Are you proposing an in-computer router/firewall card, or a
stand-along router/firewall, or both? They could both be viable products,
and fall within the skills available in the project group.
This strikes me as a much more suitable product area than
professional audio.
However, the first question to ask is, what would an open-design
router bring to the world that off-the-shelf devices don't provide? Our
time is limited, so we want to use it for something that will make a
difference.
Getting to some of the questions:
I think a firewall should have at least 3 network ports, and
preferably four. They're used for WAN, DMZ, main internal LAN, and a
sandbox LAN for untrusted hosts such as Windows machines and visitors'
laptops.
The program memory should be socketed, so that undoing a failed
upgrade is a simple matter of unplugging the candidate EPROM and plugging
the original one back in. It should be physically impossible for an
executing firmware load to write to the memory device it resides in --
that's basic security. There should be a separate socket, which is
writeable and not executable, for burning new firmware downloads. It would
also be desirable to store configuration settings in a separate socketed
memory device (EEPROM) which is both readable and writeable. This would
allow complete configurations to be swapped out, stored, and restored.
The main sysadmin interface should appear as a lynx-friendly web
server. SSH might also be provided. There should be a physical front-panel
switch to disable configuration changes. New firmware should be delivered
by either ftp or scp.
One thing about this is, it doesn't require any IC design. It's all
electronics, board layout, sheet metal, and firmware.
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