According to a report by TechNews, TSMC’s Arizona-based Fab21, currently in the intensive equipment installation phase, has initiated the construction of a small-scale trial production line. With a small amount of equipment expected from multiple supply chain by the end of 2023, industry sources suggest that Fab21 is planning to commence trial production in the first quarter of 2024.

The reason behind TSMC’s anticipated trial production in the first quarter of 2024 stems from orders from its U.S. clients. Market reports indicate that among Fab21’s U.S. clients, in addition to major players like , NVIDIA CEO Jensen Huang has not ruled out placing orders with Fab21. Furthermore, there are indications that Intel, planning to outsource core computing to TSMC’s N3B process, is likely to place orders to Fab21 in the near future.

However, due to cost considerations, despite the commencement of a small-scale trial production line, the initial capacity increase for Fab21’s 4-nanometer process will not accelerate. This situation is expected to persist into the subsequent second phase of the 3-nanometer production line.

Looking back at TSMC’s progress in Arizona, the company announced the construction of the 12-inch wafer Fab21 in Arizona back in 2020, anticipating the commencement of formal equipment installation in the first quarter of 2024 and official mass production before the end of 2024. The initial phase of Fab21 will produce on the 5-nanometer process, with a monthly production capacity of 20,000 wafers.

TSMC later upgraded the initial processs from 5-nanometer to 4-nanometer. However, due to a shortage of skilled installation workers in the region, TSMC postponed the mass production start date to 2025.

In addition, the second phase of the project is currently slated for mass production in 2026, introducing the 3-nanometer process. The total investment for both phases amounts to $40 billion.

Industry sources also acknowledge that Fab21’s manufacturing costs are high, and its capacity cannot compete with TSMC’s fab in Taiwan, making U.S. client orders primarily a response to U.S. government requirements, with the majority of production still centered in Taiwan.

(Image: TSMC)

In mid-December, Intel is set to unveil its latest Core Ultra processor, Meteor Lake. Global PC brands like Lenovo, Microsoft, DELL, HP, Acer, Asus, MSI, and Samsung are rolling out new products to capture the market. The end-users is enthusiastic, and channel feedback suggests increasing orders, marking a turning point in the PC industry,  according to CTEE.

As per the designs by PC brands, AI PCs are poised to offer AI and machine learning, capable of executing intelligent applications and tasks at the edge. This translates to a boost in user productivity and entertainment experiences, enhanced communication efficiency, and improved work quality. Furthermore, these PCs prioritize data and privacy protection.

Taiwanese partners have corresponding models entering the market, with analysts anticipating AI PCs to become the primary driver for replacement demand in the latter half of the next year. Shipment volumes are estimated to surpass 100 million units in the next two years, benefiting Taiwan’s supply chain, including PC brands Acer, Asus, MSI, and ODMs Quanta, Compal, and Inventec.

On the other hand, TSMC stands up as a major upstream player, with rising utilization rate of the 5nm and 6nm advanced processes contributed to the big orders from the Meteor Lake. TSMC is in charge of the NPU, specifically designed for AI tasks.

Intel highlights 3D Foveros as the key to advanced packaging in mixing and matching compute tiles. This aspect is managed by its advanced packaging fab in Malaysia, ensuring the most efficient energy distribution.

(Image: Intel)

Despite the uncertainties in the semiconductor market, there is still an intense global competition in the development of advanced semiconductor manufacturing processes. TSMC as one of the key players in the foundry industry is actively advancing its next-generation 2nm process. According to market rumors, the schedule for the first tool-in at Hsinchu Baoshan Fab and Kaohsiung Fab has been established, along with a finalized production capacity plan.

CNA has reported that TSMC’s 2nm process will be deployed in the Phase 2 Expansion Area of the Baoshan Site at the Hsinchu Science Park. The first tool-in is scheduled for April 2024. Industry sources have revealed that the initial production capacity for this process will be around 30,000 wafers per month, with mass production planned for the following year.

In addition, TSMC’s fab in Kaohsiung has notified equipment suppliers that this facility is set to begin in the third quarter of 2025. According to MoneyDJ, the pilot run is planned for the end of the same year, with the aim of achieving mass production in 2026. The Kaohsiung fab will adopt the N2P process, which is an enhanced version of the 2nm process with the backside power rail technology. The initial monthly production capacity is also expected to be around 30,000 wafers.

According to previous disclosures made by TSMC during financial calls, the company has developed a backside power rail solution for the N2 process, which is particularly suitable for high-performance computing (HPC) applications. This innovative technology is expected to boost speed by 10% to 12% and increase logic density by 10% to 15%. TSMC plans to introduce the backside power rail solution to customers in the latter half of 2025, with mass production scheduled for 2026. This timetable aligns with recent rumor circulating in the supply chain.

In addition to the latest progress on the N2P process, TSMC made an official announcement at the IEEE International Electron Devices Meeting (IEDM) on December 12th. Specifically, the company revealed its plans to introduce a 1.4nm process as the successor to the 2nm process. As reported by Tom’s Hardware, this new process, named A14, continues the naming convention from the 2nm process (A20). Production using the A14 process is anticipated to take place between 2027 and 2028.

(Image: TSMC)

Explore more

• [News] TSMC Responds to Rumors of New 1.4nm Fab
• [News] TSMC President Highlights 2024 Semiconductor Challenges While Envisioning Abundant AI Opportunities
• [News] TSMC May Reduce Next Year’s Capital Expenditure, Affecting Orders for Equipment & Testing-Related Companies

As the Japanese government injects substantial funds to revitalize its semiconductor industry, the dynamics of the Japanese semiconductor industry have been a global focus. TrendForce, during this year’s SEMICON Japan, organized its first overseas industry-focused information seminar, delving into the global semiconductor, optoelectronics, and electric vehicle industries, with a particular focus on the dynamics and strategies of the Japanese market and companies. The event attracted over a hundred participants from Japanese technology industry.

The seminar, opened by TrendForce CEO Kevin Lin, under the theme of “the era of challenges,” served as a commentary on the future development of the technology industry in the coming years. Lin pointed out that global technological industries, influenced by geopolitical factors, are experiencing a trend of supply chain restructuring. He also highlighted China’s expansion in the semiconductor, electric vehicle, and downstream supply chains, reshaping the global supply chain landscape—an aspect requiring global attention.

During the seminar, TrendForce’s Senior Research Vice President, Ken Kuo, presented an analysis of the global memory and AI server market. He noted that after a year and a half of adjustments, prices in the DRAM and NAND markets started to rise across the board in the fourth quarter, driven primarily by robust growth in AI. This trend is expected to continue into the next year.

Beyond AI servers, the introduction of technologies such as Microsoft’s Copilot, as well as AI PCs and AI smartphones, is poised to be a growth driver next year. In terms of AI chip shipments, NVIDIA is projected to maintain its dominance, with an estimated 1.5 million units shipped this year and an anticipated 100% growth next year.

The semiconductor foundry market is expected to recover in 2024.

The recovery of the semiconductor market in 2024 was a major focus for participants. TrendForce’s analyst Joanne Chiao mentioned that as supply chain inventory pressures gradually ease, the semiconductor foundry industry is expected to experience a recovery in 2024, driven by TSMC’s advanced processes and inventory replenishment momentum, with a projected growth of 7%.

In light of geopolitics, , semiconductor foundry supply chains are undergoing restructuring. In 2023, Taiwan is expected to account for approximately 46% of global semiconductor foundry capacity, followed by China at 26%, South Korea at 12%, the United States at 6%, and Japan at 2%. With the drive from subsidy policies in China and the United States to increase local production capacity, by 2027, Taiwan and South Korea’s production capacity shares are expected to converge to 41% and 10%, respectively.

Meanwhile, Japan is actively implementing subsidy policies to support local company Rapidus and attract Taiwan’s TSMC and PSMC to establish facilities, aiming to secure a place in the semiconductor foundry market.

The introduction of Apple Watch with Micro LED is expected in 2026, with estimated display costs 2.5-3 times higher than OLED.

TrendForce’s Senior Research Vice President, Eric Chiou, analyzed Apple’s progress in adopting new display technologies during the display technology session. He mentioned that the next-generation Apple Watch panel would use Micro LED as the display technology, with a size larger than the current Apple Watch Ultra at 2.12 inches.

The product will have two key suppliers: German LED giant ams OSRAM, which will exclusively supply Micro LED chips smaller than 10x10um, and South Korean panel manufacturer LG Display, responsible for the chip mass transfer engineering in addition to providing LTPO glass backplates.

Chiou pointed out that the adoption of small-sized chips inherently helps compress costs. Considering Apple’s strong bargaining power in the supply chain, he estimated that when the product is launched in 2026, the cost of the Micro LED display panel could be controlled below $120, equivalent to 2.5 to 3 times the current price of OLED panels—a reasonable range for a new technology.

Moreover, with Apple’s outstanding ability to integrate new technologies and specifications, there is an expectation of achieving million-unit-level shipments in the first year of launch, injecting abundant vitality into the demand for Micro LED chips and the overall industry’s development.

China’s EV expansion brings impact to the global automotive industry.

In 2023, China became the world’s primary exporter of automobiles, prompting the global automotive industry to recognize that competition with Chinese automakers will extend from the domestic market to the global market. TrendForce analyst Caroline Chen highlighted in her speech that the most significant threat to international automakers is China’s advantage in EV( including BEV, PHV, FCV).

She emphasized that due to China’s early development of EVs, it has established a complete supply chain, particularly in the proactive development of power battery production capacity and upstream materials. EVs account for over a quarter of China’s passenger car exports.

On the other hands, with a nearly 60% market share in the Southeast Asian market, Chinese automakers gradually threaten Japanese automakers’ long-term dominance in the Southeast Asian automotive market.

She believes that as Chinese automakers expand into the international market, Japanese automakers should not only accelerate the development of new energy vehicles but also leverage their long-accumulated brand value and well-established maintenance systems as core competitive advantages. Additionally, maintaining leadership positions in semiconductor and chemical materials is a strategy for sustained investment to consolidate their influence in the automotive industry.

Due to escalating raw material and labor expenses, The Elec reported that Dongwoo Fine-Chemistry, a subsidiary of Japan’s Sumitomo Chemical, plans to increase the prices of KrF and L-line photoresists for South Korean semiconductor companies. Price increases vary depending on the type of offering, ranging from around 10% to 20%.

As a pivotal material in semiconductor manufacturing, photoresist leverages photochemical reactions and undergoes processes like exposure and development through photolithography. This facilitates the transfer of intricate patterns from the reticle to the processing substrate. The KrF photoresist highlighted in this report represents a high-end variant, marking a significant competitive market for future players.

The photoresist market has been dominated by several major manufacturers such as Tokyo Ohka Kogyo, DuPont, JSR, Shin-Etsu Chemical, Sumitomo Chemical, and Dongjin Semichem. This market concentration is particularly pronounced in the market segment for semiconductor photoresist.

The photoresist industry demands high specialization, involving intricate formulations of resins, photosensitive acids, and additives—guarded as trade secrets by each company. The substantial technological barrier, coupled with the necessity for purity and performance from laboratory trials to market production, makes the entire product development process time-consuming and intricate. Additionally, meeting customer requirements and adaptation of the production line requires 1 to 3 years of validation, making it challenging for the customers to shift from current photoresist companies.

Faced with technological and customer-centric challenges, photoresist companies wield substantial negotiating power. The recent uptick in photoresist prices has prompted a noteworthy response from the South Korean semiconductor industry.

Insiders from the foundries commented, “In the face of rising photoresist prices, foundries have little choice but to pass on some of the costs to customers (fabless companies).” They further noted, “The price increase in Dongwoo Fine-Chemistry’s photoresist may contribute to a decline in the profitability of foundries and the fabless industry.”

(Image: Dongwoo Fine-Chemistry)