Add FluidNC firmware flash script and dw flash command

Interactive script to flash FluidNC onto connected ESP32 boards.
Supports v3.9.5 (all tables) and v3.8.3 (Mini Dune Weaver), with
serial port selection and success verification.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

dw

@@ -16,6 +16,7 @@
 #   checkout    Switch to a branch and rebuild
 #   touch       Manage touch screen app
 #   wifi        Manage WiFi and hotspot
+#   flash       Flash FluidNC firmware onto ESP32
 #   help        Show this help message
 #
 
@@ -462,6 +463,11 @@ cmd_wifi() {
     esac
 }
 
+cmd_flash() {
+    check_installed
+    bash "$INSTALL_DIR/flash-fluidnc.sh"
+}
+
 cmd_help() {
     echo -e "${GREEN}Dune Weaver CLI${NC}"
     echo ""
@@ -479,6 +485,7 @@ cmd_help() {
     echo "  shell       Open a shell with the venv activated"
     echo "  touch       Manage touch screen app (run 'dw touch help')"
     echo "  wifi        Manage WiFi and hotspot (run 'dw wifi help')"
+    echo "  flash       Flash FluidNC firmware onto connected ESP32"
     echo "  help        Show this help message"
     echo ""
     if [[ -n "$INSTALL_DIR" ]]; then
@@ -524,6 +531,9 @@ case "${1:-help}" in
         shift
         cmd_wifi "$@"
         ;;
+    flash)
+        cmd_flash
+        ;;
     help|--help|-h)
         cmd_help
         ;;

flash-fluidnc.sh

@@ -0,0 +1,236 @@
+#!/bin/bash
+#
+# Flash FluidNC firmware onto a connected ESP32 board
+#
+# Usage: bash flash-fluidnc.sh
+#
+# Interactive script that:
+#   1. Lets user choose FluidNC version (v3.9.5 for all tables, v3.8.3 for Mini Dune Weaver)
+#   2. Lets user select a serial port
+#   3. Downloads, extracts, and flashes the firmware
+#   4. Confirms success by checking esptool output
+#
+
+set -e
+
+# Colors
+RED='\033[0;31m'
+GREEN='\033[0;32m'
+YELLOW='\033[1;33m'
+BLUE='\033[0;34m'
+CYAN='\033[0;36m'
+BOLD='\033[1m'
+NC='\033[0m'
+
+# Versions
+VERSION_ALL="3.9.5"
+VERSION_MINI="3.8.3"
+GITHUB_BASE="https://github.com/bdring/FluidNC/releases/download"
+
+cleanup() {
+    if [[ -n "${WORK_DIR:-}" && -d "$WORK_DIR" ]]; then
+        echo -e "\n${BLUE}Cleaning up temporary files...${NC}"
+        rm -rf "$WORK_DIR"
+    fi
+}
+trap cleanup EXIT
+
+# ─── Step 1: Choose version ────────────────────────────────────────────────
+
+echo -e "${BOLD}${CYAN}"
+echo "  ╔═══════════════════════════════════════╗"
+echo "  ║     FluidNC Firmware Flasher          ║"
+echo "  ║         for Dune Weaver               ║"
+echo "  ╚═══════════════════════════════════════╝"
+echo -e "${NC}"
+
+echo -e "${BOLD}Select FluidNC version:${NC}"
+echo ""
+echo -e "  ${GREEN}1)${NC} v${VERSION_ALL}  -  All tables (Dune Weaver, Pro, Gold, Mini Pro)"
+echo -e "  ${GREEN}2)${NC} v${VERSION_MINI}  -  Mini Dune Weaver only"
+echo ""
+read -p "Enter choice [1/2]: " version_choice
+
+case "$version_choice" in
+    1)
+        VERSION="$VERSION_ALL"
+        echo -e "\nSelected: ${GREEN}FluidNC v${VERSION}${NC}"
+        ;;
+    2)
+        VERSION="$VERSION_MINI"
+        echo -e "\nSelected: ${GREEN}FluidNC v${VERSION}${NC}"
+        ;;
+    *)
+        echo -e "${RED}Invalid choice. Exiting.${NC}"
+        exit 1
+        ;;
+esac
+
+# ─── Step 2: Detect and select serial port ─────────────────────────────────
+
+echo ""
+echo -e "${BOLD}Detecting serial ports...${NC}"
+
+# Collect available serial ports (Linux + macOS patterns)
+PORTS=()
+for port in /dev/ttyUSB* /dev/ttyACM* /dev/cu.usbserial* /dev/cu.wchusbserial* /dev/cu.SLAB_USBtoUART*; do
+    if [[ -e "$port" ]]; then
+        PORTS+=("$port")
+    fi
+done
+
+if [[ ${#PORTS[@]} -eq 0 ]]; then
+    echo -e "${RED}No serial ports found!${NC}"
+    echo ""
+    echo "Make sure your ESP32 board is connected via USB."
+    echo "On Linux, you may need to add your user to the 'dialout' group:"
+    echo "  sudo usermod -a -G dialout \$USER"
+    exit 1
+fi
+
+if [[ ${#PORTS[@]} -eq 1 ]]; then
+    PORT="${PORTS[0]}"
+    echo -e "Found port: ${GREEN}${PORT}${NC}"
+    read -p "Use this port? [Y/n]: " confirm
+    if [[ "$confirm" =~ ^[Nn] ]]; then
+        echo -e "${RED}Exiting.${NC}"
+        exit 1
+    fi
+else
+    echo -e "Found ${GREEN}${#PORTS[@]}${NC} serial ports:"
+    echo ""
+    for i in "${!PORTS[@]}"; do
+        echo -e "  ${GREEN}$((i + 1)))${NC} ${PORTS[$i]}"
+    done
+    echo ""
+    read -p "Select port [1-${#PORTS[@]}]: " port_choice
+
+    if [[ "$port_choice" -ge 1 && "$port_choice" -le ${#PORTS[@]} ]] 2>/dev/null; then
+        PORT="${PORTS[$((port_choice - 1))]}"
+    else
+        echo -e "${RED}Invalid choice. Exiting.${NC}"
+        exit 1
+    fi
+fi
+
+echo -e "Using port: ${GREEN}${PORT}${NC}"
+
+# ─── Step 3: Check for esptool ─────────────────────────────────────────────
+
+if ! command -v esptool.py &> /dev/null && ! command -v esptool &> /dev/null; then
+    echo ""
+    echo -e "${YELLOW}esptool not found. Installing...${NC}"
+    pip install esptool
+fi
+
+# Determine the esptool command name
+if command -v esptool.py &> /dev/null; then
+    ESPTOOL="esptool.py"
+elif command -v esptool &> /dev/null; then
+    ESPTOOL="esptool"
+else
+    echo -e "${RED}Failed to install esptool. Please install manually: pip install esptool${NC}"
+    exit 1
+fi
+
+# ─── Step 4: Download and extract ──────────────────────────────────────────
+
+ZIP_NAME="fluidnc-v${VERSION}-posix.zip"
+DOWNLOAD_URL="${GITHUB_BASE}/v${VERSION}/${ZIP_NAME}"
+EXTRACT_DIR="fluidnc-v${VERSION}-posix"
+
+WORK_DIR=$(mktemp -d)
+echo ""
+echo -e "${BLUE}Downloading FluidNC v${VERSION}...${NC}"
+if ! curl -L --fail --progress-bar "$DOWNLOAD_URL" -o "$WORK_DIR/$ZIP_NAME"; then
+    echo -e "${RED}Download failed!${NC}"
+    echo "URL: $DOWNLOAD_URL"
+    exit 1
+fi
+
+echo -e "${BLUE}Extracting...${NC}"
+unzip -q "$WORK_DIR/$ZIP_NAME" -d "$WORK_DIR"
+
+if [[ ! -d "$WORK_DIR/$EXTRACT_DIR" ]]; then
+    echo -e "${RED}Expected directory $EXTRACT_DIR not found after extraction.${NC}"
+    exit 1
+fi
+
+FLASH_DIR="$WORK_DIR/$EXTRACT_DIR"
+
+# ─── Step 5: Flash firmware ────────────────────────────────────────────────
+
+echo ""
+echo -e "${BOLD}${CYAN}══════════════════════════════════════════${NC}"
+echo -e "${BOLD}  Flashing FluidNC v${VERSION} to ${PORT}${NC}"
+echo -e "${BOLD}${CYAN}══════════════════════════════════════════${NC}"
+echo ""
+echo -e "${YELLOW}Do NOT disconnect the board during flashing!${NC}"
+echo ""
+
+FLASH_SUCCESS=true
+
+# --- 5a: Flash WiFi firmware ---
+echo -e "${BLUE}[1/2] Flashing WiFi firmware...${NC}"
+echo ""
+
+WIFI_OUTPUT=$($ESPTOOL --chip esp32 --port "$PORT" --baud 460800 \
+    --before default_reset --after hard_reset \
+    write_flash -z --flash_mode dio --flash_freq 80m --flash_size detect \
+    0x1000  "$FLASH_DIR/wifi/bootloader.bin" \
+    0x8000  "$FLASH_DIR/wifi/partitions.bin" \
+    0xe000  "$FLASH_DIR/common/boot_app0.bin" \
+    0x10000 "$FLASH_DIR/wifi/firmware.bin" 2>&1) || true
+
+echo "$WIFI_OUTPUT"
+echo ""
+
+if echo "$WIFI_OUTPUT" | grep -q "Hard resetting via RTS pin"; then
+    echo -e "${GREEN}Firmware flash successful!${NC}"
+else
+    echo -e "${RED}Firmware flash may have failed!${NC}"
+    FLASH_SUCCESS=false
+fi
+
+# --- 5b: Flash filesystem (LittleFS) ---
+echo ""
+echo -e "${BLUE}[2/2] Flashing filesystem (LittleFS)...${NC}"
+echo ""
+
+FS_OUTPUT=$($ESPTOOL --chip esp32 --port "$PORT" --baud 460800 \
+    --before default_reset --after hard_reset \
+    write_flash -z --flash_mode dio --flash_freq 80m --flash_size detect \
+    0x3d0000 "$FLASH_DIR/wifi/littlefs.bin" 2>&1) || true
+
+echo "$FS_OUTPUT"
+echo ""
+
+if echo "$FS_OUTPUT" | grep -q "Hard resetting via RTS pin"; then
+    echo -e "${GREEN}Filesystem flash successful!${NC}"
+else
+    echo -e "${RED}Filesystem flash may have failed!${NC}"
+    FLASH_SUCCESS=false
+fi
+
+# ─── Step 6: Summary ──────────────────────────────────────────────────────
+
+echo ""
+echo -e "${BOLD}${CYAN}══════════════════════════════════════════${NC}"
+if [[ "$FLASH_SUCCESS" == true ]]; then
+    echo -e "${GREEN}  FluidNC v${VERSION} flashed successfully!${NC}"
+    echo -e "${BOLD}${CYAN}══════════════════════════════════════════${NC}"
+    echo ""
+    echo "The board has been reset and should now be running FluidNC."
+    echo "Connect to the 'FluidNC' WiFi network to access the web UI."
+else
+    echo -e "${RED}  Flashing completed with errors!${NC}"
+    echo -e "${BOLD}${CYAN}══════════════════════════════════════════${NC}"
+    echo ""
+    echo "Review the output above for error details."
+    echo "Common fixes:"
+    echo "  - Hold the BOOT button on the ESP32 while flashing"
+    echo "  - Try a different USB cable (data cable, not charge-only)"
+    echo "  - Check port permissions: sudo chmod 666 $PORT"
+    echo "  - Try a lower baud rate by editing this script (change 460800 to 115200)"
+    exit 1
+fi