Communication Encryption Board PCBA

Inline Hardware Security Module — CC EAL5+, AES-256-GCM, Active Tamper Zeroization — DO-254 / IPC-6012 Class 3

Product Overview

The Communication Encryption Board is a dedicated hardware security module (HSM) PCBA designed by Superb Automation to provide cryptographic protection for all data flowing between UAVs and their ground infrastructure. This board operates as an inline encryptor/decryptor placed between the flight controller (or payload processor) and the communication radio, transparently encrypting all outbound data and decrypting all inbound traffic with zero added latency beyond the cryptographic processing time — typically less than 50 microseconds per packet. By isolating encryption functions to dedicated hardware, this board ensures that cryptographic keys never reside in general-purpose processor memory where they could be extracted through software exploits or physical memory attacks. The design follows DO-254 DAL C processes for safety-critical cryptographic functions.

The 6-layer PCB incorporates a secure element IC certified to Common Criteria EAL5+, with active tamper detection mesh covering the entire cryptographic boundary. Any attempt to probe, drill, or delaminate the board triggers immediate key zeroization — the secure erasure of all stored keys. The board implements AES-256-GCM for authenticated encryption, ECDH (Curve25519) for key agreement, SHA-512 for integrity verification, and SM2/SM3/SM4 algorithms for applications requiring compliance with Chinese national cryptographic standards. A true random number generator (TRNG) with entropy sourced from semiconductor junction noise ensures cryptographic-quality nonces and session keys. All fabrication meets IPC-6012 Class 3 for the tamper mesh layers.

Key Specifications

Tamper Detection Architecture

The 6-layer PCB implements an active tamper detection mesh spanning the entire cryptographic boundary. The mesh consists of interleaved serpentine traces on the top and bottom layers, continuously monitored by the secure element. Any break, short, or impedance change in the mesh — caused by drilling, probing, or delamination — triggers key zeroization within 10 nanoseconds. The secure element's internal memory is zeroized through a dedicated hardware path that does not depend on software execution or external power. A separate battery-backed tamper alarm records the event with a timestamp in non-volatile memory. The board also includes light sensors and temperature sensors to detect decapsulation and thermal attacks.

Test Strategy

Each board undergoes cryptographic known-answer testing for all implemented algorithms. The TRNG output is validated against NIST SP 800-22 randomness criteria across 1 million bits. Tamper mesh continuity is verified through impedance measurement at every node. Key loading is performed in a secure facility with documented chain of custody, and each board is shipped with a unique X.509 device certificate. Sustained throughput is verified at 200 Mbps with zero packet loss for 24 hours.

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