They may be making a finer point here, I’m not an expert on packaging, but generally speaking there are packaging processes that support using only “known good die”. You still have the issue of testing the final integrated product, so the packaging process itself needs to have high yield.
For more info check out Dylan Patel’s series on advanced packaging:
There are companies today building various types of "multi-chip-modules" (MCM) and "systems-in-package" (SiP) that mix chips and passives from different vendors.
- Octavo Systems puts Ti SOC's and PMIC's in a package with outside vendor DRAM and ROM chips.
- NXP builds some auto parts with a mix of NXP chips on different process nodes and third party flash.
I spent a few years designing these types of systems. In my mind the the biggest value of a standard like this is to push companies to make it worth their while to sell "known-good-die" (KGD) or fully-tested die.
Modern chip manufacturing basically has a two part test flow - a partial test of each die on the wafer then after slicing and packaging each part goes through final test. Packaging is expensive and so imagine building a multi chip module which might have an SOC, DRAM, PMIC and FLASH bare dies and then it goes through final test and each of those dies had a 90% final test yield then the MCM might only have a 65% yield. That's a lot of money down the drain.....
If I built the same part using fully tested die then my yields should be closer to 95-99% - basically the failures are not due to bad silicon, but bad packaging....
Right now it's tough to get companies to spend the resources on a KGD test program because the market is just too small/scattered. A standard helps to build a market.
With that said - I haven't seen this standard yet. I just requested a copy. From the little info available on the website (https://www.uciexpress.org/) it sounds like it's just an IO interconnect standard - along the lines of something like MIPI DSI + D-PHY. That's a good start but the dream of "lego" like chips will require standardized foot prints and pinouts which may just never be feasible but there are people exploring this idea....
> Are you sure? TSMC definitely does packaging. And it seems like it would be crazy to ship a delicate unpackaged die to a different factory when you could just keep it in a clean room and do everything in one place. I think it would be mad for Intel not to do packaging there.
True, the very advanced packaging techniques, such as TSMC CoWoS or Intel EMIB, are done at the fabs by those companies. These packages are for very high performance multi-chip interconnects. In both cases, the "package" itself actually is partially constructed from silicon, so we are kind of blurring the lines between what is "chip" and what is "package". The vast majority of chips do not use packages anywhere near this advanced and are not done at fabs.
Also, it's not crazy to ship finished wafers (i.e. "unpackaged die"); it's standard practice. Once the final process steps are complete in the fab, the chip is not as sensitive to fine particles any more. The wafers get loaded into cassettes then vacuum-sealed in anti-static bags. They ship out to the backend assembly sites just fine. In fact, globally, there are probably ~100,000 wafers shipped like this every day.
> Intel sells lots of CPUs that aren't soldered to PCBs.
True. But if you are buying an LGA socketed Intel CPU, the silicon die had to first be mounted on a substrate and the heatspreader attached. That wasn't done at fab, it was done at backend assembly. Ever notice that Intel CPU's often say something about "assembled in Malaysia" on top? That's because it was assembled in Malaysia. Intel does not have any semiconductor fabs in Malaysia, meaning, they fabbed it in one place and assembled it in another.
If you are a company like Dell or HP and you are buying the laptop BGA CPUs, Intel still had to assemble those into the BGA package before shipping to Dell/HP. And the BGA package assembly also is not done at fab.
A packaging facility is not a fab. It doesn't really give them any advantage in reverse engineering the silicon over someone that buys the end product and de-packages the die.
don't forget the cost of testing - that adds up, often people do simple testing on the wafer to avoid the cost of packaging bad die, then full testing once packaged - remember a bad chip for a semi manufacturer is a whole bad board for their customers
Couldn't they make a "dummy" die for non-cache products? Basically the only features on the die would be whatever through vias were necessary; I'd assume this could be done on with comparatively old/cheap/debugged processes and have an extremely high yield.
It is an interesting technology. It is basically a packaging innovation, sounds pretty boring I guess, but larger chips have a super-linearly bad effect on yield, so breaking up the design into chiplets is very nice.
I wonder if anyone knows of a good place to look up Intel vs TSMC yield numbers or defect density?
This part isn't new, or why this is significant. For example, AMD has been doing this since Zen 2 (Ryzen 2xxx), combining 14nm and 7nm components.
On the other hand, the top chip designers and foundries working together and standardizing is potentially very significant, though I reserve judgement until actual products are produced on this new standard.
I'd love to see a full layer-by-layer teardown of the actual die. Multi-die packages are nothing special. Getting past metal8, even it it means going straight to silicon, would let you pick out individual blocks.
For the simplicity of this discussion let's just focus on companies selling physical chiplets.
Assuming the company follows normal manufacturing processes (and assuming that company is "fabless" then this is a pretty safe assumption) then there is no risk of mixing different silicon from different vendors/fabs in a single package. This is being done today. Currently designers do have to take into account mixing parts that were designed for various package technologies. If a chip was designed for "flip-chp" and another chip for "wire-bond" then putting them both in the same package might require some different packaging techniques...
That said - I'd assume if a company was going to build a chip and specifically market it for this new UCIe standard then they'd probably target a WLCSP type final process which is fairly common today.
What about the dies that aren't 100% perfect, and don't work at those high end specs? If there's a defect in a core or two, or in some area of cache, why not trim it down to a lower spec part and sell it for something (rather than scrapping it)?
Most dies already have to go through multiple processes even when it's not a SOC/CPU so I don't think the extra cost is that high.
You are saving money on binning and packaging costs, and multi die packages are also a possibility if you want to make low cost BGA parts with less performance.
> This tutorial will discuss advanced packaging technologies that enable performance and density improvements.
I'm interested in advanced packaging. Does anyone know anything about it? My impression is that BGA, MicroBGA, CSP, WLP, Flip-Chip are the evolutionary dead end of packaging, you can't really find a denser way to put a chip on the board. So instead, you put more things into the package or onto the interposer, and for the user, the new "module" can be used just like a chip, this is the System-in-Package approach, such as integrating the chiplet and RAM to a processor, or stacking multiple silicon dies on top of each other. This is my understanding, but is there anything new to see?
It's a lot more practical to put several dies insides one package, which is already happening (for example, the largest FPGAs from Xilinx have 4 dies in a single package).
Intra-package communication is not quite as good as intra-die communication (from a performance and energy point of view), but it's a lot better than inter-package communication, and several small dies have a higher yield than one large die.
Since they are wiring the chips on the wafer and routing around defects, I imagine a chiplet design on a wafer-sized interposer would help them deal with yield issues. I wonder what their competition will do. It's certainly possible for Nvidia or AMD to bundle GPU dies on top of large interposers and TSMC has already shown large ones, though nothing on this scale.
For more info check out Dylan Patel’s series on advanced packaging:
https://semianalysis.substack.com/p/advanced-packaging-part-...
https://semianalysis.substack.com/p/advanced-packaging-part-...
https://semianalysis.substack.com/p/advanced-packaging-part-...
Or this from SemiWiki for a shorter overview of just TSMC processes:
https://semiwiki.com/semiconductor-manufacturers/tsmc/290560...
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