Failing to build; region `FLASH' overflowed by 680 bytes

[Will_20241202]

I am in process up migrating a legacy project from SDK v2.4 to v3.2 and going through each revision incrementally to catch all the changes needed to modernize it and maintain functionality.  I am able to build up to SDK v2.6.1 so far but stepping to v2.7.0 I am apparently running out of space, even though none of the configuration or source files have changed.  The target board uses an nrf52840 and what is especially peculiar is that the same code with the same proj.conf file and build configuration but targeting a board with an nrf52832 fits just fine, even though that chip has half the FLASH and a fraction of the RAM.  Clearly I'm missing a setting or something but honestly the Zephyr build environment is painfully opaque and unintuitive so I'm having trouble tracking it down.  For reference, the specific error I'm getting during build is:

[254/259] Linking C executable zephyr\zephyr_pre0.elf
FAILED: zephyr/zephyr_pre0.elf zephyr/zephyr_pre0.map C:/<REDACTED>/mcuboot/zephyr/zephyr_pre0.map
cmd.exe /C "cd . && C:\ncs\toolchains\ce3b5ff664\opt\zephyr-sdk\arm-zephyr-eabi\bin\arm-zephyr-eabi-gcc.exe  -gdwarf-4 zephyr/CMakeFiles/zephyr_pre0.dir/misc/empty_file.c.obj -o zephyr\zephyr_pre0.elf  zephyr/CMakeFiles/offsets.dir/./arch/arm/core/offsets/offsets.c.obj  -fuse-ld=bfd  -T  zephyr/linker_zephyr_pre0.cmd  -Wl,-Map=C:/<REDACTED>/mcuboot/zephyr/zephyr_pre0.map  -Wl,--whole-archive  app/libapp.a  zephyr/libzephyr.a  zephyr/arch/common/libarch__common.a  zephyr/arch/arch/arm/core/libarch__arm__core.a  zephyr/arch/arch/arm/core/cortex_m/libarch__arm__core__cortex_m.a  zephyr/arch/arch/arm/core/mpu/libarch__arm__core__mpu.a  zephyr/lib/libc/minimal/liblib__libc__minimal.a  zephyr/lib/libc/common/liblib__libc__common.a  zephyr/soc/soc/arm/nordic_nrf/lib..__modules__soc-hwmv1__soc__arm__nordic_nrf.a  zephyr/drivers/clock_control/libdrivers__clock_control.a  zephyr/drivers/flash/libdrivers__flash.a  zephyr/drivers/pinctrl/libdrivers__pinctrl.a  zephyr/drivers/timer/libdrivers__timer.a  modules/nrf/lib/fprotect/lib..__nrf__lib__fprotect.a  modules/nrf/drivers/hw_cc3xx/lib..__nrf__drivers__hw_cc3xx.a  modules/mcuboot/boot/bootutil/zephyr/libmcuboot_util.a  modules/mbedtls/libmbedTLSBase.a  modules/mbedtls/libmbedTLSCrypto.a  modules/mbedtls/libmbedTLSX509.a  modules/mbedtls/libmodules__mbedtls.a  modules/hal_nordic/nrfx/libmodules__hal_nordic__nrfx.a  -Wl,--no-whole-archive  zephyr/kernel/libkernel.a  -L"c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/thumb/v7e-m/nofp"  -LC:/<REDACTED>/mcuboot/zephyr  -lgcc  zephyr/arch/common/libisr_tables.a  modules/mbedtls/libmbedTLSBase.a  modules/mbedtls/libmbedTLSCrypto.a  modules/mbedtls/libmbedTLSX509.a  -mcpu=cortex-m4  -mthumb  -mabi=aapcs  -mfp16-format=ieee  -Wl,--gc-sections  -Wl,--build-id=none  -Wl,--sort-common=descending  -Wl,--sort-section=alignment  -Wl,-u,_OffsetAbsSyms  -Wl,-u,_ConfigAbsSyms  -nostdlib  -static  -Wl,-X  -Wl,-N  -Wl,--orphan-handling=warn  -Wl,-no-pie  C:/ncs/v2.7.0/nrfxlib/crypto/nrf_cc310_platform/lib/cortex-m4/soft-float/no-interrupts/libnrf_cc310_platform_0.9.19.a
&& cmd.exe /C "cd /D C:\<REDACTED>\mcuboot\zephyr && C:\ncs\toolchains\ce3b5ff664\opt\bin\cmake.exe -E true""c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.bfd.exe: zephyr\zephyr_pre0.elf section `rodata' will not fit in region `FLASH'
c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.bfd.exe: region `FLASH' overflowed by 680 bytes
collect2.exe: error: ld returned 1 exit status
ninja: build stopped: subcommand failed.

[Will_20241202]

I tried removing giant swathes of code from my project (both functions and static variables) and it still says I am exactly 680 bytes too big...  Which leads me to believe the problem lies outside of my code, and likely in the bootloader.  Is there an easy way to check how big the bootloader is and how big the container that it is being put into is?

[Amanda Hsieh]

You can check the CONFIG_PM_PARTITION_SIZE_MCUBOOT value in the .config file under build/mcuboot/zephyr and try to increase it. 

[Will_20241202]

Changing to 0x7000 (in all four files) had no effect.  The other three files auto-regenerated back to 0x6000 and the build still failed because it was too big by 680 bytes.

[Amanda Hsieh]

Are you using sysbuild? If so, you can try to add to sysbuild/mcuboot/prj.conf.

[Will_20241202]

I'm not (yet) using sysbuild.  I'm trying to step one change at a time from a very old SDK (v2.4.0) to a very new one (v3.2.1) and only make small incremental changes along the way so that detecting/fixing problems are manageable. Once I get this variant building, I plan to migrate from HWMv1 to HWMv2 (still on SDK v2.7.0), and after that from the child_image flavor to sysbuild.  However I don't want to add more variables to the mix until this set of issues is resolved.  

[Amanda Hsieh]

Will_20241202 said:

I'm not (yet) using sysbuild. 

Then you have to figure out why changing to 0x7000 in child_image\mcuboot\prj.conf had no effect. Check if there are any config conflicts or warnings in the build log. 

Do other configs in child_image\mcuboot\prj.conf take effect in build\mcuboot\zephyr\.config?

You can refer to bootloader\mcuboot\boot\zephyr\prj_minimal.conf for your child_image\mcuboot\prj.conf to reduce the mcuboot size. 

[Will_20241202]

The only line(s) in the build log that maybe seems suspect is:

=== child image mcuboot -  begin ===
loading initial cache file C:/Projects/<REDACTED>/build/mcuboot/child_image_preload.cmake

The rest contains a few warnings (most of which I'm already planning to address, after) but none look like they would impact the mcuboot image.  The full (redacted) build log is below.

-----------------------------------------------------------------------------------

 *  Executing task: nRF Connect: Build [pristine]: <REDACTED>/build (active) 

Building <REDACTED>
west build --build-dir c:/Projects/<REDACTED>/build c:/Projects/<REDACTED> --pristine --board my_board --no-sysbuild -- -DNCS_TOOLCHAIN_VERSION="NONE" -DCONF_FILE="prj.conf" -DDEBUG_THREAD_INFO=On -DCONFIG_DEBUG_THREAD_INFO=y -Dmcuboot_EXTRA_CONF_FILE=C:/ncs/v2.7.0/nrf/subsys/partition_manager/partition_manager_enabled.conf -Dmcuboot_CONF_FILE=c:/Projects/<REDACTED>/child_image/mcuboot/prj.conf -DBOARD_ROOT=c:/projects/<REDACTED>

-- west build: generating a build system
Loading Zephyr default modules (Zephyr base).
-- Application: C:/Projects/<REDACTED>
-- CMake version: 3.21.0
-- Found Python3: C:/ncs/toolchains/ce3b5ff664/opt/bin/python.exe (found suitable version "3.9.13", minimum required is "3.8") found components: Interpreter
-- Cache files will be written to: C:/ncs/v2.7.0/zephyr/.cache
-- Zephyr version: 3.6.99 (C:/ncs/v2.7.0/zephyr)
-- Found west (found suitable version "1.2.0", minimum required is "0.14.0")
-- Board: my_board
-- Found host-tools: zephyr 0.16.5 (C:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk)
-- Found toolchain: zephyr 0.16.5 (C:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk)
-- Found Dtc: C:/ncs/toolchains/ce3b5ff664/opt/bin/dtc.exe (found suitable version "1.4.7", minimum required is "1.4.6")
-- Found BOARD.dts: C:/Projects/<REDACTED>/boards/arm/MyBoard/my_board.dts
-- Generated zephyr.dts: C:/Projects/<REDACTED>/build/zephyr/zephyr.dts
-- Generated devicetree_generated.h: C:/Projects/<REDACTED>/build/zephyr/include/generated/devicetree_generated.h
-- Including generated dts.cmake file: C:/Projects/<REDACTED>/build/zephyr/dts.cmake

warning: THREAD_MONITOR (defined at kernel/Kconfig:471) was assigned the value 'n' but got the value
'y'. See docs.zephyrproject.org/.../kconfig.html and/or look up
THREAD_MONITOR in the menuconfig/guiconfig interface. The Application Development Primer, Setting
Configuration Values, and Kconfig - Tips and Best Practices sections of the manual might be helpful
too.


warning: Deprecated symbol GPIO_AS_PINRESET is enabled.


warning: Experimental symbol BT_LL_SW_SPLIT is enabled.

Parsing C:/ncs/v2.7.0/zephyr/Kconfig
Loaded configuration 'C:/Projects/<REDACTED>/boards/arm/MyBoard/my_board_defconfig'
Merged configuration 'C:/Projects/<REDACTED>/prj.conf'
Merged configuration 'C:/Projects/<REDACTED>/build/zephyr/misc/generated/extra_kconfig_options.conf'
Configuration saved to 'C:/Projects/<REDACTED>/build/zephyr/.config'
Kconfig header saved to 'C:/Projects/<REDACTED>/build/zephyr/include/generated/autoconf.h'
-- Found GnuLd: c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/arm-zephyr-eabi/bin/ld.bfd.exe (found version "2.38")
-- The C compiler identification is GNU 12.2.0
-- The CXX compiler identification is GNU 12.2.0
-- The ASM compiler identification is GNU
-- Found assembler: C:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/arm-zephyr-eabi-gcc.exe
CMake Deprecation Warning at C:/ncs/v2.7.0/zephyr/soc/CMakeLists.txt:15 (message):


            ---------------------------------------------------------------------
            --- WARNING: Functionality to describe SoCs in HWMv1 is           ---
            --- deprecated and should be replaced with HWMv2, including       ---
            --- boards. HWMv1 SoCs support remains only to ease the migration ---
            --- of out-of-tree SoCs and associated boards. It will not be     ---
            --- possible to build using HWMv1 SoCs at all in future releases. ---
            ---------------------------------------------------------------------


CMake Warning at C:/ncs/v2.7.0/zephyr/subsys/bluetooth/controller/CMakeLists.txt:4 (message):
  

  CONFIG_BT_CTLR_ADVANCED_FEATURES=y, Advanced Features' default value change
  could change Zephyr Bluetooth Controller's functional behavior.


-- Found Python3: C:/ncs/toolchains/ce3b5ff664/opt/bin/python.exe (found version "3.9.13") found components: Interpreter

=== child image mcuboot -  begin ===
loading initial cache file C:/Projects/<REDACTED>/build/mcuboot/child_image_preload.cmake
Loading Zephyr default modules (Zephyr base).
-- Application: C:/ncs/v2.7.0/bootloader/mcuboot/boot/zephyr
-- CMake version: 3.21.0
-- Found Python3: C:/ncs/toolchains/ce3b5ff664/opt/bin/python.exe (found suitable version "3.9.13", minimum required is "3.8") found components: Interpreter
-- Cache files will be written to: C:/ncs/v2.7.0/zephyr/.cache
-- Zephyr version: 3.6.99 (C:/ncs/v2.7.0/zephyr)
-- Found west (found suitable version "1.2.0", minimum required is "0.14.0")
-- Board: my_board
-- Found host-tools: zephyr 0.16.5 (C:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk)
-- Found toolchain: zephyr 0.16.5 (C:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk)
-- Found Dtc: C:/ncs/toolchains/ce3b5ff664/opt/bin/dtc.exe (found suitable version "1.4.7", minimum required is "1.4.6")
-- Found BOARD.dts: C:/Projects/<REDACTED>/boards/arm/MyBoard/my_board.dts
-- Found devicetree overlay: C:/ncs/v2.7.0/bootloader/mcuboot/boot/zephyr/app.overlay
-- Generated zephyr.dts: C:/Projects/<REDACTED>/build/mcuboot/zephyr/zephyr.dts
-- Generated devicetree_generated.h: C:/Projects/<REDACTED>/build/mcuboot/zephyr/include/generated/devicetree_generated.h
-- Including generated dts.cmake file: C:/Projects/<REDACTED>/build/mcuboot/zephyr/dts.cmake

warning: PRINTK (defined at subsys/debug/Kconfig:204) was assigned the value 'n' but got the value
'y'. See docs.zephyrproject.org/.../kconfig.html and/or look up PRINTK in
the menuconfig/guiconfig interface. The Application Development Primer, Setting Configuration
Values, and Kconfig - Tips and Best Practices sections of the manual might be helpful too.


warning: Deprecated symbol GPIO_AS_PINRESET is enabled.

Parsing C:/ncs/v2.7.0/bootloader/mcuboot/boot/zephyr/Kconfig
Loaded configuration 'C:/Projects/<REDACTED>/boards/arm/MyBoard/my_board_defconfig'
Merged configuration 'c:/Projects/<REDACTED>/child_image/mcuboot/prj.conf'
Merged configuration 'C:/ncs/v2.7.0/nrf/subsys/partition_manager/partition_manager_enabled.conf'
Merged configuration 'C:/Projects/<REDACTED>/build/mcuboot/zephyr/misc/generated/extra_kconfig_options.conf'
Configuration saved to 'C:/Projects/<REDACTED>/build/mcuboot/zephyr/.config'
Kconfig header saved to 'C:/Projects/<REDACTED>/build/mcuboot/zephyr/include/generated/autoconf.h'
-- Found GnuLd: c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/arm-zephyr-eabi/bin/ld.bfd.exe (found version "2.38")
-- The C compiler identification is GNU 12.2.0
-- The CXX compiler identification is GNU 12.2.0
-- The ASM compiler identification is GNU
-- Found assembler: C:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/arm-zephyr-eabi-gcc.exe
CMake Deprecation Warning at C:/ncs/v2.7.0/zephyr/soc/CMakeLists.txt:15 (message):


            ---------------------------------------------------------------------
            --- WARNING: Functionality to describe SoCs in HWMv1 is           ---
            --- deprecated and should be replaced with HWMv2, including       ---
            --- boards. HWMv1 SoCs support remains only to ease the migration ---
            --- of out-of-tree SoCs and associated boards. It will not be     ---
            --- possible to build using HWMv1 SoCs at all in future releases. ---
            ---------------------------------------------------------------------


CMake Warning at C:/ncs/v2.7.0/nrf/lib/flash_patch/CMakeLists.txt:8 (message):


        ----------------------------------------------------------
        --- WARNING: To maintain the integrity of secure boot, ---
        --- enable CONFIG_DISABLE_FLASH_PATCH in production.   ---
        ----------------------------------------------------------


CMake Deprecation Warning at C:/ncs/v2.7.0/nrf/cmake/partition_manager.cmake:32 (message):


            ---------------------------------------------------------------------
            --- WARNING: Child and parent image functionality is deprecated   ---
            --- and should be replaced with sysbuild. Child and parent image  ---
            --- support remains only to allow existing customer applications  ---
            --- to build and allow porting to sysbuild, it is no longer       ---
            --- receiving updates or new features and it will not be possible ---
            --- to build using child/parent image at all in nRF Connect SDK   ---
            --- version 2.9 onwards.                                          ---
            ---------------------------------------------------------------------
Call Stack (most recent call first):
  C:/ncs/v2.7.0/zephyr/cmake/modules/kernel.cmake:253 (include)
  C:/ncs/v2.7.0/zephyr/cmake/modules/zephyr_default.cmake:141 (include)
  C:/ncs/v2.7.0/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:66 (include)
  C:/ncs/v2.7.0/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:92 (include_boilerplate)
  CMakeLists.txt:12 (find_package)


MCUBoot bootloader key file: c:/Projects/<REDACTED>/child_image/mcuboot/my_private_key.pem
-- Configuring done
-- Generating done
-- Build files have been written to: C:/Projects/<REDACTED>/build/mcuboot
=== child image mcuboot -  end ===

CMake Deprecation Warning at C:/ncs/v2.7.0/nrf/cmake/partition_manager.cmake:32 (message):


            ---------------------------------------------------------------------
            --- WARNING: Child and parent image functionality is deprecated   ---
            --- and should be replaced with sysbuild. Child and parent image  ---
            --- support remains only to allow existing customer applications  ---
            --- to build and allow porting to sysbuild, it is no longer       ---
            --- receiving updates or new features and it will not be possible ---
            --- to build using child/parent image at all in nRF Connect SDK   ---
            --- version 2.9 onwards.                                          ---
            ---------------------------------------------------------------------
Call Stack (most recent call first):
  C:/ncs/v2.7.0/zephyr/cmake/modules/kernel.cmake:253 (include)
  C:/ncs/v2.7.0/zephyr/cmake/modules/zephyr_default.cmake:141 (include)
  C:/ncs/v2.7.0/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:66 (include)
  C:/ncs/v2.7.0/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:92 (include_boilerplate)
  CMakeLists.txt:2 (find_package)


CMake Warning at C:/ncs/v2.7.0/nrf/cmake/partition_manager.cmake:102 (message):
  

          ---------------------------------------------------------------------
          --- WARNING: Using a bootloader without pm_static.yml.            ---
          --- There are cases where a deployed product can consist of       ---
          --- multiple images, and only a subset of these images can be     ---
          --- upgraded through a firmware update mechanism. In such cases,  ---
          --- the upgradable images must have partitions that are static    ---
          --- and are matching the partition map used by the bootloader     ---
          --- programmed onto the device.                                   ---
          ---------------------------------------------------------------------
          

Call Stack (most recent call first):
  C:/ncs/v2.7.0/zephyr/cmake/modules/kernel.cmake:253 (include)
  C:/ncs/v2.7.0/zephyr/cmake/modules/zephyr_default.cmake:141 (include)
  C:/ncs/v2.7.0/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:66 (include)
  C:/ncs/v2.7.0/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:92 (include_boilerplate)
  CMakeLists.txt:2 (find_package)


-- Configuring done
-- Generating done
CMake Warning:
  Manually-specified variables were not used by the project:

    DEBUG_THREAD_INFO


-- Build files have been written to: C:/Projects/<REDACTED>/build
←[92m-- west build: building application
[8/383] Generating include/generated/version.h
-- Zephyr version: 3.6.99 (C:/ncs/v2.7.0/zephyr), build: v3.6.99-ncs2
[13/383] Performing build step for 'mcuboot_subimage'
[7/259] Generating include/generated/version.h
-- Zephyr version: 3.6.99 (C:/ncs/v2.7.0/zephyr), build: v3.6.99-ncs2
[12/259] Building C object zephyr/CMakeFiles/zephyr.dir/C_/ncs/v2.7.0/nrfxlib/crypto/nrf_cc310_platform/src/nrf_cc3xx_platform_abort_zephyr.c.o[31/259] Building C object modules/mbedtls/CMakeFiles/modules__mbedtls.dir/C_/ncs/v2.7.0/modules/crypto/mbedtls/library/ssl_debug_helpers_gener[44/259] Building C object modules/hal_nordic/nrfx/CMakeFiles/modules__hal_nordic__nrfx.dir/C_/ncs/v2.7.0/modules/hal/nordic/nrfx/mdk/system_nr[46/259] Building C object modules/hal_nordic/nrfx/CMakeFiles/modules__hal_nordic__nrfx.dir/C_/ncs/v2.7.0/modules/hal/nordic/nrfx/helpers/nrfx_[48/259] Building C object modules/mbedtls/CMakeFiles/modules__mbedtls.dir/C_/ncs/v2.7.0/modules/crypto/mbedtls/library/ssl_debug_helpers_gener[49/259] Building C object modules/hal_nordic/nrfx/CMakeFiles/modules__hal_nordic__nrfx.dir/C_/ncs/v2.7.0/modules/hal/nordic/nrfx/drivers/src/n[62/259] Building C object modules/hal_nordic/nrfx/CMakeFiles/modules__hal_nordic__nrfx.dir/C_/ncs/v2.7.0/modules/hal/nordic/nrfx/helpers/nrfx_[136/259] Building ASM object zephyr/soc/soc/arm/nordic_nrf/CMakeFiles/..__modules__soc-hwmv1__soc__arm__nordic_nrf.dir/common/soc_nrf_common.S[138/259] Building C object zephyr/soc/soc/arm/nordic_nrf/CMakeFiles/..__modules__soc-hwmv1__soc__arm__nordic_nrf.dir/validate_enabled_instance[139/259] Building C object zephyr/soc/soc/arm/nordic_nrf/CMakeFiles/..__modules__soc-hwmv1__soc__arm__nordic_nrf.dir/validate_base_addresses.c[179/259] Building C object modules/mcuboot/boot/bootutil/zephyr/CMakeFiles/mcuboot_util.dir/C_/ncs/v2.7.0/bootloader/mcuboot/boot/bootutil/src[254/259] Linking C executable zephyr\zephyr_pre0.elf
FAILED: zephyr/zephyr_pre0.elf zephyr/zephyr_pre0.map C:/Projects/<REDACTED>/build/mcuboot/zephyr/zephyr_pre0.map
cmd.exe /C "cd . && C:\ncs\toolchains\ce3b5ff664\opt\zephyr-sdk\arm-zephyr-eabi\bin\arm-zephyr-eabi-gcc.exe  -gdwarf-4 zephyr/CMakeFiles/zephyr_pre0.dir/misc/empty_file.c.obj -o zephyr\zephyr_pre0.elf  zephyr/CMakeFiles/offsets.dir/./arch/arm/core/offsets/offsets.c.obj  -fuse-ld=bfd  -T  zephyr/linker_zephyr_pre0.cmd  -Wl,-Map=C:/Projects/<REDACTED>/build/mcuboot/zephyr/zephyr_pre0.map  -Wl,--whole-archive  app/libapp.a  zephyr/libzephyr.a  zephyr/arch/common/libarch__common.a  zephyr/arch/arch/arm/core/libarch__arm__core.a  zephyr/arch/arch/arm/core/cortex_m/libarch__arm__core__cortex_m.a  zephyr/arch/arch/arm/core/mpu/libarch__arm__core__mpu.a  zephyr/lib/libc/minimal/liblib__libc__minimal.a  zephyr/lib/libc/common/liblib__libc__common.a  zephyr/soc/soc/arm/nordic_nrf/lib..__modules__soc-hwmv1__soc__arm__nordic_nrf.a  zephyr/drivers/clock_control/libdrivers__clock_control.a  zephyr/drivers/flash/libdrivers__flash.a  zephyr/drivers/pinctrl/libdrivers__pinctrl.a  zephyr/drivers/timer/libdrivers__timer.a  modules/nrf/lib/fprotect/lib..__nrf__lib__fprotect.a  modules/nrf/drivers/hw_cc3xx/lib..__nrf__drivers__hw_cc3xx.a  modules/mcuboot/boot/bootutil/zephyr/libmcuboot_util.a  modules/mbedtls/libmbedTLSBase.a  modules/mbedtls/libmbedTLSCrypto.a  modules/mbedtls/libmbedTLSX509.a  modules/mbedtls/libmodules__mbedtls.a  modules/hal_nordic/nrfx/libmodules__hal_nordic__nrfx.a  -Wl,--no-whole-archive  zephyr/kernel/libkernel.a  -L"c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/thumb/v7e-m/nofp"  -LC:/Projects/<REDACTED>/build/mcuboot/zephyr  -lgcc  zephyr/arch/common/libisr_tables.a  modules/mbedtls/libmbedTLSBase.a  modules/mbedtls/libmbedTLSCrypto.a  modules/mbedtls/libmbedTLSX509.a  -mcpu=cortex-m4  -mthumb  -mabi=aapcs  -mfp16-format=ieee  -Wl,--gc-sections  -Wl,--build-id=none  -Wl,--sort-common=descending  -Wl,--sort-section=alignment  -Wl,-u,_OffsetAbsSyms  -Wl,-u,_ConfigAbsSyms  -nostdlib  -static  -Wl,-X  -Wl,-N  -Wl,--orphan-handling=warn  -Wl,-no-pie  C:/ncs/v2.7.0/nrfxlib/crypto/nrf_cc310_platform/lib/cortex-m4/soft-float/no-interrupts/libnrf_cc310_platform_0.9.19.a && cmd.exe /C "cd /D C:\Projects\<REDACTED>\build\mcuboot\zephyr && C:\ncs\toolchains\ce3b5ff664\opt\bin\cmake.exe -E true""c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.bfd.exe: zephyr\zephyr_pre0.elf section `rodata' will not fit in region `FLASH'
c:/ncs/toolchains/ce3b5ff664/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.bfd.exe: region `FLASH' overflowed by 680 bytes
collect2.exe: error: ld returned 1 exit status
ninja: build stopped: subcommand failed.
[56/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[58/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[59/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[60/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[61/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[62/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[63/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[64/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[65/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[66/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[67/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
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[77/383] Building C object CMakeFiles/app.dir/src/<REDACTED>.c.obj
[366/383] Linking C executable zephyr\zephyr_pre0.elf
FAILED: modules/mcuboot/mcuboot_subimage-prefix/src/mcuboot_subimage-stamp/mcuboot_subimage-build mcuboot/zephyr/zephyr.hex mcuboot/zephyr/zephyr.elf C:/Projects/<REDACTED>/build/modules/mcuboot/mcuboot_subimage-prefix/src/mcuboot_subimage-stamp/mcuboot_subimage-build C:/Projects/<REDACTED>/build/mcuboot/zephyr/zephyr.hex C:/Projects/<REDACTED>/build/mcuboot/zephyr/zephyr.elf
cmd.exe /C "cd /D C:\Projects\<REDACTED>\build\mcuboot && C:\ncs\toolchains\ce3b5ff664\opt\bin\cmake.exe --build . --"
[368/383] Linking C executable zephyr\zephyr_pre0.elf
ninja: build stopped: subcommand failed.
FATAL ERROR: command exited with status 1: 'C:\ncs\toolchains\ce3b5ff664\opt\bin\cmake.EXE' --build 'c:\Projects\<REDACTED>\build'

 *  The terminal process terminated with exit code: 1. 
 *  Terminal will be reused by tasks, press any key to close it. 

[Amanda Hsieh]

Try to build with "-Dmcuboot_CONF_FILE=prj_minimal.conf" to see if it helps. 

[Will_20241202]

Ok, couple new data points:

• If I change my build configuration Extra CMake arguments to "-Dmcuboot_CONF_FILE=prj_minimal.conf" it builds without overflowing
• Changing to "-Dmcuboot_CONF_FILE=C:/ncs/v2.7.0/bootloader/mcuboot/boot/zephyr/prj_minimal.conf" also builds within permitted size
• Editing the prj.conf file in the local mcuboot subdirectoy to mimic the above and using that builds  within size
• Experimenting with adding back in the original contents of the local prj.conf, the only line that seems to cause issues (meaning it no longer links within the permitted size) is the removal of "CONFIG_BOOT_USE_MIN_PARTITION_SIZE=y"

I cannot find any documentation from Google searching on what exactly this directive does or why I would want it set to either yes or no.

[Amanda Hsieh]

See https://github.com/nrfconnect/sdk-nrf/blob/v2.7.0/modules/mcuboot/boot/zephyr/Kconfig#L10-L25 

[Will_20241202]

Ok, but what does that mean?  Why wouldn't it always "Build for a minimal image size"?  What specifically changes if that option is not yes or is omitted altogether?

[Amanda Hsieh]

It will set the mcuboot partition to 0x7c00 for the mini size. The default size is 0xc000 if you don't use a static partition or CONFIG_PM_PARTITION_SIZE_MCUBOOT.