I’ve managed twice to have the Pixhawk not bootable. Both times because the memory card was full. It isn’t very obvious what causing the problem and takes some time to find-out as it shouldn’t happen too often.
Would it be hard to add some logfile purging at a certain level? Currently you cannot use the last log as it is corrupt (not fully written)
To be able to use the log for a more commercial use there must be some solution for this as the system refuse to work when the SD-card is full