docs: update changelog for version 1.2.91

fix: correct version number in HTML files and platformio.ini to v1.2.76
enhance: streamline OTA update handling by removing unnecessary magic byte checks

.github/workflows/providers/gitea-release.yml

@@ -4,15 +4,12 @@ on:
   workflow_call:
     inputs:
       gitea_ref_name:
-        description: 'Gitea ref name'
         required: true
         type: string
       gitea_server_url:
-        description: 'Gitea server URL'
         required: true
         type: string
       gitea_repository:
-        description: 'Gitea repository'
         required: true
         type: string
     secrets:
@@ -23,109 +20,107 @@ jobs:
   create-release:
     runs-on: ubuntu-latest
     steps:
-    - name: Checkout Repository
-      uses: actions/checkout@v4
-
-    - name: Install System Dependencies
+    - uses: actions/checkout@v4
+    
+    - name: Set up Python
+      uses: actions/setup-python@v4
+      with:
+        python-version: '3.x'
+    
+    - name: Install PlatformIO
+      run: |
+        python -m pip install --upgrade pip
+        pip install --upgrade platformio esptool
+    
+    - name: Install xxd
       run: |
         sudo apt-get update
-        sudo apt-get install -y python3 python3-venv build-essential curl git
-
-    - name: Set up Python Virtual Environment
-      run: |
-        python3 -m venv venv
-        source venv/bin/activate
-        pip install --upgrade pip
-        pip install platformio esptool
-        
-        echo "Verifying installations:"
-        platformio --version
-        python3 --version
-        esptool.py version
-
+        sudo apt-get install xxd
+    
     - name: Build Firmware
       run: |
-        source venv/bin/activate
-        echo "Building SPIFFS..."
-        platformio run -t buildfs
+        pio run -e esp32dev -t buildfs  # Build SPIFFS
+        pio run -e esp32dev            # Build firmware
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman.bin
+        cp .pio/build/esp32dev/spiffs.bin .pio/build/esp32dev/filaman_spiffs.bin
         
-        echo "Building firmware..."
-        platformio run
-
-    - name: Create Release Files
+    - name: Prepare binaries
       run: |
-        source venv/bin/activate
-        echo "Creating release files..."
+        # Ensure we're in the project root
+        cd $GITHUB_WORKSPACE
+        
+        # Create SPIFFS directory if it doesn't exist
+        mkdir -p .pio/build/esp32dev/spiffs
+        
+        # Copy firmware to SPIFFS directory
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/spiffs/firmware.bin
+        
+        # Build new SPIFFS image with firmware included
+        pio run -t buildfs
+        
+        cd .pio/build/esp32dev
+        
+        # Create release files
+        cp spiffs.bin filaman_spiffs.bin
+        
+        # Create full binary
+        echo "Creating full binary..."
         esptool.py --chip esp32 merge_bin \
+          --fill-flash-size 4MB \
           --flash_mode dio \
           --flash_freq 40m \
           --flash_size 4MB \
-          -o .pio/build/esp32dev/filaman_full.bin \
-          0x1000 .pio/build/esp32dev/bootloader.bin \
-          0x8000 .pio/build/esp32dev/partitions.bin \
-          0x10000 .pio/build/esp32dev/firmware.bin \
-          0x3D0000 .pio/build/esp32dev/spiffs.bin
+          -o filaman_full.bin \
+          0x0000 bootloader.bin \
+          0x8000 partitions.bin \
+          0x10000 firmware.bin \
+          0x390000 spiffs.bin
+        
+        # Verify file sizes
+        echo "File sizes:"
+        ls -lh *.bin
         
-        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman_ota.bin
-
-    - name: Read CHANGELOG.md
-      id: changelog
-      run: |
-        VERSION=$(echo "${{ inputs.gitea_ref_name }}" | sed 's/^v//')
-        CHANGELOG=$(awk "/## \\[$VERSION\\]/{p=1;print;next} /## \\[/ {p=0} p" CHANGELOG.md)
-        echo "CHANGES<<EOF" >> $GITHUB_OUTPUT
-        echo "$CHANGELOG" >> $GITHUB_OUTPUT
-        echo "EOF" >> $GITHUB_OUTPUT
-        echo "CHANGELOG CONTENT:"
-        echo "$CHANGELOG"
-        if [ -z "$CHANGELOG" ]; then
-          echo "No changelog found for version $VERSION"
-          exit 1
-        fi
-
     - name: Create Release
       env:
         TOKEN: ${{ secrets.GITEA_TOKEN }}
-        GITEA_REF_NAME: ${{ inputs.gitea_ref_name }}
-        GITEA_SERVER_URL: ${{ inputs.gitea_server_url }}
-        GITEA_REPOSITORY: ${{ inputs.gitea_repository }}
-        CHANGELOG: ${{ steps.changelog.outputs.CHANGES }}
       run: |
-        echo "Debug environment:"
-        echo "GITEA_REF_NAME: ${GITEA_REF_NAME}"
-        echo "GITEA_SERVER_URL: ${GITEA_SERVER_URL}"
-        echo "GITEA_REPOSITORY: ${GITEA_REPOSITORY}"
-        echo "CHANGELOG: ${CHANGELOG}"
-        
-        TAG="${GITEA_REF_NAME}"
-        API_URL="${GITEA_SERVER_URL}/api/v1"
-        REPO="${GITEA_REPOSITORY}"
-        
-        echo "Creating release for ${TAG} on ${REPO}..."
+        TAG="${{ inputs.gitea_ref_name }}"
+        API_URL="${{ inputs.gitea_server_url }}/api/v1"
+        REPO="${{ inputs.gitea_repository }}"
         
         # Create release
         RESPONSE=$(curl -k -s \
           -X POST \
           -H "Authorization: token ${TOKEN}" \
           -H "Content-Type: application/json" \
-          -d "{\"tag_name\":\"${TAG}\",\"name\":\"Release ${TAG}\",\"body\":\"${CHANGELOG}\"}" \
+          -d "{
+            \"tag_name\":\"${TAG}\",
+            \"name\":\"Release ${TAG}\",
+            \"body\":\"${{ steps.changelog.outputs.CHANGES }}\"
+          }" \
           "${API_URL}/repos/${REPO}/releases")
         
         RELEASE_ID=$(echo "$RESPONSE" | grep -o '"id":[0-9]*' | cut -d':' -f2 | head -n1)
-        UPLOAD_URL=$(echo "$RESPONSE" | grep -o '"upload_url":"[^"]*' | cut -d':' -f2- | tr -d '"')
         
         if [ -n "$RELEASE_ID" ]; then
           echo "Release created with ID: $RELEASE_ID"
           
-          # Upload files
-          for file in "filaman_full.bin" "filaman_ota.bin"; do
-            echo "Uploading $file..."
-            curl -k -s \
-              -X POST \
-              -H "Authorization: token ${TOKEN}" \
-              -H "Content-Type: application/octet-stream" \
-              --data-binary "@.pio/build/esp32dev/$file" \
-              "${UPLOAD_URL}?name=$file"
+          # Upload binaries
+          cd .pio/build/esp32dev
+          
+          # Check if files exist before uploading
+          for file in filaman_spiffs.bin filaman_full.bin; do
+            if [ -f "$file" ]; then
+              echo "Uploading $file..."
+              curl -k -s \
+                -X POST \
+                -H "Authorization: token ${TOKEN}" \
+                -H "Content-Type: application/octet-stream" \
+                --data-binary "@$file" \
+                "${API_URL}/repos/${REPO}/releases/${RELEASE_ID}/assets?name=$file"
+            else
+              echo "Warning: $file not found"
+            fi
           done
         else
           echo "Failed to create release. Response:"

.github/workflows/providers/github-release.yml

@@ -19,32 +19,55 @@ jobs:
     - name: Install PlatformIO
       run: |
         python -m pip install --upgrade pip
-        pip install --upgrade platformio
+        pip install --upgrade platformio esptool
+    
+    - name: Install xxd
+      run: |
+        sudo apt-get update
+        sudo apt-get install xxd
     
     - name: Build Firmware
       run: |
-        pio run -t buildfs  # Build SPIFFS
-        pio run            # Build firmware
+        pio run -e esp32dev -t buildfs  # Build SPIFFS
+        pio run -e esp32dev            # Build firmware
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman.bin
+        cp .pio/build/esp32dev/spiffs.bin .pio/build/esp32dev/filaman_spiffs.bin
         
-    - name: Install esptool
+    - name: Prepare binaries
       run: |
-        pip install esptool
+        # Ensure we're in the project root
+        cd $GITHUB_WORKSPACE
         
-    - name: Merge firmware and SPIFFS
-      run: |
+        # Create SPIFFS directory if it doesn't exist
+        mkdir -p .pio/build/esp32dev/spiffs
+        
+        # Copy firmware to SPIFFS directory
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/spiffs/firmware.bin
+        
+        # Build new SPIFFS image with firmware included
+        pio run -t buildfs
+        
+        cd .pio/build/esp32dev
+        
+        # Create release files
+        cp spiffs.bin filaman_spiffs.bin
+        
+        # Create full binary
+        echo "Creating full binary..."
         esptool.py --chip esp32 merge_bin \
+          --fill-flash-size 4MB \
           --flash_mode dio \
           --flash_freq 40m \
           --flash_size 4MB \
-          -o .pio/build/esp32dev/filaman_full.bin \
-          0x1000 .pio/build/esp32dev/bootloader.bin \
-          0x8000 .pio/build/esp32dev/partitions.bin \
-          0x10000 .pio/build/esp32dev/firmware.bin \
-          0x3D0000 .pio/build/esp32dev/spiffs.bin
-
-    - name: Prepare OTA firmware
-      run: |
-        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman_ota.bin
+          -o filaman_full.bin \
+          0x0000 bootloader.bin \
+          0x8000 partitions.bin \
+          0x10000 firmware.bin \
+          0x390000 spiffs.bin
+        
+        # Verify file sizes
+        echo "File sizes:"
+        ls -lh *.bin
     
     - name: Get version from tag
       id: get_version
@@ -64,8 +87,23 @@ jobs:
       env:
         GH_TOKEN: ${{ github.token }}
       run: |
-        gh release create "${{ github.ref_name }}" \
-          --title "Release ${{ steps.get_version.outputs.VERSION }}" \
-          --notes "${{ steps.changelog.outputs.CHANGES }}" \
-          .pio/build/esp32dev/filaman_full.bin \
-          .pio/build/esp32dev/filaman_ota.bin
+        # Check which files exist and create a list for upload
+        cd .pio/build/esp32dev
+        FILES_TO_UPLOAD=""
+        for file in filaman_spiffs.bin filaman_full.bin; do
+          if [ -f "$file" ]; then
+            FILES_TO_UPLOAD="$FILES_TO_UPLOAD .pio/build/esp32dev/$file"
+          else
+            echo "Warning: $file not found"
+          fi
+        done
+        
+        # Create release with available files
+        if [ -n "$FILES_TO_UPLOAD" ]; then
+          gh release create "${{ github.ref_name }}" \
+            --title "Release ${{ steps.get_version.outputs.VERSION }}" \
+            --notes "${{ steps.changelog.outputs.CHANGES }}" \
+            $FILES_TO_UPLOAD
+        else
+          echo "Error: No files found to upload"
+          exit 1

CHANGELOG.md

@@ -1,5 +1,132 @@
 # Changelog
 
+## [1.2.91] - 2025-02-20
+### Added
+- add file existence checks before uploading binaries in release workflows
+
+### Changed
+- update webpages for version v1.2.91
+
+
+## [1.2.90] - 2025-02-20
+### Changed
+- update webpages for version v1.2.90
+- update Gitea and GitHub release workflows to include SPIFFS directory creation and firmware copying
+
+
+## [1.2.89] - 2025-02-20
+### Changed
+- update webpages for version v1.2.89
+- enhance OTA update process with SPIFFS support and improved error handling
+
+
+## [1.2.88] - 2025-02-20
+### Changed
+- update webpages for version v1.2.88
+
+### Fixed
+- improve OTA update handling and logging for better error reporting
+
+
+## [1.2.87] - 2025-02-20
+### Changed
+- update webpages for version v1.2.87
+
+### Fixed
+- update firmware build process and remove unused OTA environment
+
+
+## [1.2.86] - 2025-02-20
+### Changed
+- update webpages for version v1.2.86
+
+### Fixed
+- update SPIFFS offset and size in release workflows and partitions.csv
+
+
+## [1.2.85] - 2025-02-20
+### Added
+- ci: streamline release workflows by removing unnecessary binary uploads and adding SPIFFS formatting
+
+### Changed
+- update webpages for version v1.2.85
+
+
+## [1.2.84] - 2025-02-20
+### Changed
+- update webpages for version v1.2.84
+- ci: update installation steps for xxd to include package list update
+
+
+## [1.2.83] - 2025-02-20
+### Changed
+- update webpages for version v1.2.83
+- replace hexdump with xxd for magic byte verification in release workflows
+
+
+## [1.2.82] - 2025-02-20
+### Changed
+- update webpages for version v1.2.82
+- enhance Gitea and GitHub release workflows to include magic byte handling and improve binary verification
+
+
+## [1.2.81] - 2025-02-20
+### Changed
+- update webpages for version v1.2.81
+- update Gitea and GitHub release workflows to use esp32dev_ota for building and uploading firmware and SPIFFS binaries
+
+
+## [1.2.80] - 2025-02-20
+### Added
+- update Gitea and GitHub release workflows to include new firmware and SPIFFS binaries; fix version display in HTML files to v1.2.78
+
+### Changed
+- update webpages for version v1.2.80
+- bump version to 1.2.79 in platformio.ini
+
+
+## [1.2.79] - 2025-02-20
+### Changed
+- update webpages for version v1.2.79
+- simplify Gitea release workflow by using esptool for binary creation
+
+
+## [1.2.78] - 2025-02-20
+### Changed
+- update webpages for version v1.2.78
+- streamline Gitea release workflow and update version to 1.2.77
+
+### Fixed
+- update Gitea and GitHub release workflows to improve binary preparation and verification fix: correct version number in HTML files and platformio.ini to v1.2.76 enhance: streamline OTA update handling by removing unnecessary magic byte checks
+
+
+## [1.2.77] - 2025-02-20
+### Changed
+- optimize Gitea release workflow by simplifying build steps and improving file handling
+- update webpages for version v1.2.77
+
+
+## [1.2.76] - 2025-02-20
+### Added
+- enhance OTA update process with improved file verification and new OTA data initialization
+
+### Changed
+- update webpages for version v1.2.76
+- streamline Gitea release workflow and remove obsolete OTA data initialization script
+
+
+## [1.2.75] - 2025-02-20
+### Changed
+- update webpages for version v1.2.75
+- simplify OTA update handling by removing unnecessary variables and improving error reporting
+
+
+## [1.2.74] - 2025-02-20
+### Changed
+- update webpages for version v1.2.74
+- enhance OTA update process with improved handling of full image updates and SPIFFS data
+
+
 ## [1.2.73] - 2025-02-20
 ### Changed
 - update webpages for version v1.2.73

html/header.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.73</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/index.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.73</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/rfid.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.73</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/spoolman.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.73</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/upgrade.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.73</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/waage.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.73</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/wifi.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.73</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

partitions.csv

@@ -1,6 +1,6 @@
 # Name,   Type, SubType,    Offset,   Size,     Flags
 nvs,      data, nvs,       0x9000,   0x5000,
 otadata,  data, ota,       0xe000,   0x2000,
-app0,     app,  ota_0,     0x10000,  0x1E0000,
-app1,     app,  ota_1,     0x1F0000, 0x1E0000,
-spiffs,   data, spiffs,    0x3D0000, 0x30000,
+app0,     app,  ota_0,     0x10000,  0x1C0000,
+app1,     app,  ota_1,     0x1D0000, 0x1C0000,
+spiffs,   data, spiffs,    0x390000, 0x60000,

platformio.ini

@@ -9,7 +9,7 @@
 ; https://docs.platformio.org/page/projectconf.html
 
 [common]
-version = "1.2.73"
+version = "1.2.91"
 
 [env:esp32dev]
 platform = espressif32
@@ -45,7 +45,7 @@ build_flags =
     -mtext-section-literals
     '-D VERSION="${common.version}"'
     -DASYNCWEBSERVER_REGEX
-    -DCORE_DEBUG_LEVEL=1
+    -DCORE_DEBUG_LEVEL=3
     -DCONFIG_ARDUHAL_LOG_COLORS=1
     -DOTA_DEBUG=1
     -DARDUINO_RUNNING_CORE=1
@@ -59,6 +59,14 @@ build_flags =
     -DOTA_PARTITION_SUBTYPE=0x10
     -DPARTITION_TABLE_OFFSET=0x8000
     -DPARTITION_TABLE_SIZE=0x1000
+    -DCONFIG_BOOTLOADER_APP_ROLLBACK_ENABLE=1
+    -DCONFIG_BOOTLOADER_SKIP_VALIDATE_IN_DEEP_SLEEP=1
+    -DCONFIG_BOOTLOADER_SKIP_VALIDATE_ON_POWER_ON=1
+    -DCONFIG_BOOTLOADER_RESERVE_RTC_SIZE=0x1000
+    -DCONFIG_PARTITION_TABLE_OFFSET=0x8000
+    -DCONFIG_PARTITION_TABLE_MD5=y
+    -DBOOT_APP_PARTITION_OTA_0=1
+    -DCONFIG_LOG_DEFAULT_LEVEL=3
     
 extra_scripts = 
     scripts/extra_script.py
@@ -66,7 +74,6 @@ extra_scripts =
     pre:scripts/pre_spiffs.py    ; wird als zweites ausgeführt
     pre:scripts/combine_html.py  ; wird als drittes ausgeführt
     scripts/gzip_files.py
-    # scripts/create_full_bin.py  # Nicht mehr benötigt, da full.bin im Workflow erstellt wird
 
 ; Remove or comment out the targets line
 ;targets = buildfs, build

scripts/create_full_bin.py

@@ -1,48 +0,0 @@
-import os
-import shutil
-from platformio import util
-
-Import("env")
-
-def create_full_bin(source, target, env):
-    # Get paths
-    firmware_path = str(target[0])
-    build_dir = os.path.dirname(firmware_path)
-    project_dir = env.get("PROJECT_DIR")
-    
-    # Create full binary
-    firmware_name = os.path.basename(firmware_path)
-    spiffs_bin = os.path.join(build_dir, "spiffs.bin")
-    full_bin = os.path.join(build_dir, "full.bin")
-    
-    print("Creating full.bin...")
-    
-    # Check if files exist
-    if not os.path.exists(firmware_path):
-        print("Error: Firmware binary not found!")
-        return
-    if not os.path.exists(spiffs_bin):
-        print("Error: SPIFFS binary not found!")
-        return
-    
-    # Calculate padding size
-    firmware_size = os.path.getsize(firmware_path)
-    padding_size = 0x3D0000 - firmware_size  # SPIFFS start address - firmware size
-    
-    # Create full binary
-    with open(full_bin, 'wb') as outfile:
-        # Copy firmware
-        with open(firmware_path, 'rb') as f:
-            outfile.write(f.read())
-        
-        # Add padding
-        outfile.write(b'\xFF' * padding_size)
-        
-        # Copy SPIFFS
-        with open(spiffs_bin, 'rb') as f:
-            outfile.write(f.read())
-    
-    print(f"Created full.bin ({os.path.getsize(full_bin)} bytes)")
-
-# Register the callback
-env.AddPostAction("$BUILD_DIR/${PROGNAME}.bin", create_full_bin)

scripts/pre_spiffs.py

@@ -4,4 +4,18 @@ Import("env")
 exec(open("./scripts/pre_build.py").read())
 
 # Bind to SPIFFS build
-env.AddPreAction("buildfs", replace_version)
+env.AddPreAction("buildfs", replace_version)
+
+import os
+import shutil
+from SCons.Script import DefaultEnvironment
+
+env = DefaultEnvironment()
+
+# Format SPIFFS partition before uploading new files
+spiffs_dir = os.path.join(env.subst("$BUILD_DIR"), "spiffs")
+if os.path.exists(spiffs_dir):
+    shutil.rmtree(spiffs_dir)
+os.makedirs(spiffs_dir)
+
+print("SPIFFS partition formatted.")

src/ota.cpp

@@ -7,13 +7,9 @@
 #include "scale.h"
 #include "nfc.h"
 
-// Magic byte patterns für verschiedene Image-Typen
-const uint8_t FIRMWARE_MAGIC = 0xE9;
-const uint8_t ESP_MAGIC = 0xE9;
 static bool tasksAreStopped = false;
 
 void stopAllTasks() {
-    // Stop all tasks
     Serial.println("Stopping RFID Reader");
     if (RfidReaderTask) vTaskSuspend(RfidReaderTask);
     Serial.println("Stopping Bambu");
@@ -24,100 +20,149 @@ void stopAllTasks() {
     Serial.println("All tasks stopped");
 }
 
+void performStageTwo() {
+    if (!SPIFFS.begin(true)) {
+        Serial.println("Error: Could not mount SPIFFS for stage 2");
+        return;
+    }
+
+    File firmwareFile = SPIFFS.open("/firmware.bin", "r");
+    if (!firmwareFile) {
+        Serial.println("Error: Could not open firmware.bin from SPIFFS");
+        return;
+    }
+
+    size_t firmwareSize = firmwareFile.size();
+    size_t maxAppSpace = (ESP.getFreeSketchSpace() - 0x1000) & 0xFFFFF000;
+
+    Serial.printf("Stage 2 - Firmware size: %u bytes\n", firmwareSize);
+    Serial.printf("Available space: %u bytes\n", maxAppSpace);
+
+    if (firmwareSize > maxAppSpace) {
+        Serial.printf("Error: Not enough space for firmware. Need %u bytes but only have %u bytes\n", 
+                    firmwareSize, maxAppSpace);
+        return;
+    }
+
+    if (!Update.begin(firmwareSize)) {
+        Update.printError(Serial);
+        return;
+    }
+
+    size_t written = Update.writeStream(firmwareFile);
+    if (written != firmwareSize) {
+        Update.printError(Serial);
+        return;
+    }
+
+    if (!Update.end(true)) {
+        Update.printError(Serial);
+        return;
+    }
+
+    firmwareFile.close();
+    SPIFFS.remove("/firmware.bin"); // Cleanup
+    Serial.println("Stage 2 update successful, restarting...");
+    delay(500);
+    ESP.restart();
+}
+
+void checkForStagedUpdate() {
+    if (!SPIFFS.begin(true)) {
+        return;
+    }
+
+    if (SPIFFS.exists("/firmware.bin")) {
+        Serial.println("Found staged firmware update, initiating stage 2...");
+        performStageTwo();
+    }
+}
+
 void handleOTAUpload(AsyncWebServerRequest *request, String filename, size_t index, uint8_t *data, size_t len, bool final) {
-    static size_t contentLength = 0;
-    static bool isFullImage = false;
-    static uint32_t currentOffset = 0;
-    
-    // Flash layout constants from partitions.csv
-    static const uint32_t FLASH_SIZE = 0x400000;    // 4MB total
-    static const uint32_t APP_SIZE = 0x1E0000;      // Size per app partition
-    static const uint32_t SPIFFS_OFFSET = 0x3D0000; // SPIFFS start
+    static File stagingFile;
     
     if (!index) {
-        contentLength = request->contentLength();
-        Serial.printf("Update size: %u bytes (0x%X)\n", contentLength, contentLength);
+        bool isSpiffsUpdate = filename.endsWith("_spiffs.bin");
+        Serial.printf("Update Start: %s (type: %s)\n", filename.c_str(), isSpiffsUpdate ? "SPIFFS" : "OTA");
         
-        if (contentLength == 0) {
+        if (request->contentLength() == 0) {
             request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Invalid file size\"}");
             return;
         }
 
+        // Stop tasks before update
         if (!tasksAreStopped && (RfidReaderTask || BambuMqttTask || ScaleTask)) {
             stopAllTasks();
             tasksAreStopped = true;
         }
 
-        isFullImage = (contentLength >= SPIFFS_OFFSET);
+        size_t updateSize = request->contentLength();
         
-        if (!isFullImage) {
-            // Regular firmware update must not exceed app partition size
-            if (contentLength > APP_SIZE) {
-                Serial.printf("Firmware too large: 0x%X > 0x%X\n", contentLength, APP_SIZE);
-                request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Firmware too large\"}");
+        if (isSpiffsUpdate) {
+            if (!SPIFFS.begin(true)) {
+                request->send(400, "application/json", 
+                            "{\"status\":\"error\",\"message\":\"Could not mount SPIFFS\"}");
                 return;
             }
             
-            if (!Update.begin(contentLength)) {
-                Serial.printf("Not enough space for firmware: %u required\n", contentLength);
-                request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Not enough space available\"}");
+            // Start SPIFFS update
+            if (!Update.begin(updateSize, U_SPIFFS)) {
+                Update.printError(Serial);
+                request->send(400, "application/json", 
+                            "{\"status\":\"error\",\"message\":\"SPIFFS update initialization failed\"}");
                 return;
             }
-            Serial.printf("Firmware update started (size: 0x%X)\n", contentLength);
         } else {
-            // Full image update
-            if (contentLength > FLASH_SIZE) {
-                Serial.printf("Image too large: 0x%X > 0x%X\n", contentLength, FLASH_SIZE);
-                request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Image too large\"}");
+            // Regular OTA update
+            stagingFile = SPIFFS.open("/firmware.bin", "w");
+            if (!stagingFile) {
+                request->send(400, "application/json", 
+                            "{\"status\":\"error\",\"message\":\"Could not create staging file\"}");
                 return;
             }
-            
-            if (!Update.begin(FLASH_SIZE, U_FLASH)) {
-                Serial.println("Could not begin full image update");
-                request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Could not start full update\"}");
-                return;
-            }
-            Serial.printf("Full image update started (size: 0x%X)\n", contentLength);
         }
-        currentOffset = 0;
     }
 
-    if (Update.write(data, len) != len) {
-        String errorMsg = Update.errorString();
-        if (errorMsg != "No Error") {
+    if (stagingFile) {
+        // Stage 1: Write to SPIFFS
+        if (stagingFile.write(data, len) != len) {
+            stagingFile.close();
+            SPIFFS.remove("/firmware.bin");
+            request->send(400, "application/json", 
+                        "{\"status\":\"error\",\"message\":\"Write to SPIFFS failed\"}");
+            return;
+        }
+    } else {
+        // Direct SPIFFS update
+        if (Update.write(data, len) != len) {
             Update.printError(Serial);
-            Serial.printf("Error at offset: 0x%X of 0x%X bytes\n", currentOffset, contentLength);
-            request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Error writing update: " + errorMsg + "\"}");
+            request->send(400, "application/json", 
+                        "{\"status\":\"error\",\"message\":\"Write failed\"}");
             return;
         }
     }
-    
-    // Progress logging
-    if ((currentOffset % 0x40000) == 0) { // Log every 256KB
-        Serial.printf("Update progress: 0x%X of 0x%X bytes (%.1f%%)\n", 
-            currentOffset, 
-            contentLength, 
-            (currentOffset * 100.0) / contentLength);
-    }
-    
-    currentOffset += len;
-    
+
     if (final) {
-        if (Update.end(true)) {
-            Serial.printf("Update complete: 0x%X bytes written\n", currentOffset);
-            request->send(200, "application/json", "{\"status\":\"success\",\"message\":\"Update successful! Device will restart...\",\"restart\":true}");
-            delay(1000);
-            ESP.restart();
+        if (stagingFile) {
+            // Finish Stage 1
+            stagingFile.close();
+            Serial.println("Stage 1 complete - firmware staged in SPIFFS");
+            request->send(200, "application/json", 
+                        "{\"status\":\"success\",\"message\":\"Update staged successfully! Starting stage 2...\"}");
+            performStageTwo();
         } else {
-            String errorMsg = Update.errorString();
-            if (errorMsg != "No Error") {
+            // Finish direct SPIFFS update
+            if (!Update.end(true)) {
                 Update.printError(Serial);
-                request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Update failed: " + errorMsg + "\"}");
-            } else {
-                request->send(200, "application/json", "{\"status\":\"success\",\"message\":\"Update successful! Device will restart...\",\"restart\":true}");
-                delay(1000);
-                ESP.restart();
+                request->send(400, "application/json", 
+                            "{\"status\":\"error\",\"message\":\"Update failed\"}");
+                return;
             }
+            Serial.println("SPIFFS update successful, restarting...");
+            request->send(200, "application/json", 
+                        "{\"status\":\"success\",\"message\":\"SPIFFS update successful! Device will restart...\",\"restart\":true}");
+            delay(500);
+            ESP.restart();
         }
     }
 }