Fraunhofer Institute for Production Technology IPTResearch project "OTP2"
Security for satellite-based communication
The European satellite navigation system Galileo enables protected communication for authorized users such as government agencies and security forces with the Public Regulated Service (PRS) The mobile receivers require a special security module for this purpose, which houses the security-critical data and is completely encapsulated.
The protective cover must meet the highest requirements for tamper protection and secrecy. Seals that register tampering attempts and delete the protected secret in an emergency are used to detect unauthorized access. So-called active seals are important for autonomous, permanent monitoring – a so-called “tamper protection”. Unlike passive seals, which only register physical changes, active seals can be continuously monitored and provide immediate feedback on their condition.
Complete 3D enclosure with an optical seal for PRS security modules using sensor-equipped thin glass foils
A novel security solution is being developed in the research project “OTP2 – Optical Tamper Protection for PRS Security Module”: a fully enclosed 3D protective cover made of ultra-thin glass with integrated optical sensors. These sensor foils enable a tamper-proof, permanent seal – an optical tamper protection (OTP). This OTP system provides reliable tamper detection and automatic erasure of a secret in the event of a physical attack.
In a previous project, the sensor technology and structures for an OTP system have already been developed and successfully demonstrated on a two-dimensional thin glass component. In the current project, the technology is being further developed, the two-dimensional lid is becoming a three-dimensional hood suitable for protecting mobile, security-relevant satellite communication systems.
Simulations optimize the design and determine advantageous process parameters
Initially, various concepts for manufacturing the protective covers are developed and evaluated for their suitability. The Fraunhofer IPT analyzes various designs for 3D encapsulation. Finite element methods (FEM) are used to define the requirements and optimize the designs. In addition, a material characterization is carried out to examine the thermal-mechanical properties and stress-strain relationships of the materials used. A structural analysis using FEM simulations helps to predict stresses and crack growth and to model the forming process of the thin glass foils.
This comprehensive and structured approach ensures that the solutions developed are both functional and efficient and meet the project requirements.
Process development for forming the sensor foils
Once the simulation results and the final design are available, a process for thermoforming the 2D sensor foils into 3D sensor domes is developed. This involves creating forming tool systems and adapting process parameters to take into account the optical requirements of the glass foil.
At the end of the project, a process for 3D forming of the optical sensor foils will be available to ensure encapsulation of the PRS components. A demonstrator of the OTP system will be created, and risks and weak points will be identified and improved through technical measures. The aim is to achieve final external certification of the OTP system after project completion in order to enable product approval of the PRS receivers.
Funding
The research project “OTP2 - Optical Tamper Protection for PRS Security Modules” is funded by the Federal Ministry of Digital and Transport (BMDV) as part of the national program to promote the Galileo Public Regulated Service, by the German Aerospace Center (DLR).
Funding reference: 50NP2402B
Project partners
- OHB System AH, Bremen (coordination)
- Fraunhofer Institute for Production Technology IPT, Aachen
- Fraunhofer Institute for Telecommunications, Heinrich-Hertz-Institut HHI, Goslar
- Fraunhofer Institute for Integrated Circuits IIS, Nürnberg
- Fraunhofer Institute for Reliability and Microintegration IZM, Berlin
What is Public Regulated Service (PRS)?
The Public Regulated Service (PRS) is a communication service of the European satellite navigation system Galileo that is specifically designed for authorized users such as government agencies and security forces. It is used primarily for safety-related applications such as emergency services and military operations.
PRS uses a network of Galileo satellites to send signals to authorized receivers. These signals contain positioning, timing and integrity information. Access to PRS is controlled by special security modules in the receivers, which detect unauthorized access and manipulation.
The received signals are processed to calculate precise position data, with algorithms evaluating signal strengths and travel times. In addition, PRS offers integrated error detection that identifies anomalies and warns users to ensure the reliability of the data. PRS thus enables secure and precise navigation for authorized applications.
What is optical tamper protection (OTP)?
Optical tamper protection (OTP) is a technology used to ensure that electronic devices and systems are protected against unauthorized access or manipulation. It uses optical methods to verify the integrity of components or housings.
OTP is frequently used in security-critical applications, such as in medical technology or in the financial sector, to ensure the security and trustworthiness of the systems.
The optical-based OTP technology can be made robust against false alarms by using suitable algorithms, which allow a clear distinction between environmental influences and attacks. This technology is used in cryptophones, smart locks, alarm systems and encrypted hard drives.
How does Optical Tamper Protection (OTP) work?
Optical tamper protection (OTP) uses optical sensors to detect tampering with electronic devices. These sensors continuously monitor the light pattern created by certain coatings or structures.
If the optical pattern is altered, for example by unauthorized opening of the device, an alarm is immediately triggered or access to sensitive data is blocked. In addition, many OTP systems log tampering attempts, which is helpful for tracking security incidents. In this way, OTP provides effective protection against unauthorized access and ensures the integrity of security-critical applications.