RealSense firmware upgrade via flash chip programming

[nooway077]

Hey everyone!

I'm trying to fix a RealSense D457 camera which was bricked by a firmware upgrade. (Relevant #14437) The camera was out of warranty and we've already ordered a replacement Vision Processor D4 V5 board as suggested in the relevant github issue, however the shipping estimate is June 2026 and in the mean time since the board is physically in good condition I'm trying to fix it.

I've successfully desoldered and read out the contents of the onboard firmware storage chip which seems to contain the full firmware image (2MB). The firmware upgrades listed on the Firmware releases D400 site appear to contain 1.5MB bin files which are missing some regions and the camera won't boot if the latest firmware from the site is programmed to the onboard flash storage. I'm wondering if it is possible to download or get the full firmware image for the device that is used for programming them in the factory or is there some way to craft the full image from the broken (wrong version, correctly booting) and latest supported image?

[MartyG-RealSense]

Hi @nooway077 There is no way for RealSense users to firmware-update a bricked D457 that has a bad firmware driver, unfortunately.

Approved RealSense parts supplier Rutronik24 are currently estimating a lead time of 4 weeks for new stock of the D4 V5 board, so it may be worth registering with them to be notified when they have stock and cancelling your June order if you can get a board from Rutronik24.

https://www.rutronik24.com/product/realsense/99c2m4/20357915.html

[nooway077]

Hi @MartyG-RealSense!

I see, so this is probably because of some NDA thing that the full fw is not available for download I guess. I'm not familiar with Rutronik24, we've ordered from DigiKey but might try to cancel that one then.

Thank you for your help.

[MartyG-RealSense]

You are very welcome.

An engineering image of the firmware would not work as it needs to be digitally signed (like the public firmware file releases are) in order to be recognized by the camera.

[nooway077]

You are very welcome.

An engineering image of the firmware would not work as it needs to be digitally signed (like the public firmware file releases are) in order to be recognized by the camera.

Thanks for this info!

So essentially it has some sort of secure boot function. Just for curiosity, If I send you the raw firmware that was read off the device, would you be able to make a signed engineering firmware that is programmable to this board? (I assume it contains some specific identifiers that are tied to this board.) Also, If I understand this correctly, even if I read out the firmware from the brand new board (the one that is expected in June) and program that into this "bricked" board would not boot, correct?

[MartyG-RealSense]

If the camera is outside of the warranty period then RealSense engineers cannot carry out work to assist in restoring it, unfortunately.

A firmware file is not tied to a specific camera, but it does have to be digitally signed in order for the camera to operate after the firmware is installed.

I do not personally have knowledge of RealSense firmware engineering and the flash memory hardware component of the camera that stores it. So I cannot offer advice on the feasibility of writing an extracted firmware file directly to the flash storage of the bricked D4 V5. As far as I am aware it has not been previously attempted by a RealSense user.

Depending on how urgent your need is and your available budget, an 8-pack of D450 modules and D4 V5 boards is currently in stock in the RealSense Store for $2,136.

https://store.realsenseai.com/intelr-realsensetm-depth-module-d450-vision-processor-d4-board-v5-gmsl-fakra-8-pack.html

If you are using your D457 as a water-resistant camera in USB mode instead of GMSL then the D456 USB camera which also has an IP65 protective casing is currently in stock as a possible replacement.

https://store.realsenseai.com/buy-intel-realsense-depth-camera-d456.html

Otherwise, Rutronik24 is likely your best chance of obtaining a D4 V5 in the near future.

[nooway077]

Okay, thanks for explaining this in detail!

The device is used in education, in fact my university provided it. It was bricked before I got access to it sadly. (I decided to try fixing it as I have some tools for embedded systems work and could use it for my thesis work) Because it is just a single device I think multiple quantity orders are out of the question and as I mentioned they already placed an order for the new board. Well, if there is nothing to be done I think the case can be closed.

Thank you for your help @MartyG-RealSense!

[MartyG-RealSense]

I'm pleased that I could be of assistance. Thanks very much for the update!

[nooway077]

UPDATE

I managed to upgrade the firmware on the Vision Processor D4 V5 board!

Seems like it will allow firmware upgrade from the Realsense Viewer GUI if it is disconnected from the camera sensor board (interposer cable) and put into DFU mode manually by sending an interrupt (160ms Pulse) to Pin1 of the External Sensor Connector while its powered on and connected to a computer through the USB C connector. (Intel-RealSense-D457-Datasheet-September-2022.pdf Revision 001 page 50-51) The interrupt signal can be generated with a programmable function generator or possibly with most microcontroller evaluation boards.

The camera is now working (tested with SDK v2.57.4), however I managed to burn the switch near the external sensor connector when resoldering the flash chip (and possibly weakened the pcb with the thermal stress) so the board will need to be replaced, but I can use it until the new one arrives.

The issue is resolved and can be closed, thanks again @MartyG-RealSense!

[MartyG-RealSense]

It's great to hear that you were able to develop an advanced solution for replacing the D555 firmware. Thanks so much for sharing the details for the future benefit of D555 users with similar electronics skills to yours.