FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

dejans — Tue, 25 Nov 2025 08:51:34 GMT

Hi Milan,

You could check if there are any unused features and drivers that can be disabled in your application. You could also consider disabling logging. Additionally, you can look at this guide for some hints.

Best regards,
Dejan

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

Milan Pipaliya — Mon, 24 Nov 2025 11:02:58 GMT

here means is

when one paripheral disable that time my nearly 99% flash use that time not boot and more 2 paripheral disable that time 94% flash usage in primary app usage that time build ,flash,boot successfully

it means flash overflow issue

when i secondary app partition remove so primary app total 800KB available and its working with all paripheral my firmware use 400 KB its perfectly working

so when we primary and secondary parition that time flash overflow after adding this aws_iot_mqtt part it use huge flash usage so any solution for reduce flash usage

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

dejans — Mon, 24 Nov 2025 10:31:29 GMT

Hi Milan,

[quote user="Milan Pipaliya"]merge time we check different scinarios check like

1) when we we one of paripheral disable that time build but flash is full thats why not boot
2) when we multiple 2 or 3 paripheral disable that time build flash and boot also[/quote]

Can you elaborate on 2 mentioned scenarios?
Are there any other differences between 2 mentioned scenarios apart from different number of peripherals disabled?

Best regards,
Dejan

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

Milan Pipaliya — Sat, 22 Nov 2025 04:39:36 GMT

merge time we check different scinarios check like

1) when we we one of paripheral disable that time build but flash is full thats why not boot
2) when we multiple 2 or 3 paripheral disable that time build flash and boot also

so my concern is after merge aws_iot_mqtt example to our main code that time our flash is overflow due to above reason as i mantion my firmware is nearly 400KB but partitions.yml dynamically set 384KB thats why flash overflow is final conclusion

so please guide us how to manage it

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

dejans — Fri, 21 Nov 2025 14:21:04 GMT

Hi Milan,

It is not clear to me if you managed to build and flash your project successfully or your build failed with the error due to flash overflow? Can you clarify this?

Best regards,
Dejan

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

Milan Pipaliya — Fri, 21 Nov 2025 12:53:24 GMT

Hi Dejan,

Thanks for the support.

Yes, the main issue right now is flash overflow.
When we merge the AWS IoT MQTT + mbedTLS configs, our firmware size increases to ~400 KB, but our primary app partition is only 384 KB (because we use OTA/DFU with two app partitions).
Because of this, the build fails inside TF-M due to FLASH overflow.

We have already shared our prj.conf, pm_static.yml, and the merged AWS code.
Could you please guide us on whether it’s possible to reduce flash usage or optimize the configuration so that AWS IoT can fit within the available partition size?

Best regards,
Milan

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

dejans — Fri, 21 Nov 2025 11:53:43 GMT

Hi,

Are you able to get any logs if you add CONFIG_AWS_IOT_LOG_LEVEL_DBG and CONFIG_MQTT_HELPER_LOG_LEVEL_DBG?

Best regards,
Dejan

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

Milan Pipaliya — Wed, 19 Nov 2025 13:54:07 GMT

We are currently developing an application on the nRF9151 using nRF Connect SDK 2.9.0.
The project integrates multiple peripherals and features, all of which are working correctly with DFU OTA support.

Integrated Peripherals
SPI Interfaces

MAX30001G – ECG acquisition module

MT29F NAND Flash – External storage

I2C Interfaces

RTC module

LIS2DW12 – Accelerometer

NPM1300 – Power management IC

UART Interface

SIWG917Y Wi-Fi module

Current Application Status

All major functionalities are implemented and working as expected.

DFU OTA update mechanism is functional and stable.

Upcoming Enhancement

We now want to extend the application by adding Cellular connectivity (LTE-M / NB-IoT) in addition to the existing Wi-Fi support.
The goal is to have both Wi-Fi and Cellular as available communication options, integrated cleanly within the same firmware.

NO as per above configuration boot so no log and no led on

now we using partitions.yml using we create pm_static.yml and we add configuration in main code and cellular aws driver add and prj.conf change but not call just add

now our main code boot but cellular modular code not boot

# AWS IoT MQTT
CONFIG_AWS_IOT_LOG_LEVEL_DBG=y
CONFIG_AWS_TEST_SUITE_DQP=n
CONFIG_MQTT_LIB=y
CONFIG_MQTT_LIB_TLS=y
CONFIG_MQTT_KEEPALIVE=600
CONFIG_MQTT_LIB_TLS_USE_ALPN=y

# TLS (nRF Security only)
CONFIG_NRF_SECURITY=y
CONFIG_MBEDTLS_TLS_LIBRARY=y
CONFIG_MBEDTLS_LEGACY_CRYPTO_C=y
CONFIG_MBEDTLS_ENABLE_HEAP=y
CONFIG_MBEDTLS_HEAP_SIZE=10240
CONFIG_MBEDTLS_SSL_MAX_CONTENT_LEN=10240
CONFIG_MBEDTLS_PEM_CERTIFICATE_FORMAT=y
CONFIG_MBEDTLS_SERVER_NAME_INDICATION=y
CONFIG_MBEDTLS_AES_ROM_TABLES=y
CONFIG_MBEDTLS_TLS_VERSION_1_2=y
CONFIG_MBEDTLS_MEMORY_DEBUG=y
CONFIG_MBEDTLS_HAVE_TIME_DATE=y
CONFIG_MBEDTLS_SSL_ALPN=y
CONFIG_MBEDTLS_SSL_CLI_C=y
CONFIG_MBEDTLS_X509_CRT_PARSE_C=y
CONFIG_MBEDTLS_KEY_EXCHANGE_ECDHE_ECDSA_ENABLED=y
CONFIG_MBEDTLS_KEY_EXCHANGE_ECDH_ECDSA_ENABLED=y
CONFIG_MBEDTLS_KEY_EXCHANGE_PSK_ENABLED=y
CONFIG_MBEDTLS_KEY_EXCHANGE_ECDHE_PSK_ENABLED=y
CONFIG_MBEDTLS_SSL_SRV_C=y
CONFIG_MBEDTLS_KEY_EXCHANGE_RSA_ENABLED=y
CONFIG_MBEDTLS_CIPHER=y
CONFIG_MBEDTLS_MD=y
CONFIG_MBEDTLS_PK_C=y
CONFIG_MBEDTLS_PK_PARSE_C=y
CONFIG_MBEDTLS_PK_WRITE_C=y
CONFIG_MBEDTLS_RSA_C=y
CONFIG_MBEDTLS_PKCS1_V15=y
CONFIG_MBEDTLS_ECP_C=y
CONFIG_MBEDTLS_ECDSA_C=y
CONFIG_MBEDTLS_ECDH_C=y
CONFIG_MBEDTLS_DHM_C=y
CONFIG_MBEDTLS_GCM_C=y
CONFIG_MBEDTLS_SHA256_C=y
CONFIG_MBEDTLS_X509_USE_C=y
CONFIG_MBEDTLS_SSL_CONTEXT_SERIALIZATION=y
CONFIG_MBEDTLS_SSL_PROTO_TLS1_2=y

# LTE/Modem
CONFIG_NRF_MODEM_LIB=y
CONFIG_LTE_LINK_CONTROL=y

# Sockets offload for modem (if using LTE for AWS)
CONFIG_NET_NATIVE=n
CONFIG_NET_SOCKETS_OFFLOAD=y

# AWS IoT MQTT Helper
CONFIG_MQTT_HELPER_SEC_TAG=212

# SNTP
CONFIG_SNTP=y
CONFIG_SNTP_LOG_LEVEL_DBG=y

so we want configurtion and modular code which work saperatly and after merge it working

so please guide us to solve

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

dejans — Wed, 19 Nov 2025 13:04:06 GMT

Hi,

[quote user=""]The project builds until TF-M, but after merging AWS configs, the build fails with a FLASH overflow inside TF-M[/quote]

How did you resolve this initial error?

Can you provide details about your main application? What is your final goal after integrating AWS IoT functionality?

Do you get any output after resetting the board? Do you have any log that you can share?

Best regards,
Dejan

RE: FLASH overflow when merging AWS IoT MQTT sample into existing project (TF-M overflow issue)

Milan Pipaliya — Tue, 18 Nov 2025 06:50:47 GMT

after updating my

pm_static.yml my code successfully build and flash but not run other prj config, overlay as it is

updated pm_static.yml

EMPTY_0:
  address: 0xc000
  end_address: 0x10000
  placement:
    before:
      - mcuboot_pad
  region: flash_primary
  size: 0x4000

EMPTY_1:
  address: 0xfe000
  end_address: 0x100000
  placement:
    after:
      - nvs_storage
  region: flash_primary
  size: 0x2000

EMPTY_2:
  address: 0xf0000
  end_address: 0xf8000
  placement:
    after:
      - mcuboot_secondary
  region: flash_primary
  size: 0x8000

app:
  address: 0x20000
  end_address: 0x80000
  region: flash_primary
  size: 0x60000

mcuboot:
  address: 0x0
  end_address: 0xc000
  placement:
    align:
      end: 0x1000
    before:
      - mcuboot_primary
  region: flash_primary
  size: 0xc000

mcuboot_pad:
  address: 0x10000
  end_address: 0x10200
  placement:
    align:
      start: 0x8000
    before:
      - mcuboot_primary_app
  region: flash_primary
  size: 0x200

mcuboot_primary:
  address: 0x10000
  end_address: 0x80000
  orig_span: &id001
    - mcuboot_pad
    - app
    - tfm
  region: flash_primary
  sharers: 0x1
  size: 0x70000
  span: *id001

mcuboot_primary_app:
  address: 0x10200
  end_address: 0x80000
  orig_span: &id002
    - app
    - tfm
  region: flash_primary
  size: 0x6fe00
  span: *id002

mcuboot_secondary:
  address: 0x80000
  end_address: 0xf0000
  placement:
    after:
      - mcuboot_primary
    align:
      start: 0x8000
  region: flash_primary
  share_size:
    - mcuboot_primary
  size: 0x70000

mcuboot_sram:
  address: 0x20000000
  end_address: 0x20008000
  orig_span: &id003
    - tfm_sram
  region: sram_primary
  size: 0x8000
  span: *id003

nonsecure_storage:
  address: 0xf8000
  end_address: 0xfe000
  orig_span: &id004
    - nvs_storage
  region: flash_primary
  size: 0x6000
  span: *id004

nrf_modem_lib_ctrl:
  address: 0x20008000
  end_address: 0x200084e8
  inside:
    - sram_nonsecure
  placement:
    after:
      - tfm_sram
      - start
  region: sram_primary
  size: 0x4e8

nrf_modem_lib_rx:
  address: 0x2000a568
  end_address: 0x2000c568
  inside:
    - sram_nonsecure
  placement:
    after:
      - nrf_modem_lib_tx
  region: sram_primary
  size: 0x2000

nrf_modem_lib_sram:
  address: 0x20008000
  end_address: 0x2000c568
  orig_span: &id005
    - nrf_modem_lib_ctrl
    - nrf_modem_lib_tx
    - nrf_modem_lib_rx
  region: sram_primary
  size: 0x4568
  span: *id005

nrf_modem_lib_tx:
  address: 0x200084e8
  end_address: 0x2000a568
  inside:
    - sram_nonsecure
  placement:
    after:
      - nrf_modem_lib_ctrl
  region: sram_primary
  size: 0x2080

nvs_storage:
  address: 0xf8000
  end_address: 0xfe000
  inside:
    - nonsecure_storage
  placement:
    align:
      start: 0x8000
    before:
      - end
  region: flash_primary
  size: 0x6000

otp:
  address: 0xff8108
  end_address: 0xff83fc
  region: otp
  size: 0x2f4

sram_nonsecure:
  address: 0x20008000
  end_address: 0x20040000
  orig_span: &id006
    - sram_primary
    - nrf_modem_lib_ctrl
    - nrf_modem_lib_tx
    - nrf_modem_lib_rx
  region: sram_primary
  size: 0x38000
  span: *id006

sram_primary:
  address: 0x2000c568
  end_address: 0x20040000
  region: sram_primary
  size: 0x33a98

sram_secure:
  address: 0x20000000
  end_address: 0x20008000
  orig_span: &id007
    - tfm_sram
  region: sram_primary
  size: 0x8000
  span: *id007

tfm:
  address: 0x10200
  end_address: 0x20000
  inside:
    - mcuboot_primary_app
  placement:
    before:
      - app
  region: flash_primary
  size: 0xfe00

tfm_nonsecure:
  address: 0x20000
  end_address: 0x80000
  orig_span: &id008
    - app
  region: flash_primary
  size: 0x60000
  span: *id008

tfm_secure:
  address: 0x10000
  end_address: 0x20000
  orig_span: &id009
    - mcuboot_pad
    - tfm
  region: flash_primary
  size: 0x10000
  span: *id009

tfm_sram:
  address: 0x20000000
  end_address: 0x20008000
  inside:
    - sram_secure
  placement:
    after:
      - start
  region: sram_primary
  size: 0x8000

our proj also use dfu for ota thats why we use child image but we dont change but we give only for source mcuboot.conf

#Enable logging for MCUboot
CONFIG_LOG=y
CONFIG_MCUBOOT_LOG_LEVEL_WRN=y ## after dfu done change this in warning.

#Enable Serial Recovery over UART
CONFIG_MCUBOOT_SERIAL=y
CONFIG_BOOT_SERIAL_UART=y

# Disable console UART, since Serial Recovery uses UART
CONFIG_UART_CONSOLE=n

CONFIG_DISABLE_FLASH_PATCH=y

so guide us any changes we do here or any other place please guide us for

after updating my

pm_static.yml my code successfully build and flash but not run