Cyber-Physical Security for Additive Manufacturing Systems

Additive manufacturing (AM) is a growing section of the advanced manufacturing field and is being used to fabricate an increasing number of critical components, from aerospace components to medical implants. At the same time, cyber-physical attacks targeting manufacturing systems have continued to rise. For this reason, there is a need to research new techniques and methods to ensure the integrity of parts fabricated on AM systems. This work seeks to address this need by first performing a detailed analysis of vulnerabilities in the AM process chain and how these attack vectors could be used to execute malicious part sabotage attacks. This work demonstrated the ability of an internal void attack on the .STL file to reduce the yield load of a tensile specimen by 14% while escaping detection by operators. To mitigate these vulnerabilities, a new impedance-based approach for in situ monitoring of AM systems was created. Two techniques for implementing this approach were investigated, direct embedding of sensors in AM parts, and the use of an instrumented fixture as a build plate. The ability to detect changes in material as small as 1.38% of the printed volume (53.8 mm3) on a material jetting system was demonstrated. For metal laser powder bed fusion systems, a new method was created for representing side-channel meltpool emissions. This method reduces the quantity of data while remaining sensitive enough to detect changes to the toolpath and process parameters caused by malicious attacks. To enable the SCMS to validate part quality during fabrication required a way to receive baseline part quality information across an air-gap. To accomplish this a new process noise tolerant method of cyber-physical hashing for continuous data sets was presented. This method was coupled with new techniques for the storage, transmission, and reconstructing of the baseline quality data was implemented using stacks of "ghost" QR codes stored in the toolpath to transmit information through the laser position. A technique for storing and transmitting quality information in the toolpath files of parts using acoustic emissions was investigated. The ATTACH (additive toolpath transmission of acoustic cyber-physical hash) method used speed modulation of infill roads in a material extrusion system to generate acoustic tones containing quality information about the part. These modulations were able to be inserted without affecting the build time or requiring additional material and did not affect the quality of the part that contained them. Finally, a framework for the design and implementation of a SCMS for protecting AM systems against malicious cyber-physical part sabotage attacks was created. The IDEAS (Identify, Define, Establish, Aggregate, Secure) framework provides a detailed reference for engineers to use to secure AM systems by leveraging the previous work in vulnerability assessment, creation of new side-channel monitoring techniques, concisely representing quality data, and securely transmitting information to air-gapped systems through physical emissions.