ci: Several improvements

.github/workflows/build-and-target-test.yml

@@ -33,6 +33,12 @@ on:
         type: boolean
         required: false
         default: false
+      test_filter:
+        description: 'Pytest -k expression to isolate tests (e.g. "test_app_fota").
+          Leave empty to run all tests for the selected boards.'
+        type: string
+        required: false
+        default: ""
 
   workflow_call:
     inputs:
@@ -157,3 +163,4 @@ jobs:
       artifact_run_id: ${{ needs.build.outputs.run_id }}
       devices: ${{ needs.setup.outputs.devices }}
       run_nightly_tests: ${{ needs.setup.outputs.run_nightly_tests == 'true' }}
+      pytest_args: ${{ inputs.test_filter != '' && format('-k "{0}"', inputs.test_filter) || '' }}

.github/workflows/target-test.yml

@@ -22,6 +22,12 @@ on:
         type: string
         required: true
         default: thingy91x
+      pytest_args:
+        description: Extra arguments appended to the pytest invocation
+          (e.g. "-k test_app_fota"). Leave empty for the default behaviour.
+        type: string
+        required: false
+        default: ""
 
   workflow_dispatch:
     inputs:
@@ -48,6 +54,12 @@ on:
         type: string
         required: true
         default: thingy91x
+      pytest_args:
+        description: Extra arguments appended to the pytest invocation
+          (e.g. "-k test_app_fota"). Leave empty for the default behaviour.
+        type: string
+        required: false
+        default: ""
 
 permissions:
   contents: read
@@ -161,7 +173,8 @@ jobs:
           pytest -v "${pytest_marker[@]}" \
             --junit-xml=results/test-results.xml \
             --html=results/test-results.html --self-contained-html \
-            ${PYTEST_PATH}
+            ${PYTEST_PATH} \
+            ${{ inputs.pytest_args }}
 
         shell: bash
         env:
@@ -175,6 +188,7 @@ jobs:
           MEMFAULT_ORGANIZATION_SLUG: ${{ vars.MEMFAULT_ORGANIZATION_SLUG }}
           MEMFAULT_PROJECT_SLUG: ${{ vars.MEMFAULT_PROJECT_SLUG }}
           APP_BUNDLEID: ${{ vars.APP_BUNDLEID }}
+          MCUBOOT_BUNDLEID: ${{ vars.MCUBOOT_BUNDLEID }}
 
       - name: Generate and Push Power Badge
         if: ${{ always() && matrix.device == 'ppk_thingy91x' }}

app/Kconfig.sysbuild

@@ -11,6 +11,9 @@ endchoice
 config SECURE_BOOT_APPCORE
 	default y if BOARD_NRF9151DK_NRF9151_NS
 
+config SECURE_BOOT_SIGNING_KEY_FILE
+	default "$(ZEPHYR_NRF_MODULE_DIR)/boards/nordic/thingy91x/nsib_signing_key.pem" if BOARD_NRF9151DK_NRF9151_NS
+
 config WIFI_NRF70
 	default y if BOARD_THINGY91X_NRF9151_NS
 

app/src/modules/fota/fota.c

@@ -12,6 +12,7 @@
 #include <net/nrf_cloud_fota_poll.h>
 #include <zephyr/sys/reboot.h>
 #include <zephyr/dfu/mcuboot.h>
+#include <zephyr/storage/flash_map.h>
 #include <zephyr/task_wdt/task_wdt.h>
 #include <nrf_cloud_fota.h>
 #include <zephyr/smf.h>
@@ -513,11 +514,43 @@ static enum smf_state_result state_polling_for_update_run(void *obj)
 	return SMF_EVENT_PROPAGATE;
 }
 
+/* Erase the MCUboot secondary-slot trailer (last 4 KiB) before each download.
+ *
+ * stream_flash only erases sectors it writes; the trailer sector is skipped.
+ * On external SPI-NOR secondaries, J-Link does not clear it, so a stale trailer
+ * makes boot_set_pending() fail (-EFAULT) after a good download.
+ * One trailer page (~50 ms) avoids erasing the full slot (~800 KiB).
+ */
+static void erase_secondary_trailer(void)
+{
+	const struct flash_area *fa;
+	int err = flash_area_open(PARTITION_ID(slot1_partition), &fa);
+
+	if (err) {
+		LOG_WRN("flash_area_open(slot1) failed: %d, skipping trailer erase", err);
+		return;
+	}
+
+	const size_t page_size = 4096;
+	const off_t trailer_off = fa->fa_size - page_size;
+
+	err = flash_area_erase(fa, trailer_off, page_size);
+	if (err) {
+		LOG_WRN("flash_area_erase(slot1 trailer) failed: %d", err);
+	} else {
+		LOG_DBG("Erased slot1 trailer page at offset 0x%lx", (long)trailer_off);
+	}
+
+	flash_area_close(fa);
+}
+
 static void state_downloading_update_entry(void *obj)
 {
 	ARG_UNUSED(obj);
 
 	LOG_DBG("%s", __func__);
+
+	erase_secondary_trailer();
 }
 
 static enum smf_state_result state_downloading_update_run(void *obj)

docs/common/test_and_ci_setup.md

@@ -19,7 +19,7 @@ The CI pipeline is triggered as follows:
 
 - Pull Request: `build.yml`, `sonarcloud.yml`, `compliance.yml`. No target tests are run on PR to avoid instabilities.
 - Push to main: `build-and-target-test.yml`, `sonarcloud.yml`, `doc-sync.yml`. Only "fast" target tests are run. Avoiding excessively time-consuming tests.
-- Nightly: `build-and-target-test.yml`. Full set of target tests. Includes slow tests such as the full modem FOTA test and the power consumption test.
+- Nightly: `build-and-target-test.yml`. Full set of target tests. Includes slow tests such as the full modem FOTA test, application and bootloader (MCUboot) FOTA.
 
 ### Hardware Tests
 

tests/module/fota/CMakeLists.txt

@@ -26,6 +26,7 @@ zephyr_include_directories(${ZEPHYR_BASE}/include/zephyr/)
 zephyr_include_directories(${ZEPHYR_BASE}/subsys/testsuite/include)
 zephyr_include_directories(${ZEPHYR_BASE}/../nrfxlib/nrf_modem/include)
 
+zephyr_include_directories(${NRF_DIR}/include)
 zephyr_include_directories(${NRF_DIR}/include/net)
 zephyr_include_directories(${NRF_DIR}/subsys/net/lib/nrf_cloud/include)
 zephyr_include_directories(${NRF_DIR}/subsys/net/lib/nrf_cloud/common/include)

tests/module/fota/src/fota_module_test.c

@@ -8,6 +8,9 @@
 #include <zephyr/zbus/zbus.h>
 #include <zephyr/task_wdt/task_wdt.h>
 #include <zephyr/logging/log.h>
+#include <zephyr/storage/flash_map.h>
+#include <dfu/dfu_target.h>
+#include <net/nrf_cloud.h>
 #include <net/nrf_cloud_fota_poll.h>
 
 #include "app_common.h"
@@ -22,8 +25,23 @@ FAKE_VALUE_FUNC(int, nrf_cloud_fota_poll_process_pending, struct nrf_cloud_fota_
 FAKE_VALUE_FUNC(int, nrf_cloud_fota_poll_process, struct nrf_cloud_fota_poll_ctx *);
 FAKE_VALUE_FUNC(int, nrf_cloud_fota_poll_update_apply, struct nrf_cloud_fota_poll_ctx *);
 FAKE_VALUE_FUNC(int, fota_download_cancel);
+FAKE_VALUE_FUNC(int, flash_area_open, uint8_t, const struct flash_area **);
+FAKE_VALUE_FUNC(int, flash_area_erase, const struct flash_area *, off_t, size_t);
+FAKE_VOID_FUNC(flash_area_close, const struct flash_area *);
 FAKE_VOID_FUNC1(callback_t, int);
 
+static struct flash_area fake_slot1_area = {
+	.fa_size = 800 * 1024,
+};
+
+static int flash_area_open_fake_impl(uint8_t id, const struct flash_area **fa)
+{
+	ARG_UNUSED(id);
+
+	*fa = &fake_slot1_area;
+	return 0;
+}
+
 ZBUS_MSG_SUBSCRIBER_DEFINE(fota_subscriber);
 ZBUS_CHAN_ADD_OBS(fota_chan, fota_subscriber, 0);
 
@@ -63,6 +81,12 @@ void setUp(void)
 	RESET_FAKE(nrf_cloud_fota_poll_process);
 	RESET_FAKE(nrf_cloud_fota_poll_update_apply);
 	RESET_FAKE(fota_download_cancel);
+	RESET_FAKE(flash_area_open);
+	RESET_FAKE(flash_area_erase);
+	RESET_FAKE(flash_area_close);
+
+	flash_area_open_fake.custom_fake = flash_area_open_fake_impl;
+	flash_area_erase_fake.return_val = 0;
 
 	FFF_RESET_HISTORY();
 

tests/on_target/tests/test_functional/test_fota.py

@@ -27,16 +27,22 @@
 MFW_VERSION = "mfw_nrf91x1_2.0.4"
 
 APP_BUNDLEID = os.getenv("APP_BUNDLEID")
+MCUBOOT_BUNDLEID = os.getenv("MCUBOOT_BUNDLEID")
 
 TEST_APP_BIN = {
     "thingy91x": "artifacts/stable_version_jan_2025-update-signed.bin",
     "nrf9151dk": "artifacts/nrf9151dk_mar_2025_update_signed.bin"
 }
 
 DEVICE_MSG_TIMEOUT = 60 * 5
-APP_FOTA_TIMEOUT = 60 * 10
+APP_FOTA_TIMEOUT = 60 * 15
+BOOTLOADER_FOTA_TIMEOUT = 60 * 20
 FULL_MFW_FOTA_TIMEOUT = 60 * 30
 
+BOOTLOADER_VERSION_BASELINE = "2"
+BOOTLOADER_VERSION_UPDATED = "3"
+BOOTLOADER_FIRMWARE_VERSION_LOG = "Firmware version 3"
+
 def await_nrfcloud(func, expected, field, timeout):
     start = time.time()
     logger.info(f"Awaiting {field} == {expected} in nrfcloud shadow...")
@@ -61,6 +67,41 @@ def get_modemversion(dut_fota):
     shadow = dut_fota.fota.get_device(dut_fota.device_id)
     return shadow["state"]["reported"]["device"]["deviceInfo"]["modemFirmware"]
 
+def get_bootloaderversion(dut_fota):
+    shadow = dut_fota.fota.get_device(dut_fota.device_id)
+    return shadow["state"]["reported"]["device"]["deviceInfo"]["bootloaderVersion"]
+
+def await_bootloader_version(dut_fota, expected, timeout=DEVICE_MSG_TIMEOUT):
+    start = time.time()
+    logger.info(f"Awaiting bootloaderVersion == {expected} in nrfcloud shadow...")
+    while True:
+        time.sleep(5)
+        if time.time() - start > timeout:
+            raise RuntimeError(
+                f"Timeout awaiting bootloaderVersion == {expected}")
+        try:
+            version = get_bootloaderversion(dut_fota)
+        except (KeyError, TypeError) as e:
+            logger.warning(f"bootloaderVersion not in shadow yet: {e}")
+            continue
+        except Exception as e:
+            logger.warning(f"Exception getting bootloaderVersion: {e}")
+            continue
+        logger.debug(f"Reported bootloaderVersion: {version}")
+        if version == expected:
+            return
+
+def trigger_fota_poll(dut_fota, max_attempts=3):
+    for i in range(max_attempts):
+        try:
+            time.sleep(10)
+            dut_fota.uart.write("att_button press 1\r\n")
+            dut_fota.uart.wait_for_str("nrf_cloud_fota_poll: Starting FOTA download", timeout=30)
+            return
+        except AssertionError:
+            continue
+    raise AssertionError(f"Fota update not available after {max_attempts} attempts")
+
 def perform_disconnect_reconnect(dut_fota, expected_percentage):
     """Helper function to perform a disconnect/reconnect sequence and verify resumption at expected percentage"""
     patterns_lte_offline = ["network: lte_lc_evt_handler: PDN connection network detached"]
@@ -170,17 +211,7 @@ def _run_fota(bundle_id="", fota_type="app", fotatimeout=APP_FOTA_TIMEOUT, new_v
             pytest.skip(f"FOTA create_job REST API error: {e}")
         logger.info(f"Created FOTA Job (ID: {dut_fota.data['job_id']})")
 
-        # Sleep a bit and trigger fota poll
-        for i in range(3):
-            try:
-                time.sleep(10)
-                dut_fota.uart.write("att_button press 1\r\n")
-                dut_fota.uart.wait_for_str("nrf_cloud_fota_poll: Starting FOTA download", timeout=30)
-                break
-            except AssertionError:
-                continue
-        else:
-            raise AssertionError(f"Fota update not available after {i} attempts")
+        trigger_fota_poll(dut_fota)
 
         if reschedule:
             run_fota_reschedule(dut_fota, fota_type)
@@ -284,6 +315,77 @@ def test_app_fota(run_fota_fixture):
         bundle_id=APP_BUNDLEID,
     )
 
+@pytest.mark.slow
+def test_bootloader_fota(dut_fota, hex_file):
+    '''
+    Test MCUboot bootloader (B1) FOTA on Thingy:91 X.
+
+    Verifies deviceInfo.bootloaderVersion in the nRF Cloud shadow (baseline v2,
+    v3 after FOTA) and B0 UART "Firmware version 3" after the swap reboot.
+
+    The finally block re-flashes baseline merged.hex to restore the DUT.
+    '''
+    if os.getenv("DUT_DEVICE_TYPE") != "thingy91x":
+        pytest.skip("Bootloader FOTA test runs on thingy91x only")
+    if not MCUBOOT_BUNDLEID:
+        pytest.skip("MCUBOOT_BUNDLEID environment variable not set")
+
+    try:
+        flash_device(os.path.abspath(hex_file))
+        dut_fota.uart.xfactoryreset()
+        dut_fota.uart.flush()
+        reset_device()
+
+        dut_fota.uart.wait_for_str_with_retries(
+            "Connected to Cloud", max_retries=3, timeout=240, reset_func=reset_device)
+
+        await_bootloader_version(dut_fota, BOOTLOADER_VERSION_BASELINE)
+
+        try:
+            dut_fota.data["job_id"] = dut_fota.fota.create_fota_job(
+                dut_fota.device_id, MCUBOOT_BUNDLEID)
+            dut_fota.data["bundle_id"] = MCUBOOT_BUNDLEID
+        except NRFCloudFOTAError as e:
+            pytest.skip(f"FOTA create_job REST API error: {e}")
+        logger.info(f"Created bootloader FOTA job (ID: {dut_fota.data['job_id']})")
+
+        trigger_fota_poll(dut_fota)
+
+        dut_fota.uart.wait_for_str("fota_download: B1 update, selected", timeout=120)
+        dut_fota.uart.wait_for_str("Download complete", timeout=BOOTLOADER_FOTA_TIMEOUT)
+        post_download_pos = dut_fota.uart.get_size()
+
+        # B1 FOTA: reboot, MCUboot test-swap, then B0 boots slot 1 with new fw_info.
+        dut_fota.uart.wait_for_str(
+            BOOTLOADER_FIRMWARE_VERSION_LOG,
+            timeout=BOOTLOADER_FOTA_TIMEOUT,
+            start_pos=post_download_pos,
+            error_msg="Expected B0 fw_info v3 after download",
+        )
+
+        await_nrfcloud(
+            functools.partial(dut_fota.fota.get_fota_status, dut_fota.data["job_id"]),
+            "IN_PROGRESS",
+            "FOTA status",
+            BOOTLOADER_FOTA_TIMEOUT,
+        )
+        await_nrfcloud(
+            functools.partial(dut_fota.fota.get_fota_status, dut_fota.data["job_id"]),
+            "COMPLETED",
+            "FOTA status",
+            BOOTLOADER_FOTA_TIMEOUT,
+        )
+        if not dut_fota.fota.get_fota_completed_executions(dut_fota.data["job_id"]) > 0:
+            raise AssertionError("Bootloader FOTA job completed but no devices succeeded")
+
+        dut_fota.uart.wait_for_str_with_retries(
+            "Connected to Cloud", max_retries=5, timeout=300, reset_func=reset_device)
+
+        await_bootloader_version(dut_fota, BOOTLOADER_VERSION_UPDATED,
+                                 timeout=BOOTLOADER_FOTA_TIMEOUT)
+    finally:
+        flash_device(os.path.abspath(hex_file))
+
 def test_delta_mfw_fota(run_fota_fixture):
     '''
     Test delta modem FOTA on nrf9151