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Additive Manufacturing (AM) systems such as 3D printers use inexpensivemicrocontrollers that rarely feature cybersecurity defenses. This is a risk,especially given the rising threat landscape within the larger digitalmanufacturing domain. In this work we demonstrate this risk by presenting thedesign and study of a malicious Trojan (the FLAW3D bootloader) for AVR-basedMarlin-compatible 3D printers (>100 commercial models). We show that the Trojancan hide from programming tools, and even within tight design constraints (lessthan 1.7 kilobytes in size), it can compromise the quality of additivelymanufactured prints and reduce tensile strengths by up to 50%.

FLAW3D: A Trojan-based Cyber Attack on the Physical Outcomes of Additive Manufacturing