tl;dr If newlib is built using --disable-newlib-multithread, its object files will have been built using __SINGLE_THREAD__, so any application linking to newlib must also define __SINGLE_THREAD__ or some newlib headers will have structs with different fields between newlib and the application. Or just rebuild newlib with --enable-newlib-multithread.
I’ve been working on a personal project of mine. At this point, revision A of the hardware works, and the firmware also works. But getting to this point wasn’t exactly easy. As expected of embedded software development, there are a lot of potholes in the road.
I thought I had finished my basic firmware implementation last night, and then I tried rebuilding it on my desktop instead of my laptop… and was greeted by hardfaults due to null-pointer dereferences on the Raspberry Pi Pico on the board (I have configured to MPU to prevent access to the first 256 bytes specifically to catch null pointer dereferences). That was… bizarre, as the code worked fine if I built it on my laptop.
After some debugging, I noticed the problem– for some reason, the stdout, which is part of an array of three elements of the type __sFILE struct (defined in newlib/libc/include/sys/reent.h) looked… like it was shifted over by 4 bytes. So as a sanity check, I printed the sizeof() of the struct while debugging… and found something I have honestly never seen before. If I printed the sizeof() from within newlib code, I got a size of 100 bytes. But if I printed it from my own application, I got 104 bytes. Well, that would explain the 4 byte offset, but… why was there a discrepancy?
Taking a look at the reent.h header in newlib, I noticed something in the __sFILE struct– one element is ifndef __SINGLE_THREAD__’d, specifically a lock for multi-threading… and then it clicked. I built my newlib for cross-compilation using Gentoo’s crossdev, and by default it builds newlib for single-threading, which forces newlib’s build systems to define the__SINGLE_THREAD__ macro. However, my own application nor the many CMake layers used by the pico-sdk do not define __SINGLE_THREAD__ anywhere, leading to my application to interpret this structure, defined in the header, as having that lock field. This led to a struct definition conflict between my application and newlib’s static library.
My fix was to simply re-build newlib with multi-threading enabled, as this is apparently the default used by upstream anyway. Also, the reason the firmware built on my laptop worked was that I just happened to have enabled newlib multi-threading… for reasons I no longer remember. In theory, one could also just define the __SINGLE_THREAD__ macro themselves when building the application, and should work as well.