diff --git a/.github/actions/build-firmware/action.yml b/.github/actions/build-firmware/action.yml
index 08871adb4..2317b64e0 100644
--- a/.github/actions/build-firmware/action.yml
+++ b/.github/actions/build-firmware/action.yml
@@ -26,6 +26,13 @@ runs:
     - name: 'Release'
       shell: bash
       run: Buildscripts/release.sh ${{ inputs.board_id }}
+    - name: 'Merge binary'
+      shell: bash
+      run: |
+        python -m pip install esptool
+        cd release/Tactility-${{ inputs.board_id }}
+        bash ./merge.sh ${{ inputs.arch }}
+        mv Binaries/merged_binary.bin ../Tactility-${{ inputs.board_id }}.bin
     - name: 'Upload Artifact: Release'
       uses: actions/upload-artifact@v4
       with:
@@ -38,3 +45,9 @@ runs:
         name: Tactility-${{ inputs.board_id }}-symbols
         path: release/Tactility-${{ inputs.board_id }}-symbols
         retention-days: 30
+    - name: 'Upload Artifact: Merged binary'
+      uses: actions/upload-artifact@v4
+      with:
+        name: Tactility-${{ inputs.board_id }}.bin
+        path: release/Tactility-${{ inputs.board_id }}.bin
+        retention-days: 30
diff --git a/Buildscripts/CDN/generate-firmware-files.py b/Buildscripts/CDN/generate-firmware-files.py
index 0489f0743..23fd6126e 100644
--- a/Buildscripts/CDN/generate-firmware-files.py
+++ b/Buildscripts/CDN/generate-firmware-files.py
@@ -191,7 +191,7 @@ def main(in_path: str, out_path: str, version: str):
         devices=[]
     )
     for artifact_directory in artifact_directories:
-        if artifact_directory.endswith("-symbols") or artifact_directory.startswith("TactilitySDK-"):
+        if artifact_directory.endswith("-symbols") or artifact_directory.endswith(".bin") or artifact_directory.startswith("TactilitySDK-"):
             continue
         device_id = artifact_directory.removeprefix("Tactility-")
         if not device_id:
diff --git a/Buildscripts/Flashing/merge.ps1 b/Buildscripts/Flashing/merge.ps1
new file mode 100644
index 000000000..1a9a408fc
--- /dev/null
+++ b/Buildscripts/Flashing/merge.ps1
@@ -0,0 +1,26 @@
+param(
+    # "--chip esp32s3" is irrelevant, just need to be added, fallback to "esp32s3"
+    [string]$chip = "esp32s3"
+)
+
+if ($null -eq (Get-Command "esptool" -ErrorAction SilentlyContinue))
+{
+    Write-Host "Unable to find esptool in your path. Make sure you have Python installed and on your path. Then run `pip install esptool`."
+    exit 1
+}
+
+# Create merge command based on partitions
+$json = Get-Content .\Binaries\flasher_args.json -Raw | ConvertFrom-Json
+$jsonClean = $json.flash_files -replace '[\{\}\@\;]', ''
+$jsonClean = $jsonClean -replace '[\=]', ' '
+
+$mergeArgs = @('--chip', $chip, 'merge-bin', '--output', 'merged_binary.bin') + ($jsonClean -split '\s+' | Where-Object { $_ })
+Push-Location Binaries
+& esptool @mergeArgs
+$exitCode = $LASTEXITCODE
+Pop-Location
+
+if ($exitCode -ne 0) {
+    exit $exitCode
+}
+
diff --git a/Buildscripts/Flashing/merge.sh b/Buildscripts/Flashing/merge.sh
new file mode 100644
index 000000000..2a8cff8a5
--- /dev/null
+++ b/Buildscripts/Flashing/merge.sh
@@ -0,0 +1,52 @@
+#!/usr/bin/env bash
+
+# Usage:
+#   merge.sh [chip]
+#
+# Arguments:
+#   chip - optional ESP32 SOC variant (e.g. esp32, esp32s3, esp32c6)
+#
+# Requirements:
+#   jq - run 'pip install jq'
+#   esptool.py - run 'pip install esptool'
+#
+# Documentation:
+#   https://docs.espressif.com/projects/esptool/en/latest/esp32/
+#
+
+# Source: https://stackoverflow.com/a/53798785
+function is_bin_in_path {
+  builtin type -P "$1" &> /dev/null
+}
+
+function require_bin {
+  program=$1
+  if ! is_bin_in_path $program; then
+      exit 1
+  else
+      exit 0
+  fi
+}
+
+# Find either esptool (installed via system package manager) or esptool.py (installed via pip)
+if ! is_bin_in_path esptool; then
+  if ! is_bin_in_path esptool.py; then
+    echo "\e[31m⚠️  esptool not found! Install it from your package manager or install python and run 'pip install esptool'\e[0m"
+    exit 1
+  else 
+    esptoolPath=esptool.py
+  fi
+else
+  esptoolPath=esptool
+fi
+
+chip=${1:-esp32s3}
+
+# Take the flash_arg file contents and join each line in the file into a single line
+flash_args="$(tr '\n' ' ' < Binaries/flash_args)"
+read -r -a flash_args_array <<< "$flash_args"
+(
+  cd Binaries || exit 1
+  "$esptoolPath" --chip "$chip" merge-bin --output merged_binary.bin "${flash_args_array[@]}"
+) || exit 1
+