How Temporal-powered Ignition flashed 2,300 conference badges in two nights

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Engineers at Replay conference built a custom firmware flashing system called Ignition, powered by Temporal, to program 2,300 ESP32-based conference badges in under two days. The team used lazy Susans from Target as rotating carriers for 16-port USB hubs, allowing coworkers to load and flash 32 badges at a time across six laptops. A critical last-minute bug emerged when QA firmware caused devices to reappear under different USB identities after resetting into the bootloader, confusing the tracking system. Engineer Edward Amsden patched the USB re-enumeration logic so Ignition could reliably identify the same physical badge across port changes. The project highlighted how flashing thousands of embedded devices in a live assembly-line setting demands the same reliability and fault-tolerance as a distributed production system.

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