Embedded Hardware Hacking for IoT Devices: Tools, Techniques, and Business Implications

By Deral Heiland, IoT Research Lead at Rapid7

Smart cars, refrigerators, security cameras, and medical implants are increasingly interconnected, constantly exchanging data with one another and the global internet. While this connectivity delivers undeniable value, it also expands the attack surface for malicious actors. Robust security is essential as IoT adoption accelerates.

Many IoT devices exhibit exploitable vulnerabilities, yet security teams often lack the bandwidth or specialized expertise to secure every connected asset. Whether you’re a researcher, engineer, or security professional curious about embedded hardware, this guide outlines the foundational tools, methods, and concepts to get you started.

For organizations developing new IoT products or deploying solutions, partnering with an experienced consultant is crucial. A skilled professional can uncover hidden risks, assess vulnerabilities, and implement mitigation strategies across the entire IoT ecosystem.

The Essential Toolset

Hardware hacking begins with the right equipment. A modest starter kit can be assembled for £15–25 (€17–28). Tools are typically grouped into three categories:

• Disassembly and assembly
• Electronic signal analysis and measurement
• System control and injection

While high‑end gear exists—often costing several hundred pounds—this guide focuses on the core instruments you can build upon.

Disassembly and Assembly

1. Reliable pliers and a complete set of screwdrivers are indispensable.
2. Invest in an adjustable temperature soldering iron with interchangeable tips to solder, desolder, and apply flux efficiently.

Electronic Signal Analysis & Measurement

Two must‑haves for this category are:

1. A digital multimeter to measure voltage levels, identify ground planes, and trace board paths.
2. A quality logic analyzer—Saleae is a popular choice—that captures digital signals from embedded devices. For quick JTAG or UART enumeration, the JTAGULATOR automatically walks through pinouts and tests header configurations.

System Control & Injection

Inexpensive yet powerful tools help you access, extract, or modify data on embedded systems:

1. The Bus Pirate supports UART, I²C, SPI, and JTAG; the Shikra offers faster SPI flash extraction and also handles UART and JTAG.
2. Segger’s J-Link (education and professional editions) is robust for JTAG and SWD debugging.
3. The BeagleBone Black serves as a versatile test platform for a variety of diagnostics.

Don’t forget simple accessories such as jumper wires and headers:

• 27 mm male straight single‑row pin header
• 54 mm male straight single‑row pin header
• Male‑to‑female solderless flexible breadboard jumper wires

Disassembling the Device

Begin by carefully accessing the hardware. The bottom of the unit usually hides screws beneath labels or rubber feet. For U.S. models, look for FCC ID markings—devices with wireless or RF capabilities must display this label. Enter the FCC ID on the FCC website to obtain RF test reports and internal images, which reveal assembly details such as glued or epoxy‑sealed cases.

Use a Dremel or similar tool for precise cuts, but always observe safety precautions to protect yourself and the circuitry.

Examining the Circuit

Once opened, map the board, identify debug ports (JTAG, UART, SWD), and locate key ICs—CPU, memory, RF, Wi‑Fi. Retrieve datasheets for each component by searching the part number stamped on the chip; datasheets provide pinout diagrams and electrical characteristics essential for deeper analysis.

Inspecting Firmware

Firmware analysis can expose critical vulnerabilities. First, check if the vendor offers a direct firmware download. If not, capture the upgrade traffic with Wireshark; the Export Objects feature can retrieve the binary if it’s unencrypted. Alternatively, use the device’s companion mobile app to discover the firmware update URL and any required authentication tokens.

When network capture fails, you may need to read flash memory directly. Depending on the board, this could involve in‑circuit SPI reading or desoldering the flash chip and using a chip reader. Research the specific device model online; community forums often document proven extraction methods.

Implications for Businesses

If your IoT product’s firmware is proprietary, protecting it is paramount. The simplest and most cost‑effective defense is to disable UART interfaces before shipping. Persistent attackers with physical access can almost always compromise UART‑enabled devices and retrieve firmware.

Professional security firms conduct comprehensive penetration and system analysis across the entire ecosystem, ensuring that every component and interaction is evaluated. While exploring hardware hacking is rewarding, engage experts when you need deeper assurance.

Author: Deral Heiland, IoT Research Lead at Rapid7