assume (it is a correct attribute for that function), and an extra declaration. Codegen may shift slightly as a result — that is the source of the binary difference. Semantics are unchanged, and the new resolution is the one PlatformIO produces for the same framework.

Verified: main firmware differs; the two post-change builds here are byte-identical to each other (firmware.bin abe3b6ae285fe8f6, firmware.elf 1a1e79faf9b22fbb).

Worth a reviewer's eye precisely because it is a build-output change, not a pure refactor.

zackees added a commit that referenced this pull request Sep 28, 2026
…uild) (#1544)

Cache-key construction normalizes every path-bearing compiler flag of every
translation unit. `path_arg_for_compile_cwd` canonicalizes *both* the path and
the compile cwd on each call, so building the ESP32-S3 framework-core cache
key performs, per build:

  385 include dirs x 46 core sources x 2 (path + cwd) = ~35,000 realpath(2)

The cwd is the same value in all 35,420 calls and the include dirs are the
same 385 for every source, so ~386 distinct resolutions are repeated 35,000
times. Measured on bench/blink -e esp32s3 (16-core Linux), this is the bulk of
the unaccounted time between the `framework-libs cache` and `framework core
cache` log lines, where no perf phase is open: it is cache-state independent
and identical on warm and cold builds.

`canonicalize_lexical` now memoizes its **successful `realpath` results only**.
The parent-plus-filename fallback is deliberately not memoized: that is the
branch answering for paths that do not exist yet, and caching it would keep
reporting a directory as missing for the rest of the process, so a
not-yet-created include dir would never resolve. A memo hit is therefore
always a path that existed and was resolved once. The map is capped at 8192
entries so a long-lived daemon cannot grow it without bound.

Fixing this at `canonicalize_lexical` rather than at the ESP32 call site also
covers the other sites that build signatures the same way —
`refresh_command_hashes` and `needs_rebuild_with_signature` run the same
per-flag normalization.

Measured (3 interleaved cold trials each, median, true cache misses):

  wall        5.96s -> 4.81s
  unphased     709ms -> 218ms

The saving overlaps PR #1543 (fewer include dirs means fewer realpath calls
too): on top of that change it is a further 3.97s -> 3.79s.

The core-cache key is unchanged by this commit (`41b106e21c2b` before and
after), which is the point: memoizing a pure function must not move the cache.

Refs #1537
`parse_pio_cpppath` counted parsed entries before deduplicating them, so a
script that repeated one entry enough times would clear
`MIN_PIO_CPPPATH_ENTRIES` and then dedupe down to a single-directory include
path - exactly the silent truncation that threshold exists to prevent.

Dedupe first, then apply the threshold, so the count that decides trust is the
number of distinct directories.

Adds a regression test that pads the CPPPATH block with 30 copies of one entry
and asserts the tree-scan fallback runs instead.
@zackees

zackees commented Sep 28, 2026

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Fixed in 85a5039 — dedupe now runs before the threshold, so the count that decides trust is distinct paths. Added a regression test that pads the CPPPATH block with 30 copies of one entry and asserts the tree-scan fallback runs.

Re-verified end-to-end after the change: 200 -I dirs (from 385), and firmware.bin/firmware.elf still hash to abe3b6ae285fe8f6/1a1e79faf9b22fbb — identical to the build validated before this fix, as expected since the real script has no duplicates.

@zackees

zackees commented Sep 28, 2026

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@zackees
zackees merged commit 601f327 into main Sep 28, 2026
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