Electromagnetic and power side-channel analysis (SCA) provides attackers a prominent tool to extract the secret key from the cryptographic engine. In this article, we present our cross-device deep learning (DL)-based side-channel attack (X-DeepSCA) which reduces the time to attack on embedded devices, thereby increasing the threat surface significantly. Consequently, with the knowledge of such advanced attacks, we performed a ground-up white-box analysis of the crypto IC to root-cause the

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... of the electromagnetic (EM) side-channel leakage. Equipped with the understanding that the higher-level metals significantly contribute to the EM leakage, we present STELLAR, which proposes to route the crypto core within the lower metals and then embed it within a current-domain signature attenuation (CDSA) hardware to ensure that the critical correlated signature gets suppressed before it reaches the top-level metal layers. CDSA-AES256 with local lower metal routing was fabricated in a TSMC 65 nm process and evaluated against different profiled and non-profiled attacks, showing protection beyond 1B encryptions, compared to ∼10K for the unprotected AES. Overall, the presented countermeasure achieved a 100× improvement over the state-of-the-art countermeasures available, with comparable power/area overheads and without any performance degradation. Moreover, it is a generic countermeasure and can be used to protect any crypto cores while preserving the legacy of the existing implementations.