Throw loud error if Espresso is not on PATH

build.mill

@@ -21,7 +21,7 @@ object `package` extends ChipModule {
     mvn"org.chipsalliance:::chisel-plugin:${chiselVersion}",
   )
 
-  object test extends ScalaTests, TestModule.ScalaTest {
+  object test extends ScalaTests, TestModule.ScalaTest, FreshForkPath {
     def moduleDeps = super.moduleDeps ++ Seq(testchipip)
 
     def mvnDeps = Seq(
@@ -124,7 +124,7 @@ object `package` extends ChipModule {
       mvn"org.chipsalliance:::chisel-plugin:${chiselVersion}",
     )
 
-    object test extends ScalaTests, TestModule.ScalaTest {
+    object test extends ScalaTests, TestModule.ScalaTest, FreshForkPath {
       def mvnDeps = Seq(
         mvn"org.scalatest::scalatest:3.2.19",
       )

module.mill

@@ -3,8 +3,22 @@ package build
 import mill._
 import scalalib._
 
-trait ChipModule extends ScalaModule {
+trait ChipModule extends ScalaModule, FreshForkPath {
   def scalaVersion = "2.13.18"
   def chiselVersion = "7.9.0"
 }
 
+/** Mill's `javaHomePathForkEnv` reads `Task.env` inside a cached task, so a
+  * forked JVM (tests, `run`, `runMain`) keeps the PATH from the first run
+  * forever. Re-read it on every run instead: tools like espresso are found
+  * through it. Test objects don't inherit this from their parent module, so
+  * each one mixes it in.
+  */
+trait FreshForkPath extends javalib.RunModule {
+  def shellPath = Task.Input { Task.env.find(_._1.equalsIgnoreCase("PATH")).map(_._2) }
+
+  override def javaHomePathForkEnv = Task {
+    val javaHomeBin = (javaHome().fold(os.Path(sys.props("java.home")))(_.path) / "bin").toString
+    Map("PATH" -> (javaHomeBin +: shellPath().toSeq).mkString(java.io.File.pathSeparator))
+  }
+}

src/Iris.scala

@@ -52,7 +52,33 @@ class IrisSystem(implicit p: Parameters)
     with testchipip.serdes.CanHavePeripheryTLSerial
     with sifive.blocks.devices.uart.HasPeripheryUART
     with edu.berkeley.cs.chippy.clocking.HasChippyPRCI
-    with constellation.soc.CanHaveGlobalNoC
+    with constellation.soc.CanHaveGlobalNoC {
+  Espresso.requireOnPath()
+}
+
+/** Constellation's route computers minimize their routing tables with Chisel's
+  * `decoder`, which quietly falls back to Quine-McCluskey when it cannot launch
+  * espresso. On the Iris NoC that fallback runs for a long time and then dies
+  * inside RouteComputer with "Vector cannot have negative size -2147483648", so
+  * fail before elaboration instead.
+  */
+object Espresso {
+  private lazy val check: Unit =
+    try os.proc("espresso").call(stdin = ".i 1\n.o 1\n.type fr\n1 1\n.e\n")
+    catch {
+      // The same failure that makes Chisel's decoder fall back to QMC.
+      case e: java.io.IOException =>
+        throw new IllegalStateException(
+          s"""Cannot run espresso (${e.getMessage}).
+             |Iris needs espresso on PATH to generate its NoC: without it,
+             |Chisel's decoder falls back to Quine-McCluskey, which blows up on
+             |the route computers. Install it from
+             |https://github.com/chipsalliance/espresso (see README.md).""".stripMargin
+        )
+    }
+
+  def requireOnPath(): Unit = check
+}
 
 class IrisTop(implicit p: Parameters) extends LazyModule with BindingScope {
   val system = LazyModule(new IrisSystem)