Reproduce merge_bin issue in Github Actions runner

.github/workflows/with-esptool.yaml

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+name: esptool as a python tool
+
+on: push
+
+jobs:
+  build:
+    strategy:
+      matrix:
+        os: [ubuntu-latest, windows-latest]
+    runs-on: ${{ matrix.os }}
+
+    steps:
+      - uses: actions/checkout@v4
+        with:
+          fetch-depth: 0
+
+      - uses: actions/setup-python@v5
+        with:
+          python-version: '3.12'
+
+      - run: pip install esptool
+
+      - name: Build firmware
+        run: python -m esptool --chip esp32 merge_bin --output output.bin 0x1000 test1.bin 0x2000 test2.bin

.github/workflows/with-platformio.yaml

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+name: esptool as a pio tool
+
+on: push
+
+jobs:
+  build:
+    strategy:
+      fail-fast: false
+      matrix:
+        os: [ubuntu-latest, windows-latest]
+    runs-on: ${{ matrix.os }}
+
+    steps:
+      - uses: actions/checkout@v4
+        with:
+          fetch-depth: 0
+
+      - uses: actions/setup-python@v5
+        with:
+          python-version: '3.12'
+
+      - run: pip install --upgrade platformio
+
+      - name: Build firmware
+        run: pio pkg exec --package "platformio/tool-esptoolpy" -- esptool --chip esp32 merge_bin --output output.bin 0x1000 test1.bin 0x2000 test2.bin

LICENSE.md

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+
+The MIT License (MIT)
+
+Copyright (c) 2024 Corentin Pane
+
+Permission is hereby granted, free of charge, to any person obtaining a copy
+of this software and associated documentation files (the "Software"), to deal
+in the Software without restriction, including without limitation the rights
+to use, copy, modify, merge, publish, distribute, sublicense, and/or sell
+copies of the Software, and to permit persons to whom the Software is
+furnished to do so, subject to the following conditions:
+
+The above copyright notice and this permission notice shall be included in all
+copies or substantial portions of the Software.
+
+THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND, EXPRESS OR
+IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF MERCHANTABILITY,
+FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT. IN NO EVENT SHALL THE
+AUTHORS OR COPYRIGHT HOLDERS BE LIABLE FOR ANY CLAIM, DAMAGES OR OTHER
+LIABILITY, WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE, ARISING FROM,
+OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR OTHER DEALINGS IN THE
+SOFTWARE.

README.md

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+# PlatformIO `esptool` fail on `merge_bin` operation in Github Actions
+
+This repo demonstrates an issue with the invocation of `merge_bin` command using `platformio/tool-esptoolpy` as a pio tool when running in Github Actions runner. A `UserSideException: [Errno 13] Permission denied: 'esptool'` is produced. The error appears on both Windows and Ubuntu.
+
+Extract of the logs from the failed Github Actions run on Ubuntu (check the [Actions tab](/actions) for the full logs):
+
+> `Run pio pkg exec --package "platformio/tool-esptoolpy" -- esptool --chip esp32 merge_bin --output output.bin 0x1000 test1.bin 0x2000 test2.bin`
+>
+> `Tool Manager: Installing platformio/tool-esptoolpy`
+>
+> `Downloading 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%`
+>
+> `Unpacking 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%`
+>
+> `Tool Manager: [email protected] has been installed!`
+>
+> `Using [email protected] package`
+>
+> `UserSideException: [Errno 13] Permission denied: 'esptool'`
+>
+> `Error: Process completed with exit code 1.`
+
+Calling the same command `merge_bin` through `python -m esptool` works.

test1.bin

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+hello

test2.bin

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+world