main no longer fits the 3.5 MiB OTA partitions: esp32s3 app image is ~44 KB over #268

Building current main (ca199f6) for esp32s3 fails the final size check:

Error: All app partitions are too small for binary micropython.bin size 0x38b120:
- Part 'ota_0' 0/16 @ 0x20000 size 0x380000 (overflow 0xb120)
- Part 'ota_1' 0/17 @ 0x3a0000 size 0x380000 (overflow 0xb120)

That's an app image of 3,715,360 bytes against the 3,670,016-byte (3.5 MiB) slots set in build_mpos.sh for the fri3d devices — 45,344 bytes over, so the next release currently can't ship for those partitions.

Data points:

• The pinned lvgl_micropython submodule (c3bbcfd3) already includes the compressed fonts from fonts: compress montserrat 10-18, saving ~19 KB of flash lvgl_micropython#8 (−19 KB) — without them this would be ~64 KB over.
• The 0.17.3 release .ota was 3,654,784 bytes (15 KB of headroom), so main has grown by ~59 KB since 0.17.3 (roughly: QR deep links + FontManager rework + unihiker k10 board support + camera hardening + everything else merged this week).
• Repro: ./scripts/build_mpos.sh esp32s3 on current main (macOS host, idf 5.5).

Happy to help hunt for savings — an obvious first step would be a small CI check that fails PRs when the esp32s3 image exceeds the partition budget, so this gets caught at merge time instead of at release time.

🤖 Generated with Claude Code