Router will not update firmware automatically and download file to attempt manually is fragmented for some reason and won't install
It is indeed frustrating that the Firmware Update process does not appear to "find" new firmware that has already appeared on the Netgear support web site. One explanation is that Netgear appears to follow an informal process in terms of firmware updates:
New firmware appears on the support web site, but the Orbi 'app' and web browser management do not detect it. Customers who regularly check the support site may come across the new firmware and install it manually. This produces reactions from those customers. Sometimes positive, and sometimes negative. On a couple of occasions over the years, user complaints were so strong that the new firmware quietly disappeared from the support site. (oops!)
At some point, Netgear decides that the firmware is suitable to roll out and begins a scheduled process where the update mechanism reports that new firmware is available, but does not force the customer to perform the update. i.e. if the customer does not open the Orbi 'app' or the web browser management interface, nothing happens. This process appears to occur in stages, perhaps by product serial numbers.
At some point after that, Netgear may force the update silently, usually in the middle of the night, again oh a phased rollout.. With the latest AX firmware versions, Netgear has introduced an option to allow/forbid automatic updates. With the default being to allow automatic updates, those customers who never look at their systems will silently update over time. It remains to be seen what will happen if Netgear faces a "Doomsday Scenario" where there is an urgent need to force an update and some customers have said "no".
It's also strange that some customers report receiving email from Netgear informing them of new firmware, while other customers do not.
All that being said, while it is not common, there are times when the file downloaded from the Netgear support site is corrupted. (Heck, my Chrome browser regularly claims it cannot unpack an update. Irritates me no end.) In that case, download the file again until you get a good copy.
