Driven by emerging technologies like AI and high-performance computing, the semiconductor foundry industry increasingly emphasizes the importance of advanced manufacturing processes. Recently, the industry has seen significant developments. Intel announced that it has commenced large-scale production of its Intel 4 process node, while TSMC and Samsung are equally committed to advancing their advanced process technologies.

Intel’s Mass Production of Intel 4 Process Node

On October 15th, Intel China’s official public account revealed that Intel has initiated large-scale production of the Intel 4 process node using Extreme Ultraviolet Lithography (EUV) technology. According to Intel, they are making significant progress with their “Four Years, Five Nodes” plan. This plan aims to produce next-generation products that meet the computational demands driven by AI’s role in the “Siliconomy.”

Being the first process node produced by Intel using EUV lithography technology, Intel 4 offers substantial improvements in performance, efficiency, and transistor density compared to its predecessors. Intel 4 was unveiled at the Intel Innovation 2023 held in September this year.

In comparison to Intel 7, Intel 4 achieves a 2x reduction in area, providing high-performance computing (HPC) logic libraries and incorporating various innovative features.

In detail, Intel 4 simplifies the EUV lithography process, optimizing it for high-performance computing applications, supporting both low voltage (<0.65V) and high voltage (>1.1V) operations. Compared to Intel 7, Intel 4 boasts more than a 20% improvement in iso-power performance, and high-density Metal-Insulator-Metal (MIM) capacitors deliver outstanding power supply performance.

Intel 7 and Intel 4 are currently in large-scale production. Intel 3 is on track to meet its planned target by the end of 2023.

Intel’s Intel 20A and Intel 18A, which use Ribbon FET all-around gate transistors and PowerVia backside power delivery technology, are also progressing well, with a target of 2024. Intel will soon introduce the Intel 18A process design kit (PDK) for Intel Foundry Services (IFS) customers.

With the adoption of Intel 4 process nodes, the Intel Core i9 Ultra processor, codenamed “Meteor Lake,” will be released on December 14th this year, ushering in the AIPC era.

On Intel 3 process nodes, the energy-efficient E-core Sierra Forest processor will be launched in the first half of 2024, and the high-performance P-core Granite Rapids processor will follow closely.

Samsung’s 2nm Process Detailed Production Plan

Samsung has already commenced production of its second-generation 3nm chips and plans to continue focusing on 2nm chips.

On June 28th, Samsung Electronics unveiled its latest foundry technology innovations and business strategies at the 7th Samsung Foundry Forum (SFF) in 2023.

In the era of artificial intelligence, Samsung’s foundry program, based on advanced GAA process technology, offers robust support for customers in AI applications. To this end, Samsung has disclosed a detailed production plan and performance levels for its 2nm process. The plan is to achieve mass production for mobile applications by 2025 and respectively expand to HPC and automotive electronics in 2026 and 2027.

Samsung reports that the 2nm process (SF2) improves performance by 12% compared to the 3nm process (SF3), increases efficiency by 25%, and reduces the area by 5%.

Furthermore, reports indicated that Samsung is ensuring the production capacity for products using the next-generation EUV lithography machine, High-NA, in September. This equipment is expected to have a prototype by the end of this year and officially enter production next year.

TSMC’s Mass Production of 2nm by 2025

This year, TSMC has unveiled its latest advanced semiconductor manufacturing roadmap in various locations, including Santa Clara, California, and Taiwan. The roadmap covers a range of processes from 3nm to 2nm.

TSMC’s current roadmap for 3nm includes N3, N3E, N3P, N3X, and N3 AE, with N3 serving as the foundational version, N3E as an enhanced version with further cost optimization, N3P focusing on improved performance with a planned start in the second half of 2024, N3X targeting high-performance computing devices with a mass production goal in 2025, and N3 AE designed specifically for the automotive sector, offering greater reliability and the potential to shorten time-to-market by 2-3 years.

In the 2nm realm, TSMC is planning to achieve mass production of the N2 process by 2025. TSMC has reported that the N2 process will offer a 15% speed improvement over N3E at the same power or a 30% reduction in power consumption, with a 15% increase in transistor density. In September, media reports revealed that TSMC has formed a task force to accelerate 2nm pilot production and mass production, aiming for risk production next year and official mass production in 2025.

To ensure the smooth development of 2nm process technology, TSMC has initiated efforts in the upstream equipment sector. On September 12th, TSMC announced the acquisition of a 10% stake in IMS Nanofabrication, a subsidiary of Intel, for a price not exceeding $432.8 million. IMS specializes in the research and production of electron beam lithography machines, which find extensive applications in semiconductor manufacturing, optical component manufacturing, MEMS manufacturing, and more. The industry sees TSMC’s IMS acquisition as vital for developing crucial equipment and meeting the demand for 2nm process commercialization.

(Image: Intel)

With the approach to the end of 2023, TrendForce revealed the tech trends in every sector, apparently, AI continues as the main focus to decide the direction of how the tech supply chain will be in the next few years, here are the seeings:

CSPs increase AI investment, driving a 38% growth in AI server shipments by 2024

• CSPs increase AI investment, fueling a 38% growth in AI server shipments by 2024.
• Major CSPs like Microsoft, Google, and AWS are driving this growth due to the rising popularity of AI applications, pushing AI server shipments to 1.2 million units in 2023.

HBM3e set to drive an annual increase of 172% in HBM revenue

• Major memory suppliers are set to introduce HBM3e with faster speeds (8 Gbps) to enhance the performance of AI accelerator chips in 2024–2025.
• HBM integration is becoming common among GPU manufacturers like NVIDIA and AMD, and it is expected that HBM will significantly contribute to memory suppliers’ revenues in 2024, with an annual growth rate of 172%.

Rising demand for advanced packaging in 2024, the emergence of 3D IC technology

• Leading semiconductor firms like TSMC, Samsung, and Intel are emphasizing advanced packaging technology’s importance in boosting chip performance, conserving space, reduce power usage, and minimize latency. They’re establishing 3D IC research centers in Japan to underscore this role.
• Generative AI is driving increased demand for 2.5D packaging tech, integrating computing chips and memory with a silicon interposer layer. Additionally, 3D packaging solutions like TSMC’s SoIC, Samsung’s X-Cube, and Intel’s Foveros.

NTN is set to begin with small-scale commercial tests, broader applications of this technology are on the way in 2024

• Collaboration between satellite operators, semiconductor firms, telecom operators, and smartphone makers is growing due to increased satellite deployments by operators. This collaboration focuses on mobile satellite communication applications and bidirectional data transmission under specific conditions.
• Major semiconductor manufacturers are ramping up efforts in satellite communication chips, leading top smartphone manufacturers to integrate satellite communication into high-end phones using the SoC model, which is expected to drive small-scale commercial testing of NTN networks and promote widespread adoption of NTN applications.

6G communication to begin in 2024, with satellite communication taking center stage

• 6G standardization begins around 2024-2025, with initial technologies expected by 2027-2028. This enables novel applications like Reconfigurable Intelligent Surfaces (RIS), terahertz bands, Optical Wireless Communication (OWC), NTN for high-altitude comms, and immersive Extended Reality (XR) experiences.
• Low-orbit satellites will play a key role in 6G as its standards solidify, peaking around the time of 6G commercialization. The use of drones for 6G communication and environmental sensing is also set to surge in the 6G era.

Innovative entrants drive cost optimization for Micro LED technology in 2024

• In 2023, the focus in Micro LED display technology is on cost reduction through chip downsizing, aiming for at least a 20-25% annual reduction. A hybrid transfer approach, combining stamping and laser bonding, is gaining attention for efficient mass production.
• Micro LED holds potential in micro-projection displays for transparent AR lenses. Challenges include achieving ultra-high PPI with 5 µm or smaller chips, particularly with red LEDs’ low efficiency. Various innovative approaches, such as InGan-based red LEDs and vertically stacked RGB LEDs.

Intensifying competition in AR/VR micro-display technologies

• Increasing AR/VR headset demand drives demand for ultra-high PPI near-eye displays, with Micro OLED technology at the forefront, poised for broader adoption.
• Challenges in brightness and efficiency impact Micro OLED displays and their dominance in the head-mounted display market depends on the development of various micro-display technologies.

Advancements in material and component technologies are propelling the commercialization of gallium oxide

• Gallium oxide (Ga₂O₃) is gaining prominence for next-gen power semiconductor devices due to its potential in high-voltage, high-temperature, and high-frequency applications in EVs, electrical grids, and aerospace.
• The industry is already producing 4-inch gallium oxide mono-crystals and advancing Schottky diode and transistor fabrication processes, with the first Schottky diode products expected by 2024.

Solid-state batteries poised to reshape the EV battery landscape over the next decade

• Major automakers and battery manufacturers are investing in solid-state and semi-solid-state battery technologies, aiming for a new cycle of technological iteration by 2024.
• After Li-ion batteries, sodium-ion batteries, with lower energy density, are suitable for budget-friendly EVs, and hydrogen fuel cells offer long-range and zero emissions, primarily for heavy-duty commercial vehicles, with widespread adoption expected after 2025, despite challenges.

BEVs in 2024 rely on power conversion efficiency, driving range, and charging efficiency

• Automakers are optimizing battery pack structures and material ratios to increase energy density and driving range. Solid-state batteries, with high energy density, may see limited installations in vehicles as semi-solid batteries in 2H23.
• The 800V platform will enable high-power fast charging, leading to the expansion of high-power charging stations. AI advancements are driving EVs toward advanced autonomous driving, with Tesla’s Dojo supercomputer investing in neural network training to maintain its position in the intelligent driving market.

Green solutions with AI simulations emerging as a linchpin for renewable energy and decarbonized manufacturing

• Under the background of optimizing energy consumption, creating interconnected data ecosystems, and visualizing energy flow and consumption. Carbon auditing tools and AI are key for organizations aiming to reduce carbon emissions and enhance sustainability.
• The IEA predicts global renewable energy generation to reach 4,500 GW by 2024, driven by policy support, rising fossil fuel prices, and energy crises. The adoption of AI-driven smart technologies in peripheral systems for stable energy generation.

OLED’s expansion will across various applications driven by the innovation of foldable phones

• OLED folding phones are improving in design by using lightweight materials, innovative hinge structures, and cost-reduction efforts to approach the thickness and weight of traditional smartphones.
• In the IT sector, industry players like Samsung, BOE Technology, JDI, and Visionox are making significant investments and developments in OLED technology to expand into various markets. Anticipated advancements in technology and materials are expected to increase OLED market penetration by 2025.

Reports indicate that the United States is poised to unveil an updated set of restrictions on chip exports to China this week. Beyond the previously reported tightening measures on AI chips and equipment exports, these new regulations are expected to restrict the supply to chip design companies. The aim is to enhance control over the sale of graphic chips and advanced chip manufacturing equipment for AI applications to Chinese enterprises, with the possibility of adding Chinese chip design companies to the list of restricted entities.

As reported from Reuters and Bloomberg, U.S. authorities will demand that overseas manufacturers obtain licenses to fulfill orders from these companies and subject Chinese firms attempting to circumvent restrictions by using third-party countries for shipping to additional inspections. While the new regulations are expected to be announced this week, the potential for delays should not be ruled out.

In October 2022, the United States declared export restrictions on advanced semiconductor processes and chip manufacturing equipment bound for China, as a measure to prevent the development of cutting-edge technology that could potentially bolster military capabilities for geopolitical adversaries.

Following the implementation of these export bans, U.S. tech companies, such as Nvidia and Applied Materials, incurred significant losses in orders. For example, Nvidia was unable to sell its two most advanced AI chips to Chinese companies, leading to the introduction of a “downgraded” chip, the H800, designed specifically for the Chinese market to bypass existing regulations.

U.S. officials have revealed plans to introduce new guidelines for AI chips, including the restriction of certain advanced data center AI chips that currently do not fall under any limitations. They are considering the removal of “bandwidth parameters” to prevent the entry of AI chips perceived as too powerful into China.

However, they plan to introduce expanded guidelines for chip control, which may reduce communication speeds among AI chips. Slower communication could increase the complexity and cost of AI development, particularly when many chips need to be connected for training large AI models. Additionally, the U.S. will introduce “performance density parameters” to guard against potential future workarounds by companies.

Reports suggest that the United States is looking to prohibit the export of Nvidia’s H800 chip, a “downgraded” chip designed for the Chinese market to legally bypass existing regulations.

The Biden administration is also preparing for additional scrutiny of Chinese companies attempting to modify shipping and manufacturing locations in a bid to evade specific country restrictions. This rule will continue to limit sales of specific chips to Chinese companies through overseas subsidiaries and related entities, requiring authorization before exporting restricted technology to countries that could serve as intermediaries.

Furthermore, the progress in Huawei’s new smartphones has prompted the U.S. authorities to tighten control further, initiating investigations for actions against Huawei or SMIC that will be carried out independently of the new export control regulations.

In response to the anticipated expansion of U.S. export controls on Chinese companies, Chinese Foreign Ministry Spokesperson Mao Ning stated, “We have made our position clear on US restrictions of chip exports to China. The US needs to stop politicizing and weaponizing trade and tech issues and stop destabilizing global industrial and supply chains. We will closely follow the developments and firmly safeguard our rights and interests.”

(Image: Nvidia)

As TSMC’s earnings call approaches, the market is abuzz with rumors that the company may revise down its capital expenditure target for this year. This potential adjustment is believed to be driven by delays in Intel’s 3-nanometer outsourcing and the deferral of the production schedule for TSMC’s 4-nanometer US fab. The initial capital expenditure target, which was close to the $32 billion to $36 billion range, may now be lowered to below $30 billion, marking its lowest point in nearly three years.

According to Taiwan’s Economic Daily, TSMC has refrained from commenting on these speculations. Even if TSMC does adjust its capital expenditure for this year, industry sources suggest that the company will increase its annual R&D expenses, continuing its commitment to advanced research and development.

In recent years, TSMC has rapidly expanded its capital expenditure, reaching a record high of $36.3 billion last year. In the first half of this year, the actual capital expenditure amounted to $18.11 billion, including $8.17 billion in the second quarter, slightly down from the $9.94 billion in the first quarter.

During their July earnings conference, TSMC stated that their capital expenditure for the year would remain in the range of $32 billion to $36 billion. However, considering market dynamics, the actual expenditure for the full year is expected to be towards the lower end of this range.

The latest reports suggest that due to the delays in Intel’s 3-nanometer outsourcing and the postponement of the 4-nanometer production schedule at the US fab, approximately $4 billion originally earmarked for this year’s capital expenditure may be postponed until next year, resulting in capital expenditure for this year falling below $30 billion. As for next year’s capital expenditure, it may remain on par with this year.

ASML, a leading supplier of semiconductor lithography equipment, previously revealed in its July earnings conference that there were delays in shipments of EUV equipment due to installation delays at customer factories. However, ASML maintained a robust order backlog and expects overall performance to continue growing in 2024.

Industry experts believe that the “installation delays” mentioned by ASML at that time were related to TSMC, and because of the delay in EUV equipment installation, TSMC’s capital expenditure for this year may be deferred accordingly.

Analysts in the industry suggest that if we consider TSMC’s earlier projection of capital expenditure falling within the $32 billion to $36 billion range, and subtract the actual expenses incurred in the first half of the year, the capital expenditure for the second half of the year could see a decline, estimated to be around $13.89 billion or more. If the postponement rumors materialize, second-half capital expenditure might fall below $10 billion.