Implement conditional ARDUINO_USB_MODE: dev=1, release=0 to fix boot hanging

pio-scripts/conditional_usb_mode.py

@@ -0,0 +1,73 @@
+#!/usr/bin/env python3
+"""
+Conditional USB Mode Script for WLED-MM
+
+This script automatically sets ARDUINO_USB_MODE based on the build context:
+- For development builds: ARDUINO_USB_MODE=1 (allows USB debugging)  
+- For release builds (CI): ARDUINO_USB_MODE=0 (allows normal boot without USB debugger)
+
+The script detects release builds by checking for the WLED_RELEASE environment variable
+which is set to True in the GitHub Actions CI workflow.
+"""
+
+Import('env')
+import os
+
+def conditional_usb_mode(env):
+    """
+    Conditionally set ARDUINO_USB_MODE based on build context.
+
+    For ESP32-C3, ESP32-S2, and ESP32-S3 variants:
+    - Development builds: ARDUINO_USB_MODE=1 (default, good for debugging)
+    - Release builds: ARDUINO_USB_MODE=0 (prevents hanging without USB debugger)
+    """
+
+    # Check if this is a release build (CI sets WLED_RELEASE=True)
+    is_release_build = os.environ.get('WLED_RELEASE', '').lower() in ('true', '1', 'yes')
+
+    if is_release_build:
+        print("WLED Release build detected - setting ARDUINO_USB_MODE=0 for production")
+
+        # Find and modify ARDUINO_USB_MODE in build flags
+        build_flags = env.get('BUILD_FLAGS', [])
+        cpp_defines = env.get('CPPDEFINES', [])
+
+        # Look through CPPDEFINES and modify ARDUINO_USB_MODE if found
+        modified = False
+        new_defines = []
+
+        for define in cpp_defines:
+            if isinstance(define, (list, tuple)) and len(define) == 2:
+                if define[0] == 'ARDUINO_USB_MODE' and define[1] == '1':
+                    # Change ARDUINO_USB_MODE from 1 to 0 for release builds
+                    new_defines.append(('ARDUINO_USB_MODE', '0'))
+                    modified = True
+                    print(f"  Changed ARDUINO_USB_MODE from 1 to 0")
+                else:
+                    new_defines.append(define)
+            else:
+                new_defines.append(define)
+
+        if modified:
+            env.Replace(CPPDEFINES=new_defines)
+
+        # Also check raw build flags for -DARDUINO_USB_MODE=1
+        new_build_flags = []
+        for flag in build_flags:
+            if isinstance(flag, str) and 'ARDUINO_USB_MODE=1' in flag:
+                # Replace ARDUINO_USB_MODE=1 with ARDUINO_USB_MODE=0
+                new_flag = flag.replace('ARDUINO_USB_MODE=1', 'ARDUINO_USB_MODE=0')
+                new_build_flags.append(new_flag)
+                modified = True
+                print(f"  Modified build flag: {flag} -> {new_flag}")
+            else:
+                new_build_flags.append(flag)
+
+        if modified:
+            env.Replace(BUILD_FLAGS=new_build_flags)
+
+    else:
+        print("Development build detected - keeping ARDUINO_USB_MODE=1 for debugging")
+
+# Apply the conditional USB mode logic
+conditional_usb_mode(env)

platformio.ini

@@ -220,6 +220,7 @@ ldscript_16m14m = eagle.flash.16m14m.ld
 extra_scripts =
   pre:pio-scripts/set_version.py
   pre:pio-scripts/build-html.py
+  pre:pio-scripts/conditional_usb_mode.py
   post:pio-scripts/output_bins.py
   post:pio-scripts/strip-floats.py
   pre:pio-scripts/user_config_copy.py