Security by design: Developing robust security systems for the automotive industry to accelerate secure software-defined, connected vehicles

Security by design

As modern vehicles become more connected and software-driven, they also become more vulnerable to cyber threats. Cybersecurity has therefore emerged as a critical part of the automotive industry. Onboard systems, electronic controls, and communication networks are just some of the vehicle infrastructures exposed to malicious attacks and unauthorised access.

Cyberattacks have reportedly cost vehicle manufacturers up to $1 billion.

Security by design was a £1.8 million project, part-funded by Innovate UK’s Digital Security by Design (DSbD) challenge. It explored cybersecurity in software-defined, connected vehicles to identify vulnerabilities and provide the automotive industry with advanced technologies that enable security integration from the outset—making systems more robust and resilient.

The approach

The five project partners used DSbD hardware and software to design and build a Telematics Control Unit (TCU)—an embedded system that manages wireless tracking, diagnostics, and communication to and from the vehicle. This TCU was integrated into an end-to-end system and installed in a connected vehicle.

The unit was tested in specific use cases involving safety-related features such as telemetry, over-the-air software updates, and incident advisory systems, with the goal of developing more secure solutions to address cyber vulnerabilities.

Use cases were selected where TCUs are part of safety-critical systems with time-sensitive performance requirements.

CSA Catapult led end-user engagement with original equipment manufacturers (OEMs) and tier-one automotive companies. It also convened an automotive steering committee, gathered industry challenges, and produced a report outlining requirements for the secure solutions developed.

The outcome

Security by Design delivered a range of benefits for the consortium:

The project demonstrated that DSbD-based TCUs can enable safe and secure vehicle connectivity

A TCU with enhanced security features offers design differentiation, establishing it as a standalone product

Beam Connectivity is now able to market DSbD-based TCUs to manufacturers and is in the process of protecting the design.

If early adoption of these technologies across the automotive industry reduces preventable road fatalities by just 1%, it could save 16 lives and £38 million in preventable costs annually—funds that could be reinvested into the UK economy.

Flexible design

The project demonstrated successful use cases for secure TCUs that can enhance vehicle safety. A TCU with improved security features offers design flexibility, allowing it to be adapted by end-users for various applications.

Opportunities for growth in EV supply chains

The UK is well-positioned to play a key role in forming new supply partnerships for future software-defined, connected vehicles. Widespread adoption of this technology is expected to generate additional revenue for the SMEs involved in the project.

Upskilling the next generation

The project has created new jobs and facilitated knowledge transfer between experienced professionals and the next generation of engineers. Industry-led case studies developed through the project are now being used in university courses to support STEM education.

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