The sustained push toward smaller and smaller technology sizes has reached a point where device reliability has moved to the forefront of concerns for next-generation designs. Silicon failure mechanisms, such as transistor wearout and manufacturing defects, are a growing challenge that threatens the yield and product lifetime of future systems. In this paper we introduce the BulletProof pipeline, the first ultra low-cost mechanism to protect a microprocessor pipeline and on-chip memory system from silicon defects. To achieve this goal we combine area-frugal on-line testing techniques and system-level checkpointing to provide the same guarantees of reliability found in traditional solutions, but at much lower cost. Our approach utilizes a microarchitectural checkpointing mechanism which creates coarse-grained epochs of execution, during which distributed on-line built in self-test (BIST) mechanisms validate the integrity of the underlying hardware. In case a failure is detected, we re...