Merge branch 'sha256_ota' into integration

tests/integration/conftest.py

@@ -58,6 +58,8 @@ def _get_platformio_env(cache_dir: Path) -> dict[str, str]:
     env["PLATFORMIO_CORE_DIR"] = str(cache_dir)
     env["PLATFORMIO_CACHE_DIR"] = str(cache_dir / ".cache")
     env["PLATFORMIO_LIBDEPS_DIR"] = str(cache_dir / "libdeps")
+    # Prevent cache cleaning during integration tests
+    env["ESPHOME_SKIP_CLEAN_BUILD"] = "1"
     return env
 
 
@@ -68,6 +70,11 @@ def shared_platformio_cache() -> Generator[Path]:
     test_cache_dir = Path.home() / ".esphome-integration-tests"
     cache_dir = test_cache_dir / "platformio"
 
+    # Create the temp directory that PlatformIO uses to avoid race conditions
+    # This ensures it exists and won't be deleted by parallel processes
+    platformio_tmp_dir = cache_dir / ".cache" / "tmp"
+    platformio_tmp_dir.mkdir(parents=True, exist_ok=True)
+
     # Use a lock file in the home directory to ensure only one process initializes the cache
     # This is needed when running with pytest-xdist
     # The lock file must be in a directory that already exists to avoid race conditions
@@ -83,17 +90,11 @@ def shared_platformio_cache() -> Generator[Path]:
             test_cache_dir.mkdir(exist_ok=True)
 
             with tempfile.TemporaryDirectory() as tmpdir:
-                # Create a basic host config
+                # Use the cache_init fixture for initialization
                 init_dir = Path(tmpdir)
+                fixture_path = Path(__file__).parent / "fixtures" / "cache_init.yaml"
                 config_path = init_dir / "cache_init.yaml"
-                config_path.write_text("""esphome:
-  name: cache-init
-host:
-api:
-  encryption:
-    key: "IIevImVI42I0FGos5nLqFK91jrJehrgidI0ArwMLr8w="
-logger:
-""")
+                config_path.write_text(fixture_path.read_text())
 
                 # Run compilation to populate the cache
                 # We must succeed here to avoid race conditions where multiple
@@ -346,7 +347,8 @@ async def wait_and_connect_api_client(
     noise_psk: str | None = None,
     client_info: str = "integration-test",
     timeout: float = API_CONNECTION_TIMEOUT,
-) -> AsyncGenerator[APIClient]:
+    return_disconnect_event: bool = False,
+) -> AsyncGenerator[APIClient | tuple[APIClient, asyncio.Event]]:
     """Wait for API to be available and connect."""
     client = APIClient(
         address=address,
@@ -359,14 +361,17 @@ async def wait_and_connect_api_client(
     # Create a future to signal when connected
     loop = asyncio.get_running_loop()
     connected_future: asyncio.Future[None] = loop.create_future()
+    disconnect_event = asyncio.Event()
 
     async def on_connect() -> None:
         """Called when successfully connected."""
+        disconnect_event.clear()  # Clear the disconnect event on new connection
         if not connected_future.done():
             connected_future.set_result(None)
 
     async def on_disconnect(expected_disconnect: bool) -> None:
         """Called when disconnected."""
+        disconnect_event.set()
         if not connected_future.done() and not expected_disconnect:
             connected_future.set_exception(
                 APIConnectionError("Disconnected before fully connected")
@@ -397,7 +402,10 @@ async def wait_and_connect_api_client(
         except TimeoutError:
             raise TimeoutError(f"Failed to connect to API after {timeout} seconds")
 
-        yield client
+        if return_disconnect_event:
+            yield client, disconnect_event
+        else:
+            yield client
     finally:
         # Stop reconnect logic and disconnect
         await reconnect_logic.stop()
@@ -430,6 +438,33 @@ async def api_client_connected(
     yield _connect_client
 
 
+@pytest_asyncio.fixture
+async def api_client_connected_with_disconnect(
+    unused_tcp_port: int,
+) -> AsyncGenerator:
+    """Factory for creating connected API client context managers with disconnect event."""
+
+    def _connect_client_with_disconnect(
+        address: str = LOCALHOST,
+        port: int | None = None,
+        password: str = "",
+        noise_psk: str | None = None,
+        client_info: str = "integration-test",
+        timeout: float = API_CONNECTION_TIMEOUT,
+    ):
+        return wait_and_connect_api_client(
+            address=address,
+            port=port if port is not None else unused_tcp_port,
+            password=password,
+            noise_psk=noise_psk,
+            client_info=client_info,
+            timeout=timeout,
+            return_disconnect_event=True,
+        )
+
+    yield _connect_client_with_disconnect
+
+
 async def _read_stream_lines(
     stream: asyncio.StreamReader,
     lines: list[str],

tests/integration/fixtures/cache_init.yaml

@@ -0,0 +1,10 @@
+esphome:
+  name: cache-init
+
+host:
+
+api:
+  encryption:
+    key: "IIevImVI42I0FGos5nLqFK91jrJehrgidI0ArwMLr8w="
+
+logger:

tests/integration/fixtures/noise_corrupt_encrypted_frame.yaml

@@ -0,0 +1,11 @@
+esphome:
+  name: oversized-noise
+
+host:
+
+api:
+  encryption:
+    key: N4Yle5YirwZhPiHHsdZLdOA73ndj/84veVaLhTvxCuU=
+
+logger:
+  level: VERY_VERBOSE

tests/integration/fixtures/oversized_payload_noise.yaml

@@ -0,0 +1,11 @@
+esphome:
+  name: oversized-noise
+
+host:
+
+api:
+  encryption:
+    key: N4Yle5YirwZhPiHHsdZLdOA73ndj/84veVaLhTvxCuU=
+
+logger:
+  level: VERY_VERBOSE

tests/integration/fixtures/oversized_payload_plaintext.yaml

@@ -0,0 +1,9 @@
+esphome:
+  name: oversized-plaintext
+
+host:
+
+api:
+
+logger:
+  level: VERY_VERBOSE

tests/integration/fixtures/oversized_protobuf_message_id_noise.yaml

@@ -0,0 +1,11 @@
+esphome:
+  name: oversized-noise
+
+host:
+
+api:
+  encryption:
+    key: N4Yle5YirwZhPiHHsdZLdOA73ndj/84veVaLhTvxCuU=
+
+logger:
+  level: VERY_VERBOSE

tests/integration/fixtures/oversized_protobuf_message_id_plaintext.yaml

@@ -0,0 +1,9 @@
+esphome:
+  name: oversized-protobuf-plaintext
+
+host:
+
+api:
+
+logger:
+  level: VERY_VERBOSE

tests/integration/test_oversized_payloads.py

@@ -0,0 +1,335 @@
+"""Integration tests for oversized payloads and headers that should cause disconnection."""
+
+from __future__ import annotations
+
+import asyncio
+
+import pytest
+
+from .types import APIClientConnectedWithDisconnectFactory, RunCompiledFunction
+
+
+@pytest.mark.asyncio
+async def test_oversized_payload_plaintext(
+    yaml_config: str,
+    run_compiled: RunCompiledFunction,
+    api_client_connected_with_disconnect: APIClientConnectedWithDisconnectFactory,
+) -> None:
+    """Test that oversized payloads (>100KiB) from client cause disconnection without crashing."""
+    process_exited = False
+    helper_log_found = False
+
+    def check_logs(line: str) -> None:
+        nonlocal process_exited, helper_log_found
+        # Check for signs that the process exited/crashed
+        if "Segmentation fault" in line or "core dumped" in line:
+            process_exited = True
+        # Check for HELPER_LOG message about message size exceeding maximum
+        if (
+            "[VV]" in line
+            and "Bad packet: message size" in line
+            and "exceeds maximum" in line
+        ):
+            helper_log_found = True
+
+    async with run_compiled(yaml_config, line_callback=check_logs):
+        async with api_client_connected_with_disconnect() as (client, disconnect_event):
+            # Verify basic connection works first
+            device_info = await client.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-plaintext"
+
+            # Create an oversized payload (>100KiB)
+            oversized_data = b"X" * (100 * 1024 + 1)  # 100KiB + 1 byte
+
+            # Access the internal connection to send raw data
+            frame_helper = client._connection._frame_helper
+            # Create a message with oversized payload
+            # Using message type 1 (DeviceInfoRequest) as an example
+            message_type = 1
+            frame_helper.write_packets([(message_type, oversized_data)], True)
+
+            # Wait for the connection to be closed by ESPHome
+            await asyncio.wait_for(disconnect_event.wait(), timeout=5.0)
+
+        # After disconnection, verify process didn't crash
+        assert not process_exited, "ESPHome process should not crash"
+        # Verify we saw the expected HELPER_LOG message
+        assert helper_log_found, (
+            "Expected to see HELPER_LOG about message size exceeding maximum"
+        )
+
+        # Try to reconnect to verify the process is still running
+        async with api_client_connected_with_disconnect() as (client2, _):
+            device_info = await client2.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-plaintext"
+
+
+@pytest.mark.asyncio
+async def test_oversized_protobuf_message_id_plaintext(
+    yaml_config: str,
+    run_compiled: RunCompiledFunction,
+    api_client_connected_with_disconnect: APIClientConnectedWithDisconnectFactory,
+) -> None:
+    """Test that protobuf messages with ID > UINT16_MAX cause disconnection without crashing.
+
+    This tests the message type limit - message IDs must fit in a uint16_t (0-65535).
+    """
+    process_exited = False
+    helper_log_found = False
+
+    def check_logs(line: str) -> None:
+        nonlocal process_exited, helper_log_found
+        # Check for signs that the process exited/crashed
+        if "Segmentation fault" in line or "core dumped" in line:
+            process_exited = True
+        # Check for HELPER_LOG message about message type exceeding maximum
+        if (
+            "[VV]" in line
+            and "Bad packet: message type" in line
+            and "exceeds maximum" in line
+        ):
+            helper_log_found = True
+
+    async with run_compiled(yaml_config, line_callback=check_logs):
+        async with api_client_connected_with_disconnect() as (client, disconnect_event):
+            # Verify basic connection works first
+            device_info = await client.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-protobuf-plaintext"
+
+            # Access the internal connection to send raw message with large ID
+            frame_helper = client._connection._frame_helper
+            # Message ID that exceeds uint16_t limit (> 65535)
+            large_message_id = 65536  # 2^16, exceeds UINT16_MAX
+            # Small payload for the test
+            payload = b"test"
+
+            # This should cause disconnection due to oversized varint
+            frame_helper.write_packets([(large_message_id, payload)], True)
+
+            # Wait for the connection to be closed by ESPHome
+            await asyncio.wait_for(disconnect_event.wait(), timeout=5.0)
+
+        # After disconnection, verify process didn't crash
+        assert not process_exited, "ESPHome process should not crash"
+        # Verify we saw the expected HELPER_LOG message
+        assert helper_log_found, (
+            "Expected to see HELPER_LOG about message type exceeding maximum"
+        )
+
+        # Try to reconnect to verify the process is still running
+        async with api_client_connected_with_disconnect() as (client2, _):
+            device_info = await client2.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-protobuf-plaintext"
+
+
+@pytest.mark.asyncio
+async def test_oversized_payload_noise(
+    yaml_config: str,
+    run_compiled: RunCompiledFunction,
+    api_client_connected_with_disconnect: APIClientConnectedWithDisconnectFactory,
+) -> None:
+    """Test that oversized payloads (>100KiB) from client cause disconnection without crashing with noise encryption."""
+    noise_key = "N4Yle5YirwZhPiHHsdZLdOA73ndj/84veVaLhTvxCuU="
+    process_exited = False
+    cipherstate_failed = False
+
+    def check_logs(line: str) -> None:
+        nonlocal process_exited, cipherstate_failed
+        # Check for signs that the process exited/crashed
+        if "Segmentation fault" in line or "core dumped" in line:
+            process_exited = True
+        # Check for the expected warning about decryption failure
+        if (
+            "[W][api.connection" in line
+            and "Reading failed CIPHERSTATE_DECRYPT_FAILED" in line
+        ):
+            cipherstate_failed = True
+
+    async with run_compiled(yaml_config, line_callback=check_logs):
+        async with api_client_connected_with_disconnect(noise_psk=noise_key) as (
+            client,
+            disconnect_event,
+        ):
+            # Verify basic connection works first
+            device_info = await client.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-noise"
+
+            # Create an oversized payload (>100KiB)
+            oversized_data = b"Y" * (100 * 1024 + 1)  # 100KiB + 1 byte
+
+            # Access the internal connection to send raw data
+            frame_helper = client._connection._frame_helper
+            # For noise connections, we still send through write_packets
+            # but the frame helper will handle encryption
+            # Using message type 1 (DeviceInfoRequest) as an example
+            message_type = 1
+            frame_helper.write_packets([(message_type, oversized_data)], True)
+
+            # Wait for the connection to be closed by ESPHome
+            await asyncio.wait_for(disconnect_event.wait(), timeout=5.0)
+
+        # After disconnection, verify process didn't crash
+        assert not process_exited, "ESPHome process should not crash"
+        # Verify we saw the expected warning message
+        assert cipherstate_failed, (
+            "Expected to see warning about CIPHERSTATE_DECRYPT_FAILED"
+        )
+
+        # Try to reconnect to verify the process is still running
+        async with api_client_connected_with_disconnect(noise_psk=noise_key) as (
+            client2,
+            _,
+        ):
+            device_info = await client2.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-noise"
+
+
+@pytest.mark.asyncio
+async def test_oversized_protobuf_message_id_noise(
+    yaml_config: str,
+    run_compiled: RunCompiledFunction,
+    api_client_connected_with_disconnect: APIClientConnectedWithDisconnectFactory,
+) -> None:
+    """Test that the noise protocol handles unknown message types correctly.
+
+    With noise encryption, message types are stored as uint16_t (2 bytes) after decryption.
+    Unknown message types should be ignored without disconnecting, as ESPHome needs to
+    read the full message to maintain encryption stream continuity.
+    """
+    noise_key = "N4Yle5YirwZhPiHHsdZLdOA73ndj/84veVaLhTvxCuU="
+    process_exited = False
+
+    def check_logs(line: str) -> None:
+        nonlocal process_exited
+        # Check for signs that the process exited/crashed
+        if "Segmentation fault" in line or "core dumped" in line:
+            process_exited = True
+
+    async with run_compiled(yaml_config, line_callback=check_logs):
+        async with api_client_connected_with_disconnect(noise_psk=noise_key) as (
+            client,
+            disconnect_event,
+        ):
+            # Verify basic connection works first
+            device_info = await client.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-noise"
+
+            # With noise, message types are uint16_t, so we test with an unknown but valid value
+            frame_helper = client._connection._frame_helper
+
+            # Test with an unknown message type (65535 is not used by ESPHome)
+            unknown_message_id = 65535  # Valid uint16_t but unknown to ESPHome
+            payload = b"test"
+
+            # Send the unknown message type - ESPHome should read and ignore it
+            frame_helper.write_packets([(unknown_message_id, payload)], True)
+
+            # Give ESPHome a moment to process (but expect no disconnection)
+            # The connection should stay alive as ESPHome ignores unknown message types
+            with pytest.raises(asyncio.TimeoutError):
+                await asyncio.wait_for(disconnect_event.wait(), timeout=0.5)
+
+            # Connection should still be alive - unknown types are ignored, not fatal
+            assert client._connection.is_connected, (
+                "Connection should remain open for unknown message types"
+            )
+
+            # Verify we can still communicate by sending a valid request
+            device_info2 = await client.device_info()
+            assert device_info2 is not None
+            assert device_info2.name == "oversized-noise"
+
+        # After test, verify process didn't crash
+        assert not process_exited, "ESPHome process should not crash"
+
+        # Verify we can still reconnect
+        async with api_client_connected_with_disconnect(noise_psk=noise_key) as (
+            client2,
+            _,
+        ):
+            device_info = await client2.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-noise"
+
+
+@pytest.mark.asyncio
+async def test_noise_corrupt_encrypted_frame(
+    yaml_config: str,
+    run_compiled: RunCompiledFunction,
+    api_client_connected_with_disconnect: APIClientConnectedWithDisconnectFactory,
+) -> None:
+    """Test that noise protocol properly handles corrupt encrypted frames.
+
+    Send a frame with valid size but corrupt encrypted content (garbage bytes).
+    This should fail decryption and cause disconnection.
+    """
+    noise_key = "N4Yle5YirwZhPiHHsdZLdOA73ndj/84veVaLhTvxCuU="
+    process_exited = False
+    cipherstate_failed = False
+
+    def check_logs(line: str) -> None:
+        nonlocal process_exited, cipherstate_failed
+        # Check for signs that the process exited/crashed
+        if "Segmentation fault" in line or "core dumped" in line:
+            process_exited = True
+        # Check for the expected warning about decryption failure
+        if (
+            "[W][api.connection" in line
+            and "Reading failed CIPHERSTATE_DECRYPT_FAILED" in line
+        ):
+            cipherstate_failed = True
+
+    async with run_compiled(yaml_config, line_callback=check_logs):
+        async with api_client_connected_with_disconnect(noise_psk=noise_key) as (
+            client,
+            disconnect_event,
+        ):
+            # Verify basic connection works first
+            device_info = await client.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-noise"
+
+            # Get the socket to send raw corrupt data
+            socket = client._connection._socket
+
+            # Send a corrupt noise frame directly to the socket
+            # Format: [indicator=0x01][size_high][size_low][garbage_encrypted_data]
+            # Size of 32 bytes (reasonable size for a noise frame with MAC)
+            corrupt_frame = bytes(
+                [
+                    0x01,  # Noise indicator
+                    0x00,  # Size high byte
+                    0x20,  # Size low byte (32 bytes)
+                ]
+            ) + bytes(32)  # 32 bytes of zeros (invalid encrypted data)
+
+            # Send the corrupt frame
+            socket.sendall(corrupt_frame)
+
+            # Wait for ESPHome to disconnect due to decryption failure
+            await asyncio.wait_for(disconnect_event.wait(), timeout=5.0)
+
+        # After disconnection, verify process didn't crash
+        assert not process_exited, (
+            "ESPHome process should not crash on corrupt encrypted frames"
+        )
+        # Verify we saw the expected warning message
+        assert cipherstate_failed, (
+            "Expected to see warning about CIPHERSTATE_DECRYPT_FAILED"
+        )
+
+        # Verify we can still reconnect after handling the corrupt frame
+        async with api_client_connected_with_disconnect(noise_psk=noise_key) as (
+            client2,
+            _,
+        ):
+            device_info = await client2.device_info()
+            assert device_info is not None
+            assert device_info.name == "oversized-noise"

tests/integration/types.py

@@ -54,3 +54,17 @@ class APIClientConnectedFactory(Protocol):
         client_info: str = "integration-test",
         timeout: float = 30,
     ) -> AbstractAsyncContextManager[APIClient]: ...
+
+
+class APIClientConnectedWithDisconnectFactory(Protocol):
+    """Protocol for connected API client factory that returns disconnect event."""
+
+    def __call__(  # noqa: E704
+        self,
+        address: str = "localhost",
+        port: int | None = None,
+        password: str = "",
+        noise_psk: str | None = None,
+        client_info: str = "integration-test",
+        timeout: float = 30,
+    ) -> AbstractAsyncContextManager[tuple[APIClient, asyncio.Event]]: ...

tests/unit_tests/conftest.py

@@ -94,3 +94,10 @@ def mock_run_git_command() -> Generator[Mock, None, None]:
     """Mock run_git_command for git module."""
     with patch("esphome.git.run_git_command") as mock:
         yield mock
+
+
+@pytest.fixture
+def mock_get_idedata() -> Generator[Mock, None, None]:
+    """Mock get_idedata for platformio_api."""
+    with patch("esphome.platformio_api.get_idedata") as mock:
+        yield mock

tests/unit_tests/test_git.py

@@ -15,7 +15,7 @@ def test_clone_or_update_with_never_refresh(
 ) -> None:
     """Test that NEVER_REFRESH skips updates for existing repos."""
     # Set up CORE.config_path so data_dir uses tmp_path
-    CORE.config_path = str(tmp_path / "test.yaml")
+    CORE.config_path = tmp_path / "test.yaml"
 
     # Compute the expected repo directory path
     url = "https://github.com/test/repo"
@@ -56,7 +56,7 @@ def test_clone_or_update_with_refresh_updates_old_repo(
 ) -> None:
     """Test that refresh triggers update for old repos."""
     # Set up CORE.config_path so data_dir uses tmp_path
-    CORE.config_path = str(tmp_path / "test.yaml")
+    CORE.config_path = tmp_path / "test.yaml"
 
     # Compute the expected repo directory path
     url = "https://github.com/test/repo"
@@ -110,7 +110,7 @@ def test_clone_or_update_with_refresh_skips_fresh_repo(
 ) -> None:
     """Test that refresh doesn't update fresh repos."""
     # Set up CORE.config_path so data_dir uses tmp_path
-    CORE.config_path = str(tmp_path / "test.yaml")
+    CORE.config_path = tmp_path / "test.yaml"
 
     # Compute the expected repo directory path
     url = "https://github.com/test/repo"
@@ -156,7 +156,7 @@ def test_clone_or_update_clones_missing_repo(
 ) -> None:
     """Test that missing repos are cloned regardless of refresh setting."""
     # Set up CORE.config_path so data_dir uses tmp_path
-    CORE.config_path = str(tmp_path / "test.yaml")
+    CORE.config_path = tmp_path / "test.yaml"
 
     # Compute the expected repo directory path
     url = "https://github.com/test/repo"
@@ -198,7 +198,7 @@ def test_clone_or_update_with_none_refresh_always_updates(
 ) -> None:
     """Test that refresh=None always updates existing repos."""
     # Set up CORE.config_path so data_dir uses tmp_path
-    CORE.config_path = str(tmp_path / "test.yaml")
+    CORE.config_path = tmp_path / "test.yaml"
 
     # Compute the expected repo directory path
     url = "https://github.com/test/repo"

tests/unit_tests/test_main.py

@@ -12,6 +12,7 @@ from unittest.mock import MagicMock, Mock, patch
 import pytest
 from pytest import CaptureFixture
 
+from esphome import platformio_api
 from esphome.__main__ import (
     Purpose,
     choose_upload_log_host,
@@ -28,7 +29,9 @@ from esphome.__main__ import (
     mqtt_get_ip,
     show_logs,
     upload_program,
+    upload_using_esptool,
 )
+from esphome.components.esp32.const import KEY_ESP32, KEY_VARIANT, VARIANT_ESP32
 from esphome.const import (
     CONF_API,
     CONF_BROKER,
@@ -220,6 +223,14 @@ def mock_run_external_process() -> Generator[Mock]:
         yield mock
 
 
+@pytest.fixture
+def mock_run_external_command() -> Generator[Mock]:
+    """Mock run_external_command for testing."""
+    with patch("esphome.__main__.run_external_command") as mock:
+        mock.return_value = 0  # Default to success
+        yield mock
+
+
 def test_choose_upload_log_host_with_string_default() -> None:
     """Test with a single string default device."""
     setup_core()
@@ -818,6 +829,122 @@ def test_upload_program_serial_esp8266_with_file(
     )
 
 
+def test_upload_using_esptool_path_conversion(
+    tmp_path: Path,
+    mock_run_external_command: Mock,
+    mock_get_idedata: Mock,
+) -> None:
+    """Test upload_using_esptool properly converts Path objects to strings for esptool.
+
+    This test ensures that img.path (Path object) is converted to string before
+    passing to esptool, preventing AttributeError.
+    """
+    setup_core(platform=PLATFORM_ESP32, tmp_path=tmp_path, name="test")
+
+    # Set up ESP32-specific data required by get_esp32_variant()
+    CORE.data[KEY_ESP32] = {KEY_VARIANT: VARIANT_ESP32}
+
+    # Create mock IDEData with Path objects
+    mock_idedata = MagicMock(spec=platformio_api.IDEData)
+    mock_idedata.firmware_bin_path = tmp_path / "firmware.bin"
+    mock_idedata.extra_flash_images = [
+        platformio_api.FlashImage(path=tmp_path / "bootloader.bin", offset="0x1000"),
+        platformio_api.FlashImage(path=tmp_path / "partitions.bin", offset="0x8000"),
+    ]
+
+    mock_get_idedata.return_value = mock_idedata
+
+    # Create the actual firmware files so they exist
+    (tmp_path / "firmware.bin").touch()
+    (tmp_path / "bootloader.bin").touch()
+    (tmp_path / "partitions.bin").touch()
+
+    config = {CONF_ESPHOME: {"platformio_options": {}}}
+
+    # Call upload_using_esptool without custom file argument
+    result = upload_using_esptool(config, "/dev/ttyUSB0", None, None)
+
+    assert result == 0
+
+    # Verify that run_external_command was called
+    assert mock_run_external_command.call_count == 1
+
+    # Get the actual call arguments
+    call_args = mock_run_external_command.call_args[0]
+
+    # The first argument should be esptool.main function,
+    # followed by the command arguments
+    assert len(call_args) > 1
+
+    # Find the indices of the flash image arguments
+    # They should come after "write-flash" and "-z"
+    cmd_list = list(call_args[1:])  # Skip the esptool.main function
+
+    # Verify all paths are strings, not Path objects
+    # The firmware and flash images should be at specific positions
+    write_flash_idx = cmd_list.index("write-flash")
+
+    # After write-flash we have: -z, --flash-size, detect, then offset/path pairs
+    # Check firmware at offset 0x10000 (ESP32)
+    firmware_offset_idx = write_flash_idx + 4
+    assert cmd_list[firmware_offset_idx] == "0x10000"
+    firmware_path = cmd_list[firmware_offset_idx + 1]
+    assert isinstance(firmware_path, str)
+    assert firmware_path.endswith("firmware.bin")
+
+    # Check bootloader
+    bootloader_offset_idx = firmware_offset_idx + 2
+    assert cmd_list[bootloader_offset_idx] == "0x1000"
+    bootloader_path = cmd_list[bootloader_offset_idx + 1]
+    assert isinstance(bootloader_path, str)
+    assert bootloader_path.endswith("bootloader.bin")
+
+    # Check partitions
+    partitions_offset_idx = bootloader_offset_idx + 2
+    assert cmd_list[partitions_offset_idx] == "0x8000"
+    partitions_path = cmd_list[partitions_offset_idx + 1]
+    assert isinstance(partitions_path, str)
+    assert partitions_path.endswith("partitions.bin")
+
+
+def test_upload_using_esptool_with_file_path(
+    tmp_path: Path,
+    mock_run_external_command: Mock,
+) -> None:
+    """Test upload_using_esptool with a custom file that's a Path object."""
+    setup_core(platform=PLATFORM_ESP8266, tmp_path=tmp_path, name="test")
+
+    # Create a test firmware file
+    firmware_file = tmp_path / "custom_firmware.bin"
+    firmware_file.touch()
+
+    config = {CONF_ESPHOME: {"platformio_options": {}}}
+
+    # Call with a Path object as the file argument (though usually it's a string)
+    result = upload_using_esptool(config, "/dev/ttyUSB0", str(firmware_file), None)
+
+    assert result == 0
+
+    # Verify that run_external_command was called
+    mock_run_external_command.assert_called_once()
+
+    # Get the actual call arguments
+    call_args = mock_run_external_command.call_args[0]
+    cmd_list = list(call_args[1:])  # Skip the esptool.main function
+
+    # Find the firmware path in the command
+    write_flash_idx = cmd_list.index("write-flash")
+
+    # For custom file, it should be at offset 0x0
+    firmware_offset_idx = write_flash_idx + 4
+    assert cmd_list[firmware_offset_idx] == "0x0"
+    firmware_path = cmd_list[firmware_offset_idx + 1]
+
+    # Verify it's a string, not a Path object
+    assert isinstance(firmware_path, str)
+    assert firmware_path.endswith("custom_firmware.bin")
+
+
 @pytest.mark.parametrize(
     "platform,device",
     [