Cybersecurity in Additive Manufacturing

Nikhil Gupta, Ph.D.

Mechanical and Aerospace Engineering

Center for Cybersecurity

New York University Brooklyn, NY 11201 USA

Http://engineering.nyu.edu/composites Email: ngupta@nyu.edu

3DPSecurity.com

Acknowledgments

Collaborators and Contributors Fei Chen (NYU TSoE) - Ph.D researcher Ashish K. Singh (NYU TSoE) - Ph.D. researcher Dr. Ramesh Karri (NYU TSoE) - Cybersecurity Michail Maniatakos (NYUAD) - Cybersecurity Dr. Khaled Shahin (NYUAD) - Metal 3D printing Dr. M. Doddamani (NIT-K, India) - AM of composites Dr. Dirk Lehmhus (IFAM, Bremen) - AM of metals and composites Steven Zeltmann - CEO, 3DP Security, Inc.

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AM fundamental concept

Start

point

Start

point

• An object is sliced into multiple layers

• 2D toolpaths were generated for each layer

• The toolpaths will be translated into an encoder file such as G-code

• Tool can be either filament extrusion or laser 2/27/2018 3

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AM Market Size

• Worldwide revenues from AM products were an estimated $2.67 billion in 2016, an increase of 12.9% than in 2015

• AM services grew to an estimated $3.4 billion in 2016, an increase of 21.2% than in 2015

• The AM market has grown by • 21.1% in 2016,

• 33% in 2015,

• 38.9% in 2014, and

• 26.3% in 2013

• McKinsey Global Institute research suggests that it could have an impact of up to $550 billion a year by 2025

Turbine rotor produced by AM

AM Advantages

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• Faster product realization and testing cycles, which accelerate the product development

• Realization of designs that could not be manufactured earlier

• Reduced tooling, assembly and inventory costs

Image courtesy: Dr. Dirk Lehmhus, Fraunhofer IFAM, Bremen, Germany

Jointless assembly of parts produced by AM

Hydraulic crossing

Model cross-sectional view Part produced by AM

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Manufacturing

• Development of new feed materials

• Consistent quality of feed materials

• Reducing the waste and cost in powder based processes

• Development of secondary processing methods

Challenges

Security

• Intellectual property compromise

• Product authentication

• Counterfeiting

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• Industrial manufacturing requires development of unique compositions of polymers with • Plasticizers, filler, high temperature stabilizers,

color pigments

• Developed a unique approach based on thermo-mechano-rheological properties

New Feed Material Development

Industrial grade high density

polyethylene (HDPE)

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New Feed Material Development

Riptide underwater autonomous

vehicle

Syntactic foam filament, density

0.6 g/cm3

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Additive Manufacturing Perception

Development of CAD model of desired shape

A top of the Line 3D Printer

Printed part ready for deployment

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Additive Manufacturing Perception

Development of CAD model of desired shape

A top of the Line 3D Printer

Printed Part ready for deployment

Actually, this is not a realistic picture, the process is much more involved and complicated

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AM Process Chain

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AM: Cyber-Physical System

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Cybersecurity in AM

• Network security tools • Traffic monitoring, firewalls,

access privileges

• Password protection of files

• File encryption

• Access control (network and physical)

• Security based design thinking

• The CAD model needs to be set up with • Security features to deter printing in high quality

• Product authentication methods

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Cybersecurity Risks

Cybersecurity spending in the U.S., percent of GDP and USD billions, 2009-2017

TIA’s 2010-2017 ICT Market Review and Forecast, available at: http://publications.atlanticcouncil.org/cyberrisks//

http://www.nbcnews.com/tech/tech-news/visa-database-found-be-vulnerable-hacking-n549011

• Lawrence Livermore National Laboratory: $2B in unapproved parts in inventory of distributors, airline, and repair stations

• US Senate (2011): counterfeit parts on C-17 transport airplane and the CH-46 helicopter, Theater High-Altitude Area Defense (THAAD) missile defense system

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Security Concerns in AM Process Chain

Premature failure under loads

Encryption and Cryptography

Secure CAD

Models

Embedded Authentication Codes

Codes Obfuscation

Cybersecurity

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NYU AM Initiative

Z XY

Secure CAD files

Start

point

Start

point

• An object is sliced into multiple layers

• 2D toolpaths were generated for each layer

• The toolpaths will be translated into an encoder file such as G-code

• Tool can be either filament extrusion or laser 2/27/2018 17

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Secure CAD Models

• Embedded spline feature

• Tessellated induced gaps lead to defective surface

• Printing of the spline split feature or not is orientation-dependent

Tensile bar designed with spline split

Sliced model Tensile testing Standard tensile bar with spline split feature

0

5

10

15

20

25

30

35

0 0.02 0.04 0.06 0.08 0.1

Str

es

s M

Pa

Strain mm/mm

Intact x-z

Spline x-z

Intact x-y

Spline x-y

• Orientation-dependent spline

CAD model

Tessellation induced

gaps

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Secure CAD Models

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Embedded Authentication Codes

2D QR code

CAD models X-ray CT scan 3D printed part

• These codes can be designed on the internal hidden surfaces or small interior sections

• A CT scanner, ultrasound scanner or other reading technologies can be used to retrieve information

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Tensile bar CAD with embedded multi-layer

code 3D printed tensile bars

Tensile testing

Intact bars QR embedded

bars Tensile

strength (MPa)

57.07±0.44 55.92±0.98

Modulus (GPa)

2.57±0.12 2.56±0.11

Weight (grams)

21.80±0.02 21.79±0.02

Embedded Authentication Codes

• Quality measurement

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Codes Obfuscation

CAD STL

XY x

y z

Z

x

y z

CT-scan front

CT-scan side

• The embedded authentication code can be controlled to only print under the specified orientation

• This incorporates the CAD security features into embedded code models, increasing security level and further obfuscating IP attackers

Sliced model

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Encryption and Cryptography

No Data Loss!

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Summary

• A new design thinking is required that integrates security into the product design and manufacturing process

• The layer by layer manufacturing process can be used for obfuscation of features that can be used for product authentication

• New possibilities such as converting design to sound are exciting for security!

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Publications

Journal papers • Zeltmann, S. E., Gupta, N., Tsoutsos, N. G., Maniatakos, M., Rajendran, J. and Karri, R. Manufacturing and security

challenges in 3D printing. JOM: Journal of The Minerals, Metals, and Materials Society, 2016, 68(7) p. 1872–1881.

• Chen, F., Mac, G., Gupta, N. Security features embedded in computer aided design (CAD) solid models for additive manufacturing, Materials and Design. 2017, 128: p. 182-194.

• Singh, A.K., B. Patil, N. Hoffmann, B. Saltonstall, M. Doddamani, and N. Gupta, Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments. JOM, 2018. 70(3): p. 303-309.

• Singh, A.K., B. Saltonstall, B. Patil, N. Hoffmann, M. Doddamani, and N. Gupta, Additive Manufacturing of Syntactic Foams: Part 2: Specimen Printing and Mechanical Property Characterization. JOM, 2018. 70(3): p. 310-314.

Book chapters • Gupta, N., Chen, F., and Shain, K., Design Features to Address Security Challenges in Additive Manufacturing. In Advances

in Manufacturing Techniques for Materials: Engineering and Engineered. Ed. Srivatsan, T. S., 2017.

Conference proceedings • Gupta, N., Chen, F., Tsoutsos, N.G., and Maniatakos, M., ObfusCADe: Obfuscating additive manufacturing CAD models

against counterfeiting. In 54th ACM/EDAC/IEEE Design Automation Conference (DAC) proceedings. Austin, TX, USA. June 18-22. 2017

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Thank you