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Secure air-gapped AI training is a systems-engineering problem, not a single firewall rule or GPU choice. Build a connected staging pipeline to collect and verify every dependency, transfer a signed bundle through a controlled channel, then run the isolated cluster with default-deny egress, internally mirrored software, topology-aware GPU settings, and repeatable failure tests. The design must protect the management plane, storage, firmware, and operational workflows as well as pod traffic.
What an air-gapped training baseline must accomplish
An air-gapped cluster has no routine route to the public internet. That removes a large class of exfiltration and supply-chain paths, but it also removes the convenient services on which many AI stacks silently depend: model hubs, container registries, package repositories, certificate endpoints, telemetry services, and license or key lookups. The practical objective is therefore twofold:
- Isolation: workloads cannot reach unapproved external or lateral destinations.
- Self-sufficiency: every image, model, driver, package, certificate, chart, manifest, and configuration needed for installation, startup, upgrade, and recovery is available inside the enclave.
NIST SP 800-125B (published in 2016) treats segmentation, firewall architecture, path redundancy, and traffic monitoring as core controls for secure virtual networks. The initial public draft of NIST SP 800-239, published July 27, 2026, broadens the review for AI data centers to hardware, software, workflows, and storage. Use both perspectives: pod-level policy is necessary, but it is not the whole security boundary.
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NVIDIA’s NIM air-gapped workflow separates preparation on a connected system from execution in the isolated environment. Reproduce that separation for the complete training platform rather than only for model files.
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Phase 1: connected staging
- Inventory the exact profile. Record Kubernetes and container-runtime versions, GPU Operator and driver versions, CUDA/runtime compatibility, training framework, model revisions, storage back ends, and all required platform add-ons.
- Resolve dependencies. Pull container images, Helm charts, manifests, model weights and tokenizers, driver packages, operating-system packages, certificate chains, and any init-container or sidecar assets. Include Helm test images and GPU Operator images; an image used only during installation can still break an offline deployment.
- Generate a bill of materials. For each artifact, record name, version, source, digest or cryptographic hash, architecture, license or approval status, and provenance. Keep the manifest with the transfer set.
- Scan and sign. Apply the organization’s malware, vulnerability, license, and provenance checks. Sign the approved bundle and preserve the scan reports so the receiving enclave can verify what was authorized.
- Prepare internal services. Populate the private container registry, internal OS/package repository, model store, and certificate authority material. Test pulls and package installation from these services before the transfer.
Phase 2: isolated execution
Transfer the signed artifacts through an approved controlled channel. Import images into the private registry and compare their resulting digests with the bill of materials. Mount local model and package assets for the workload. In the air-gapped phase, do not set NGC_API_KEY or HF_TOKEN; an offline deployment should not be waiting for external authentication.
Keep an immutable copy of the original bundle and a separately signed rollback bundle. A cluster that can start only after rebuilding a cache from the internet is not operationally air-gapped.
Segment the enclave before deploying workloads
Define separate security zones for management, the Kubernetes control plane, storage, east-west training traffic, and any transfer or staging function. Use VLAN or VRF boundaries and explicit firewall policy between zones. The exact implementation depends on the switch and firewall design, but the intent is consistent: a compromised training pod must not become a route to administrators, registries, or storage controllers.
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| Zone | Purpose | Policy focus |
|---|---|---|
| Management | Administrative access, monitoring, bastions, and break-glass systems | Allow only authenticated operator paths; log every session and configuration change |
| Kubernetes control plane | API servers, controllers, and cluster state | Restrict access to worker nodes and approved administrators; separate from user workloads |
| Storage | Model stores, training datasets, package mirrors, and persistent volumes | Permit only required node and service identities; monitor reads, writes, and remounts |
| East-west training | Distributed collectives and node-to-node data exchange | Permit the ports and paths required by the selected Kubernetes and training stack; monitor unusual lateral flows |
| Transfer/staging | Controlled import and export of signed bundles | One-way or tightly mediated transfers; no general workload access |
Apply least-privilege egress in Kubernetes
Start every workload namespace with a default-deny egress NetworkPolicy. Add exceptions only after identifying a real internal dependency.
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- Create the namespace and apply a policy that denies all egress by default.
- Permit UDP and TCP port 53 only to the approved internal DNS service. Do not point pods at a resolver outside the enclave.
- Permit HTTPS or other registry traffic only to the private registry addresses and ports used by the cluster. Use the registry’s internal CA; never disable TLS verification to make an image pull succeed.
- Add narrowly scoped rules for other internal services, such as a model store or metrics endpoint, only when the workload requires them. Match namespace, pod labels, destination addresses, and ports where the CNI supports those selectors.
- Log denied egress and review it during smoke tests. A denied request can reveal a missing mirror, a hard-coded public hostname, or an unexpected telemetry path.
Kubernetes and distributed-training systems still require node-to-node reachability. Run:ai documentation notes that Kubernetes assumes interconnectivity among nodes, while the exact ports vary by setup. Define the permitted control-plane, kubelet, overlay, storage, and collective-communication paths for your chosen versions, then monitor those paths rather than opening a broad any-to-any rule.
Certificate and name-resolution controls
- Issue certificates from an internal CA for the registry, package repository, model service, and administrative endpoints.
- Distribute CA bundles through controlled ConfigMaps, node configuration, or image trust stores. Rotate them with a documented overlap period so running workloads do not fail unexpectedly.
- Use internal DNS records for every service. Search paths and fallback resolvers should not send queries outside the enclave.
- Record administrative access, denied egress, registry pulls, image digests, model-file hashes, and transfer events in a log system that remains available during an external-network outage.
Mirror GPU software and pin a compatible bundle
NVIDIA GPU Operator may need both an internal image registry and an internal operating-system package repository. Configure repository and certificate ConfigMaps when drivers are installed from packages; the relevant settings include driver.repoConfig and driver.certConfig. Where supported, precompiled driver containers can remove package downloads from the installation path.
Pin the complete compatibility set, not just the GPU Operator chart:
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| Component | What to record | Offline requirement |
|---|---|---|
| GPU driver | Exact release, kernel compatibility, and architecture | Mirrored packages or a supported precompiled driver container |
| CUDA and container runtime | Runtime versions and supported driver range | Images and runtime packages in the private registry/repository |
| GPU Operator | Chart version, image digests, and configuration values | Chart, operator images, init images, and sidecars mirrored |
| Kubernetes | Control-plane and node versions | All platform images and upgrade artifacts available internally |
| Training framework | Framework, communication library, and Python/system dependencies | Wheel, package, and base-image mirrors; no runtime internet install |
Install and validate this bundle in a staging enclave before moving it to production. A version that works on a connected laptop can fail offline because a post-install script, kernel module build, or image entrypoint attempts an unmirrored download.
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Inventory GPUs, topology, fabric, and storage
GPU and network values are topology-dependent. There is no universal MTU, bandwidth target, NCCL setting, or single GPU model that is correct for every air-gapped training cluster. Capture the facts below as scheduler-visible inventory.
- GPU: model, count per node, memory capacity, compute capability, partitioning mode if used, and health state.
- CPU and NUMA: socket layout, CPU memory, NUMA distance to each GPU, huge-page policy, and CPU pinning.
- Interconnect: PCIe generation and lane assignment, NVLink topology, switch-domain boundaries, and links shared by storage or management traffic.
- Fabric: east-west link speed and oversubscription, RDMA capability, GPUDirect RDMA readiness, switch configuration, and failure domains.
- Storage: local NVMe or shared storage capacity, throughput and latency expectations, model-cache size, container-layer space, package mirror capacity, and persistence behavior after node reboot.
- Placement: which GPUs may share a node, rack, switch, or power domain, and which combinations must be avoided for a distributed job.
Use this inventory to derive NCCL, MTU, bandwidth, and placement values. Validate the result with the selected workload and fabric; copying settings from a different topology can reduce performance or produce intermittent collective failures.
RDMA and GPUDirect RDMA checks
For multi-node training, verify that the NIC, driver, firmware, switch, and container permissions support RDMA end to end. Confirm that GPUDirect RDMA can reach the intended GPUs without an unexpected host-memory bounce path. Test across every switch domain and failure boundary that a scheduler may select. If a job is restricted to a subset of nodes, encode that constraint as labels, taints, or a placement policy rather than relying on operator memory.
Storage and cache behavior in an offline cluster
Keep model stores, container layers, driver packages, and language/runtime packages on persistent local or internally shared storage sized for the selected profiles. Do not assume an ephemeral cache can be rebuilt after a node restart. Measure free space before importing a new model, and reserve capacity for at least one rollback version of critical images and drivers.
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Test storage remounts and permission behavior with the same service accounts used by training. A model that is present but unreadable by the pod is an availability failure, while a writable shared model directory can become an integrity risk. Use read-only mounts for immutable model artifacts where the framework permits them.
Offline validation sequence
- On the connected staging host, generate the bill of materials for images, charts, model files, drivers, packages, certificates, and manifests. Record versions, hashes, and provenance.
- Scan and sign the artifacts, then transfer them through the approved controlled channel.
- Import every image into the private registry and verify digest matches. Include init containers, sidecars, Helm tests, GPU Operator images, and platform images.
- Install or verify GPU Operator from the offline bundle. Confirm driver readiness and that repository and CA ConfigMaps resolve to internal services.
- Apply default-deny egress before starting the workload. Add only the internal DNS and registry exceptions required by the cluster, followed by any separately justified model or storage rules.
- Run local health checks, model listing, and inference or training smoke tests over loopback or internal service addresses. Restart the workload and repeat to prove startup does not depend on outbound access.
- Exercise node failure, registry unavailability, storage remount, and certificate rotation inside the enclave. Record observed behavior, alerting, recovery time, and the exact rollback artifacts used.
Common failure modes and recovery
An image pull fails even though the image exists
Check the image digest, architecture, registry hostname, internal CA trust, and every init or sidecar image. A tag can resolve to a different digest than the one approved for transfer. Re-import the exact digest and update the manifest rather than weakening TLS or opening external egress.
GPU Operator cannot install a driver
Verify kernel compatibility, the internal repository URL, repository metadata, proxy-free name resolution, and the driver.repoConfig and driver.certConfig references. If the release supports it, use the precompiled driver-container path to avoid an unavailable package download. Keep the previous known-good driver bundle for rollback.
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Compare the scheduler placement with the recorded PCIe/NVLink and NUMA topology. Then check east-west firewall rules, RDMA device exposure, GPUDirect RDMA readiness, switch-domain boundaries, and MTU consistency on every hop. Do not change several NCCL or fabric variables at once; isolate one path and rerun a small collective test.
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The workload tries to reach the internet
Leave the deny rule in place and inspect the destination in egress logs. Common causes are an unmirrored model tokenizer, telemetry SDK, package installer, certificate check, or hard-coded hostname. Mirror the required asset or disable the optional feature in the approved image; never grant unrestricted egress as a workaround.
How to compare air-gapped designs
Evaluate candidate architectures on the same five axes:
| Axis | Questions to answer | Evidence to retain |
|---|---|---|
| Isolation strength | Are management, control plane, storage, training, and transfer paths physically or logically separated? Is egress default-deny? | Network diagrams, firewall rules, NetworkPolicies, and denied-flow logs |
| Supply-chain completeness | Can the cluster install, start, upgrade, and roll back without public services? | Bill of materials, hashes, signatures, mirror inventories, and rehearsal results |
| GPU and fabric performance | Do memory, topology, RDMA, GPUDirect RDMA, storage, and placement match the workload? | Hardware inventory, topology captures, collective tests, and workload metrics |
| Operability | Can operators rotate certificates, replace a node, recover storage, and roll back a driver offline? | Runbooks, failure-injection records, and recovery timings |
| Evidence quality | Can every approved artifact and administrative action be traced? | Signed manifests, registry audit logs, model hashes, access logs, and transfer records |
Exact numeric settings remain profile-specific. A design with a faster fabric but incomplete mirrors is less usable offline than a slower design that can be recovered and audited without outside access.
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Final readiness checklist
- All images, models, charts, manifests, drivers, packages, and certificates have approved hashes and provenance.
- Private registry, package repository, model store, DNS, and internal CA are reachable only through documented paths.
- Namespaces begin with default-deny egress; exceptions are limited to named internal services.
- GPU Operator, driver, CUDA/runtime, Kubernetes, and training framework versions are pinned and tested together.
- GPU, CPU/NUMA, PCIe/NVLink, RDMA, GPUDirect RDMA, storage, and failure-domain inventory is available to the scheduler.
- Restart, node failure, registry outage, storage remount, and certificate rotation tests have passed inside the enclave.
- Logs cover denied egress, image pulls and digests, model hashes, administrative access, and transfer events.
- A signed rollback bundle and the procedures to use it are stored offline.
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