ci(build-all): MCU-based groups, cache seeders, build infra overhaul (#27050)

Signed-off-by: Ramon Roche <mrpollo@gmail.com>

.github/workflows/build_all_targets.yml

@@ -69,6 +69,7 @@ jobs:
     runs-on: [runs-on,runner=1cpu-linux-x64,image=ubuntu24-full-x64,"run-id=${{ github.run_id }}",spot=false]
     outputs:
       matrix: ${{ steps.set-matrix.outputs.matrix }}
+      seeders: ${{ steps.set-seeders.outputs.seeders }}
       timestamp: ${{ steps.set-timestamp.outputs.timestamp }}
       branchname: ${{ steps.set-branch.outputs.branchname }}
     steps:
@@ -82,19 +83,17 @@ jobs:
           restore-keys: |
             ${{ runner.os }}-pip-
 
-      - name: Update python packaging to avoid canonicalize_version() error
-        run: |
-            pip3 install -U packaging
-
       - name: Install Python Dependencies
-        uses: py-actions/py-dependency-install@v4
-        with:
-          path: "./Tools/setup/requirements.txt"
+        run: pip3 install -U packaging -r ./Tools/setup/requirements.txt
 
       - id: set-matrix
         name: Generate Build Matrix
         run: echo "matrix=$(./Tools/ci/generate_board_targets_json.py --group)" >> $GITHUB_OUTPUT
 
+      - id: set-seeders
+        name: Generate Seeder Matrix
+        run: echo "seeders=$(./Tools/ci/generate_board_targets_json.py --group --seeders)" >> $GITHUB_OUTPUT
+
       - id: set-timestamp
         name: Save Current Timestamp
         run: echo "timestamp=$(date +"%Y%m%d%H%M%S")" >> $GITHUB_OUTPUT
@@ -116,11 +115,52 @@ jobs:
           echo "${{ steps.set-branch.outputs.branchname }}"
           echo "$(./Tools/ci/generate_board_targets_json.py --group --verbose)"
 
+  # ===========================================================================
+  # CACHE SEEDER JOBS
+  # ===========================================================================
+  # Build one representative target per chip family to warm the ccache.
+  # Matrix jobs fall back to these caches via restore-keys when no
+  # group-specific cache exists yet. If any seeder fails, the build matrix
+  # does not start, catching common build errors early.
+  # ===========================================================================
+
+  seed:
+    name: Seed [${{ matrix.chip_family }}]
+    needs: group_targets
+    runs-on: [runs-on,"runner=8cpu-linux-${{ matrix.runner }}","image=ubuntu24-full-${{ matrix.runner }}","run-id=${{ github.run_id }}",spot=false,extras=s3-cache]
+    strategy:
+      matrix: ${{ fromJson(needs.group_targets.outputs.seeders) }}
+      fail-fast: false
+    container:
+      image: ${{ matrix.container }}
+      credentials:
+        username: ${{ github.actor }}
+        password: ${{ secrets.GITHUB_TOKEN }}
+    steps:
+      - uses: runs-on/action@v2
+      - uses: actions/checkout@v6
+        with:
+          fetch-depth: 1
+      - name: Configure Git Safe Directory
+        run: git config --system --add safe.directory '*'
+      - uses: ./.github/actions/setup-ccache
+        id: ccache
+        with:
+          cache-key-prefix: ccache-${{ matrix.chip_family }}-${{ matrix.runner }}-seeder
+          max-size: 400M
+      - name: Build seed target
+        run: make ${{ matrix.target }}
+      - uses: ./.github/actions/save-ccache
+        if: always()
+        with:
+          cache-primary-key: ${{ steps.ccache.outputs.cache-primary-key }}
+
   setup:
     name: Build [${{ matrix.runner }}][${{ matrix.group }}]
     # runs-on: ubuntu-latest
-    runs-on: [runs-on,"runner=8cpu-linux-${{ matrix.runner }}","image=ubuntu24-full-${{ matrix.runner }}","run-id=${{ github.run_id }}",spot=false]
-    needs: group_targets
+    runs-on: [runs-on,"runner=4cpu-linux-${{ matrix.runner }}","image=ubuntu24-full-${{ matrix.runner }}","run-id=${{ github.run_id }}",spot=false,extras=s3-cache]
+    needs: [group_targets, seed]
+    if: "!failure() && !cancelled()"
     strategy:
       matrix: ${{ fromJson(needs.group_targets.outputs.matrix) }}
       fail-fast: false
@@ -137,34 +177,29 @@ jobs:
       - name: Configure Git Safe Directory
         run: git config --system --add safe.directory '*'
 
-      # ccache key breakdown:
-      # ccache-<system os>-<system arch>-<builder group>-
-      # ccache-<linux>-<arm64>-<aarch64-0>-
-      # ccache-<linux>-<x64>-<nuttx-0>-
-      - name: Cache Restore from Key
-        id: cc_restore
+      - name: Cache - Restore ccache
+        id: ccache-restore
         uses: actions/cache/restore@v5
         with:
           path: ~/.ccache
-          key: ${{ format('ccache-{0}-{1}-{2}', runner.os, matrix.runner, matrix.group) }}
+          key: ccache-${{ matrix.chip_family }}-${{ matrix.runner }}-${{ matrix.group }}-${{ github.ref_name }}-${{ github.sha }}
           restore-keys: |
-            ccache-${{ runner.os }}-${{ matrix.runner }}-${{ matrix.group }}-
-            ccache-${{ runner.os }}-${{ matrix.runner }}-
-            ccache-${{ runner.os }}-${{ matrix.runner }}-
-            ccache-${{ runner.os }}-
-            ccache-
+            ccache-${{ matrix.chip_family }}-${{ matrix.runner }}-${{ matrix.group }}-${{ github.ref_name }}-
+            ccache-${{ matrix.chip_family }}-${{ matrix.runner }}-${{ matrix.group }}-${{ github.base_ref || 'main' }}-
+            ccache-${{ matrix.chip_family }}-${{ matrix.runner }}-${{ matrix.group }}-
+            ccache-${{ matrix.chip_family }}-${{ matrix.runner }}-
 
-      - name: Cache Config and Stats
+      - name: Cache - Configure ccache
         run: |
-            mkdir -p ~/.ccache
-            echo "base_dir = ${GITHUB_WORKSPACE}" > ~/.ccache/ccache.conf
-            echo "compression = true" >> ~/.ccache/ccache.conf
-            echo "compression_level = 6" >> ~/.ccache/ccache.conf
-            echo "max_size = 120M" >> ~/.ccache/ccache.conf
-            echo "hash_dir = false" >> ~/.ccache/ccache.conf
-            echo "compiler_check = content" >> ~/.ccache/ccache.conf
-            ccache -s
-            ccache -z
+          mkdir -p ~/.ccache
+          echo "base_dir = ${GITHUB_WORKSPACE}" > ~/.ccache/ccache.conf
+          echo "compression = true" >> ~/.ccache/ccache.conf
+          echo "compression_level = 6" >> ~/.ccache/ccache.conf
+          echo "max_size = ${{ matrix.cache_size }}" >> ~/.ccache/ccache.conf
+          echo "hash_dir = false" >> ~/.ccache/ccache.conf
+          echo "compiler_check = content" >> ~/.ccache/ccache.conf
+          ccache -s
+          ccache -z
 
       - name: Building Artifacts for [${{ matrix.targets }}]
         run: |
@@ -180,18 +215,10 @@ jobs:
           name: px4_${{matrix.group}}_build_artifacts
           path: artifacts/
 
-      - name: Cache Post Build Stats
-        if: always()
-        run: |
-            ccache -s
-            ccache -z
-
-      - name: Cache Save
-        if: always()
-        uses: actions/cache/save@v5
+      - uses: ./.github/actions/save-ccache
+        if: success()
         with:
-          path: ~/.ccache
-          key: ${{ steps.cc_restore.outputs.cache-primary-key }}
+          cache-primary-key: ${{ steps.ccache-restore.outputs.cache-primary-key }}
 
   # ===========================================================================
   # ARTIFACT UPLOAD JOB

Tools/ci/build_all_config.yml

@@ -0,0 +1,71 @@
+# Build All Targets CI Configuration
+#
+# Controls board grouping, cache sizes, runner specs, and seeder targets
+# for the build_all_targets workflow. Forks can customize this file to
+# adjust for their infrastructure (e.g., lower cache sizes for GitHub's
+# 10GB cache limit, fewer CPU cores for smaller runners).
+
+# Container images
+containers:
+  default: "ghcr.io/px4/px4-dev:v1.17.0-rc2"
+  voxl2: "ghcr.io/px4/px4-dev-voxl2:v1.7"
+
+# Runner specs
+runners:
+  seeder_cpu: 8
+  matrix_cpu: 4
+
+# Default ccache max-size for build groups
+cache:
+  default_size: "400M"
+  # Per-chip overrides for groups with many diverse boards
+  chip_sizes:
+    stm32h7: "800M"
+    stm32f4: "800M"
+    stm32f7: "800M"
+    imxrt: "800M"
+
+# Board grouping limits
+grouping:
+  # Max targets per group, tuned for ~10 min wall-clock with warm cache
+  chip_split_limits:
+    stm32h7: 10
+    stm32f7: 12
+    stm32f4: 20
+    stm32f1: 39
+    imxrt: 12
+    kinetis: 14
+    s32k: 17
+    rp2040: 10
+    special: 10
+    native: 17
+  default_split_limit: 12
+  # Minimum targets for a manufacturer to get a named group
+  lower_limit: 3
+  # If last chunk has fewer targets than this, merge into previous chunk
+  merge_back_threshold: 5
+
+# Labels that isolate builds into the "special" group
+special_labels:
+  - lto
+  - protected
+
+# NXP chip families are pooled under "nxp-{chip}" regardless of board directory
+nxp_chip_families:
+  - imxrt
+  - kinetis
+  - s32k
+
+# Seeder targets: one representative build per chip family
+seeders:
+  stm32h7: "px4_fmu-v6x_default"
+  stm32f7: "px4_fmu-v5_default"
+  stm32f4: "px4_fmu-v4_default"
+  stm32f1: "px4_io-v2_default"
+  imxrt: "nxp_mr-tropic_default"
+  kinetis: "nxp_fmuk66-v3_default"
+  s32k: "nxp_mr-canhubk3_default"
+  rp2040: "raspberrypi_pico_default"
+  special: "px4_fmu-v6x_default"
+  native: "px4_sitl_default"
+  voxl2: "modalai_voxl2_default"

Tools/ci/build_all_runner.sh

@@ -3,7 +3,6 @@
 # Please only modify if you know what you are doing
 set -e
 
-echo "### :clock1: Build Times" >> $GITHUB_STEP_SUMMARY
 targets=$1
 for target in ${targets//,/ }
 do
@@ -14,6 +13,5 @@ do
     diff=$(($stop-$start))
     build_time="$(($diff /60/60))h $(($diff /60))m $(($diff % 60))s elapsed"
     echo -e "\033[0;32mBuild Time: [$build_time]"
-    echo "* **$target** - $build_time" >> $GITHUB_STEP_SUMMARY
     echo "::endgroup::"
 done

Tools/ci/generate_board_targets_json.py

@@ -16,6 +16,7 @@ kconf.warn_assign_override = False
 kconf.warn_assign_redun = False
 
 source_dir = os.path.join(os.path.dirname(os.path.abspath(__file__)), '..')
+boards_dir = os.path.join(source_dir, '..', 'boards')
 
 parser = argparse.ArgumentParser(description='Generate build targets')
 
@@ -26,6 +27,8 @@ parser.add_argument('-p', '--pretty', dest='pretty', action='store_true',
 parser.add_argument('-g', '--groups', dest='group', action='store_true',
                     help='Groups targets')
 parser.add_argument('-f', '--filter', dest='filter', help='comma separated list of build target name prefixes to include instead of all e.g. "px4_fmu-v5_"')
+parser.add_argument('-s', '--seeders', dest='seeders', action='store_true',
+                    help='Output seeder matrix JSON (one entry per chip family)')
 
 args = parser.parse_args()
 verbose = args.verbose
@@ -35,8 +38,14 @@ if args.filter:
     for target in args.filter.split(','):
         target_filter.append(target)
 
-default_container = 'ghcr.io/px4/px4-dev:v1.16.0-rc1-258-g0369abd556'
-voxl2_container = 'ghcr.io/px4/px4-dev-voxl2:v1.5'
+# Load CI configuration from YAML
+import yaml
+ci_config_path = os.path.join(os.path.dirname(os.path.abspath(__file__)), 'build_all_config.yml')
+with open(ci_config_path) as f:
+    ci_config = yaml.safe_load(f)
+
+default_container = ci_config['containers']['default']
+voxl2_container = ci_config['containers']['voxl2']
 build_configs = []
 grouped_targets = {}
 excluded_boards = ['px4_ros2', 'espressif_esp32']  # TODO: fix and enable
@@ -56,6 +65,71 @@ excluded_labels = [
     'uavcanv1', # TODO: fix and enable
     ]
 
+# Labels that mark isolated/special builds (poor cache reuse with normal builds)
+special_labels = ci_config.get('special_labels', ['lto', 'protected'])
+
+def detect_chip_family(manufacturer_name, board_name, label):
+    """Detect the chip family for a board by reading its NuttX defconfig.
+
+    Returns a chip family string used for cache grouping:
+      stm32h7, stm32f7, stm32f4, stm32f1, imxrt, kinetis, s32k, rp2040, native, special
+    """
+    # Special labels get their own group regardless of chip
+    if label in special_labels:
+        return 'special'
+
+    board_path = os.path.join(boards_dir, manufacturer_name, board_name)
+    nsh_defconfig = os.path.join(board_path, 'nuttx-config', 'nsh', 'defconfig')
+
+    if not os.path.exists(nsh_defconfig):
+        # Try bootloader defconfig as fallback
+        bl_defconfig = os.path.join(board_path, 'nuttx-config', 'bootloader', 'defconfig')
+        if os.path.exists(bl_defconfig):
+            nsh_defconfig = bl_defconfig
+        else:
+            return 'native'
+
+    arch_chip = None
+    specific_chip = None
+
+    with open(nsh_defconfig) as f:
+        for line in f:
+            line = line.strip()
+            if line.startswith('CONFIG_ARCH_CHIP='):
+                arch_chip = line.split('=')[1].strip('"')
+            elif line.startswith('CONFIG_ARCH_CHIP_STM32F') and line.endswith('=y'):
+                specific_chip = line.split('=')[0].replace('CONFIG_ARCH_CHIP_', '')
+
+    if arch_chip is None:
+        return 'native'
+
+    # Direct matches for chips that have unique CONFIG_ARCH_CHIP values
+    if arch_chip == 'stm32h7':
+        return 'stm32h7'
+    elif arch_chip == 'stm32f7':
+        return 'stm32f7'
+    elif arch_chip == 'imxrt':
+        return 'imxrt'
+    elif arch_chip == 'kinetis':
+        return 'kinetis'
+    elif arch_chip.startswith('s32k'):
+        return 's32k'
+    elif arch_chip == 'rp2040':
+        return 'rp2040'
+    elif arch_chip == 'stm32':
+        # Disambiguate STM32 sub-families using specific chip define
+        if specific_chip:
+            if specific_chip.startswith('STM32F1'):
+                return 'stm32f1'
+            elif specific_chip.startswith('STM32F4'):
+                return 'stm32f4'
+            else:
+                return 'stm32f4'  # Default STM32 to F4
+        return 'stm32f4'
+    else:
+        return 'native'
+
+target_chip_families = {}  # target_name -> chip_family mapping
 github_action_config = { 'include': build_configs }
 extra_args = {}
 if args.pretty:
@@ -66,11 +140,21 @@ def chunks(arr, size):
     for i in range(0, len(arr), size):
         yield arr[i:i + size]
 
+MERGE_BACK_THRESHOLD = 5
+
+def chunks_merged(arr, size):
+    """Split array into chunks, merging the last chunk back if it's too small."""
+    result = list(chunks(arr, size))
+    if len(result) > 1 and len(result[-1]) < MERGE_BACK_THRESHOLD:
+        result[-2] = result[-2] + result[-1]
+        result.pop()
+    return result
+
 def comma_targets(targets):
     # turns array of targets into a comma split string
     return ",".join(targets)
 
-def process_target(px4board_file, target_name):
+def process_target(px4board_file, target_name, manufacturer_name=None, board_dir_name=None, label=None):
     # reads through the board file and grabs
     # useful information for building
     ret = None
@@ -107,6 +191,16 @@ def process_target(px4board_file, target_name):
         if board_name in board_container_overrides:
             container = board_container_overrides[board_name]
 
+        # Detect chip family for cache grouping
+        chip_family = 'native'
+        if manufacturer_name and board_dir_name:
+            if platform == 'nuttx':
+                chip_family = detect_chip_family(manufacturer_name, board_dir_name, label or '')
+            elif board_name in board_container_overrides or platform in platform_container_overrides:
+                chip_family = 'native'  # voxl2/qurt targets
+            else:
+                chip_family = 'native'
+
         # Boards with container overrides get their own group
         if board_name in board_container_overrides or platform in platform_container_overrides:
             group = 'voxl2'
@@ -124,7 +218,7 @@ def process_target(px4board_file, target_name):
         else:
             if verbose: print(f'unmatched platform: {platform}')
 
-        ret = {'target': target_name, 'container': container}
+        ret = {'target': target_name, 'container': container, 'chip_family': chip_family}
         if(args.group):
             ret['arch'] = group
 
@@ -147,6 +241,8 @@ grouped_targets['base']['container'] = default_container
 grouped_targets['base']['manufacturers'] = {}
 grouped_targets['base']['manufacturers']['px4'] = []
 grouped_targets['base']['manufacturers']['px4'] += metadata_targets
+for mt in metadata_targets:
+    target_chip_families[mt] = 'native'
 
 for manufacturer in sorted(os.scandir(os.path.join(source_dir, '../boards')), key=lambda e: e.name):
     if not manufacturer.is_dir():
@@ -177,7 +273,10 @@ for manufacturer in sorted(os.scandir(os.path.join(source_dir, '../boards')), ke
                 if label in excluded_labels:
                     if verbose: print(f'excluding label {label} ({target_name})')
                     continue
-                target = process_target(files.path, target_name)
+                target = process_target(files.path, target_name,
+                                       manufacturer_name=manufacturer.name,
+                                       board_dir_name=board.name,
+                                       label=label)
                 if (args.group and target is not None):
                     if (target['arch'] not in grouped_targets):
                         grouped_targets[target['arch']] = {}
@@ -186,6 +285,7 @@ for manufacturer in sorted(os.scandir(os.path.join(source_dir, '../boards')), ke
                     if(manufacturer.name not in grouped_targets[target['arch']]['manufacturers']):
                         grouped_targets[target['arch']]['manufacturers'][manufacturer.name] = []
                     grouped_targets[target['arch']]['manufacturers'][manufacturer.name].append(target_name)
+                    target_chip_families[target_name] = target['chip_family']
                 if target is not None:
                     build_configs.append(target)
 
@@ -246,6 +346,9 @@ for manufacturer in sorted(os.scandir(os.path.join(source_dir, '../boards')), ke
                 if manufacturer.name not in grouped_targets[group]['manufacturers']:
                     grouped_targets[group]['manufacturers'][manufacturer.name] = []
                 grouped_targets[group]['manufacturers'][manufacturer.name].append(deb_target)
+                # Inherit chip_family from the default target
+                default_chip = target_chip_families.get(default_target, 'native')
+                target_chip_families[deb_target] = default_chip
             build_configs.append(target_entry)
 
 if(verbose):
@@ -261,109 +364,227 @@ if(verbose):
     print("===================")
 
 if (args.group):
-    # if we are using this script for grouping builds
-    # we loop trough the manufacturers list and split their targets
-    # if a manufacturer has more than a LIMIT of boards then we split that
-    # into sub groups such as "arch-manufacturer name-index"
-    # example:
-    #   nuttx-px4-0
-    #   nuttx-px4-1
-    #   nuttx-px4-2
-    #   nuttx-ark-0
-    #   nuttx-ark-1
-    # if the manufacturer doesn't have more targets than LIMIT then we add
-    # them to a generic group with the following structure "arch-index"
-    # example:
-    #   nuttx-0
-    #   nuttx-1
+    # Group targets by chip family for better ccache reuse.
+    # Targets sharing the same MCU family (e.g. stm32h7) benefit from
+    # a shared ccache seed since they compile the same NuttX kernel and HAL.
+    #
+    # Grouping strategy:
+    #   1. Collect all targets per (arch, chip_family, manufacturer)
+    #   2. Within each chip_family, large manufacturers get their own groups
+    #      named "{manufacturer}-{chip_family}[-N]"
+    #   3. Small manufacturers are merged into "misc-{chip_family}[-N]"
+    #   4. Special groups: "special" (lto/protected/allyes), "io" (stm32f1),
+    #      "voxl2-0" (unchanged)
+    #   5. Non-NuttX groups: "base-N", "aarch64-N", "armhf-N" (unchanged)
     final_groups = []
-    last_man = ''
-    last_arch = ''
-    SPLIT_LIMIT = 10
-    LOWER_LIMIT = 5
+    # Load grouping and cache config
+    grouping_config = ci_config.get('grouping', {})
+    CHIP_SPLIT_LIMITS = grouping_config.get('chip_split_limits', {})
+    DEFAULT_SPLIT_LIMIT = grouping_config.get('default_split_limit', 12)
+    LOWER_LIMIT = grouping_config.get('lower_limit', 3)
+
+    cache_config = ci_config.get('cache', {})
+    DEFAULT_CACHE_SIZE = cache_config.get('default_size', '400M')
+    CHIP_CACHE_SIZES = cache_config.get('chip_sizes', {})
+
     if(verbose):
         print(f'=:Architectures: [{grouped_targets.keys()}]')
+
     for arch in grouped_targets:
-        runner = 'x64' if arch in ('nuttx', 'voxl2') else 'arm64'
+        runner = 'x64'
+        # armhf and aarch64 Linux boards need the arm64 container image
+        # which ships the arm-linux-gnueabihf and aarch64-linux-gnu cross compilers
+        # (the x64 container image does not include them)
+        if arch in ('armhf', 'aarch64'):
+            runner = 'arm64'
         if(verbose):
             print(f'=:Processing: [{arch}]')
-        temp_group = []
-        for man in grouped_targets[arch]['manufacturers']:
-            if(verbose):
-                print(f'=:Processing: [{arch}][{man}]')
-            man_len = len(grouped_targets[arch]['manufacturers'][man])
-            if(man_len > LOWER_LIMIT and man_len < (SPLIT_LIMIT + 1)):
-                # Manufacturers can have their own group
+
+        if arch == 'nuttx':
+            # Re-bucket NuttX targets by chip_family then manufacturer
+            chip_man_buckets = {}  # (chip_family, manufacturer) -> [target_names]
+            for man in grouped_targets[arch]['manufacturers']:
+                for target in grouped_targets[arch]['manufacturers'][man]:
+                    chip = target_chip_families.get(target, 'native')
+                    key = (chip, man)
+                    if key not in chip_man_buckets:
+                        chip_man_buckets[key] = []
+                    chip_man_buckets[key].append(target)
+
+            # Collect all chip families present
+            chip_families_seen = sorted(set(k[0] for k in chip_man_buckets.keys()))
+
+            for chip in chip_families_seen:
+                SPLIT_LIMIT = CHIP_SPLIT_LIMITS.get(chip, DEFAULT_SPLIT_LIMIT)
+                # Special naming for certain chip families
+                if chip == 'special':
+                    chip_label = 'special'
+                elif chip == 'stm32f1':
+                    chip_label = 'io'
+                elif chip == 'rp2040':
+                    chip_label = 'special'  # rp2040 goes into special group
+                else:
+                    chip_label = chip
+
+                # Gather all (manufacturer -> targets) for this chip family
+                # NXP chip families (imxrt, kinetis, s32k) pool all manufacturers
+                # under "nxp" since all boards use NXP silicon regardless of
+                # which directory they live in (e.g., px4/fmu-v6xrt is imxrt).
+                nxp_chips = tuple(ci_config.get('nxp_chip_families', ['imxrt', 'kinetis', 's32k']))
+                man_targets = {}
+                for (c, m), targets in chip_man_buckets.items():
+                    if c == chip:
+                        man_key = 'nxp' if chip in nxp_chips else m
+                        if man_key not in man_targets:
+                            man_targets[man_key] = []
+                        man_targets[man_key].extend(targets)
+
+                # Merge rp2040 targets into a flat list for the special group
+                if chip in ('special', 'rp2040'):
+                    all_targets = []
+                    for m in sorted(man_targets.keys()):
+                        all_targets.extend(man_targets[m])
+                    # These get added to the special bucket below
+                    # We'll handle after the chip loop
+                    continue
+
                 if(verbose):
-                    print(f'=:Processing: [{arch}][{man}][{man_len}]==Manufacturers can have their own group')
-                group_name = arch + "-" + man
-                targets = comma_targets(grouped_targets[arch]['manufacturers'][man])
-                final_groups.append({
-                    "container": grouped_targets[arch]['container'],
-                    "targets": targets,
-                    "arch": arch,
-                    "runner": runner,
-                    "group": group_name,
-                    "len": len(grouped_targets[arch]['manufacturers'][man])
-                })
-            elif(man_len >= (SPLIT_LIMIT + 1)):
-                # Split big man groups into subgroups
-                # example: Pixhawk
-                if(verbose):
-                    print(f'=:Processing: [{arch}][{man}][{man_len}]==Manufacturers has multiple own groups')
-                chunk_limit = SPLIT_LIMIT
+                    print(f'=:Processing chip_family: [{chip}] ({chip_label})')
+
+                # Split into large-manufacturer groups and misc groups
+                # For NXP-exclusive chip families, always use the nxp name
+                # regardless of target count (there's no other manufacturer to pool with)
+                force_named = chip in nxp_chips
+                temp_group = []  # small manufacturers pooled here
+                for man in sorted(man_targets.keys()):
+                    man_len = len(man_targets[man])
+                    if (force_named or man_len > LOWER_LIMIT) and man_len <= SPLIT_LIMIT:
+                        group_name = f"{man}-{chip_label}"
+                        if(verbose):
+                            print(f'=:  [{man}][{man_len}] -> {group_name}')
+                        final_groups.append({
+                            "container": grouped_targets[arch]['container'],
+                            "targets": comma_targets(man_targets[man]),
+                            "arch": arch,
+                            "chip_family": chip,
+                            "runner": runner,
+                            "group": group_name,
+                            "len": man_len,
+                        })
+                    elif man_len > SPLIT_LIMIT:
+                        chunk_counter = 0
+                        for chunk in chunks_merged(man_targets[man], SPLIT_LIMIT):
+                            group_name = f"{man}-{chip_label}-{chunk_counter}"
+                            if(verbose):
+                                print(f'=:  [{man}][{man_len}] -> {group_name} ({len(chunk)})')
+                            final_groups.append({
+                                "container": grouped_targets[arch]['container'],
+                                "targets": comma_targets(chunk),
+                                "arch": arch,
+                                "chip_family": chip,
+                                "runner": runner,
+                                "group": group_name,
+                                "len": len(chunk),
+                            })
+                            chunk_counter += 1
+                    else:
+                        if(verbose):
+                            print(f'=:  [{man}][{man_len}] -> misc pool')
+                        temp_group.extend(man_targets[man])
+
+                # Emit misc groups for small manufacturers
+                if temp_group:
+                    misc_chunks = chunks_merged(temp_group, SPLIT_LIMIT)
+                    num_misc_chunks = len(misc_chunks)
+                    chunk_counter = 0
+                    for chunk in misc_chunks:
+                        if num_misc_chunks == 1:
+                            group_name = f"misc-{chip_label}"
+                        else:
+                            group_name = f"misc-{chip_label}-{chunk_counter}"
+                        if(verbose):
+                            print(f'=:  [misc][{len(chunk)}] -> {group_name}')
+                        final_groups.append({
+                            "container": grouped_targets[arch]['container'],
+                            "targets": comma_targets(chunk),
+                            "arch": arch,
+                            "chip_family": chip,
+                            "runner": runner,
+                            "group": group_name,
+                            "len": len(chunk),
+                        })
+                        chunk_counter += 1
+
+            # Now handle special + rp2040 targets
+            SPLIT_LIMIT = CHIP_SPLIT_LIMITS.get('special', DEFAULT_SPLIT_LIMIT)
+            special_targets = []
+            for (c, m), targets in chip_man_buckets.items():
+                if c in ('special', 'rp2040'):
+                    special_targets.extend(targets)
+            if special_targets:
                 chunk_counter = 0
-                for chunk in chunks(grouped_targets[arch]['manufacturers'][man], chunk_limit):
-                    group_name = arch + "-" + man + "-" + str(chunk_counter)
-                    targets = comma_targets(chunk)
+                for chunk in chunks_merged(special_targets, SPLIT_LIMIT):
+                    if len(special_targets) <= SPLIT_LIMIT:
+                        group_name = 'special'
+                    else:
+                        group_name = f'special-{chunk_counter}'
+                    if(verbose):
+                        print(f'=:  [special][{len(chunk)}] -> {group_name}')
                     final_groups.append({
                         "container": grouped_targets[arch]['container'],
-                        "targets": targets,
+                        "targets": comma_targets(chunk),
                         "arch": arch,
+                        "chip_family": "special",
                         "runner": runner,
                         "group": group_name,
                         "len": len(chunk),
                     })
                     chunk_counter += 1
-            else:
-                if(verbose):
-                    print(f'=:Processing: [{arch}][{man}][{man_len}]==Manufacturers too small group with others')
-                temp_group.extend(grouped_targets[arch]['manufacturers'][man])
 
-        temp_len = len(temp_group)
-        chunk_counter = 0
-        if(temp_len > 0 and temp_len < (SPLIT_LIMIT + 1)):
-            if(verbose):
-                print(f'=:Processing: [{arch}][orphan][{temp_len}]==Leftover arch can have their own group')
-            group_name = arch + "-" + str(chunk_counter)
-            targets = comma_targets(temp_group)
-            final_groups.append({
-                "container": grouped_targets[arch]['container'],
-                "targets": targets,
-                "arch": arch,
-                "runner": runner,
-                "group": group_name,
-                "len": temp_len
-            })
-        elif(temp_len >= (SPLIT_LIMIT + 1)):
-            # Split big man groups into subgroups
-            # example: Pixhawk
-            if(verbose):
-                print(f'=:Processing: [{arch}][orphan][{temp_len}]==Leftover arch can has multpile group')
-            chunk_limit = SPLIT_LIMIT
-            chunk_counter = 0
-            for chunk in chunks(temp_group, chunk_limit):
-                group_name = arch + "-" + str(chunk_counter)
-                targets = comma_targets(chunk)
+        elif arch == 'voxl2':
+            # VOXL2 stays as its own group
+            all_targets = []
+            for man in grouped_targets[arch]['manufacturers']:
+                all_targets.extend(grouped_targets[arch]['manufacturers'][man])
+            if all_targets:
                 final_groups.append({
                     "container": grouped_targets[arch]['container'],
-                    "targets": targets,
+                    "targets": comma_targets(all_targets),
                     "arch": arch,
+                    "chip_family": "native",
                     "runner": runner,
-                    "group": group_name,
-                    "len": len(chunk),
+                    "group": "voxl2-0",
+                    "len": len(all_targets),
                 })
-                chunk_counter += 1
+
+        else:
+            # Non-NuttX groups (base, aarch64, armhf) - keep simple grouping
+            SPLIT_LIMIT = CHIP_SPLIT_LIMITS.get('native', DEFAULT_SPLIT_LIMIT)
+            all_targets = []
+            for man in grouped_targets[arch]['manufacturers']:
+                all_targets.extend(grouped_targets[arch]['manufacturers'][man])
+            if all_targets:
+                chunk_counter = 0
+                for chunk in chunks_merged(all_targets, SPLIT_LIMIT):
+                    if len(all_targets) <= SPLIT_LIMIT:
+                        group_name = f"{arch}-0"
+                    else:
+                        group_name = f"{arch}-{chunk_counter}"
+                    final_groups.append({
+                        "container": grouped_targets[arch]['container'],
+                        "targets": comma_targets(chunk),
+                        "arch": arch,
+                        "chip_family": "native",
+                        "runner": runner,
+                        "group": group_name,
+                        "len": len(chunk),
+                    })
+                    chunk_counter += 1
+
+    # Add cache_size to each group based on chip family
+    for g in final_groups:
+        g['cache_size'] = CHIP_CACHE_SIZES.get(g['chip_family'], DEFAULT_CACHE_SIZE)
+
     if(verbose):
         import pprint
         print("================")
@@ -375,6 +596,58 @@ if (args.group):
         print("= JSON output =")
         print("===============")
 
-    print(json.dumps({ "include": final_groups }, **extra_args))
+    if args.seeders:
+        # Generate one seeder entry per chip family present in the groups.
+        # Each seeder builds a representative target to warm the ccache for
+        # all groups sharing that chip family.
+        seeder_targets = ci_config.get('seeders', {})
+        seeder_containers = {
+            'native': default_container,
+        }
+        # Determine which chip families actually have groups
+        active_families = set()
+        for g in final_groups:
+            cf = g['chip_family']
+            active_families.add(cf)
+            # voxl2 gets its own seeder with a different container
+            if g['group'].startswith('voxl2'):
+                active_families.add('voxl2')
+
+        seeders = []
+        for cf in sorted(active_families):
+            if cf == 'special':
+                continue  # special group seeds from stm32h7
+            if cf == 'voxl2':
+                seeders.append({
+                    'chip_family': 'voxl2',
+                    'target': 'modalai_voxl2_default',
+                    'container': voxl2_container,
+                    'runner': 'x64',
+                })
+            elif cf == 'native':
+                # One seeder per runner arch that has native groups (exclude voxl2
+                # which has its own seeder with a different container)
+                native_runners = set()
+                for g in final_groups:
+                    if g['chip_family'] == 'native' and not g['group'].startswith('voxl2'):
+                        native_runners.add(g['runner'])
+                for r in sorted(native_runners):
+                    seeders.append({
+                        'chip_family': 'native',
+                        'target': seeder_targets['native'],
+                        'container': default_container,
+                        'runner': r,
+                    })
+            else:
+                seeders.append({
+                    'chip_family': cf,
+                    'target': seeder_targets.get(cf, seeder_targets['stm32h7']),
+                    'container': seeder_containers.get(cf, default_container),
+                    'runner': 'x64',
+                })
+
+        print(json.dumps({ "include": seeders }, **extra_args))
+    else:
+        print(json.dumps({ "include": final_groups }, **extra_args))
 else:
     print(json.dumps(github_action_config, **extra_args))