With its 3nm manufacturing process in mass production for approximately a year, TSMC is expected to have a breakthrough in customer acquisition and capacity utilization in 2024.

According to predictions from a South Korean outlet The Elec, aside from Apple, customers such as NVIDIA, AMD, Qualcomm, and MediaTek are expected to place orders for the second generation of the 3nm process within the year. This is anticipated to significantly boost TSMC’s 3nm process capacity utilization to 80% by the end of the year.

Chinese tech media ICsmart further quoted from the report, stating that although TSMC announced the mass production of its 3nm process in December 2022, the first-generation 3nm process (N3B) had only one customer throughout 2023, which was Apple. Companies like MediaTek and Qualcomm opted for the 4nm process due to cost considerations.

However, the report suggests that in 2024, more companies, in addition to Apple, are expected to place orders for the more cost-effective second generation of the 3nm process (N3E). This is anticipated to boost TSMC’s overall production capacity for the 3nm process.

Several chip companies are expected to adopt the N3E process for their new products. The report suggests that TSMC’s customers for this process may include Qualcomm, which is gearing up to launch the new Snapdragon 8 Gen 4, MediaTek with its next-generation Dimensity 9400, Apple with its M3 Ultra chip and A18 Pro processor, AMD with the Zen 5 CPU and RDNA 4 GPU, and NVIDIA with the Blackwell architecture GPU. Notably, the Apple M3 Ultra chip might make its debut in the upgraded Mac Studio around mid-year.

The report notes that TSMC initially anticipated steady growth for the 3nm process in early 2023 as yields improved, but with only Apple as a customer, the “steady growth” of the 3nm process negatively impacted TSMC’s performance.

The report suggests that with TSMC’s new orders from customers beyond Apple for the 3nm process, a considerable rebound is expected. Monthly production is projected to reach 100,000 wafers by 2024, and the 3nm production capacity utilization rate is poised to soar to 80% by the end of 2024.

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(Photo credit: TSMC)

TSMC, the world’s leading foundry in the 3nm technology, is reportedly experiencing a surge in the number of New Tape-Outs (NTOs) for the 3nm family in 2024, with Clients such as MediaTek, AMD, NVIDIA, Qualcomm, and Intel.

Among the 3nm family, the N3P process, set for mass production in the second half of 2024, is also making significant progress. Rumors suggest that Tesla has been added to the list of customers, with plans to utilize the N3P for the production of next-generation Full Self-Driving (FSD) chips after its launch.

Currently, Tesla has placed orders with TSMC for numerous chips related to electric vehicles. For instance, the supercomputer chip “D1” is utilizing TSMC’s 7nm technology along with advanced packaging processes.

Reportedly, according to industry sources, Tesla’s older FSD chips were initially produced using Samsung’s 14nm process, later upgraded to Samsung’s 7nm process. Subsequently, considering design upgrades, production quality, and scale, Tesla has shifted its HW 4.0 autonomous driving chip production to TSMC, utilizing the 5nm technology family.

The latest information per the report indicates that Tesla has recently initiated a NTO process with TSMC, planning to utilize the N3P for the production of the fifth generation of self-driving vehicle chips. Market expectations are high, with the influx of relevant orders suggesting that Tesla has the potential to become one of TSMC’s major clients.

According to TSMC’s previously disclosed process roadmap, the N3P process is an advanced version within the 3nm family, scheduled for production in 2024. Compared to the N3E, the N3P boasts a 5% improvement in performance, a 5% to 10% reduction in power consumption, and a 1.04 times increase in chip density.

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(Photo credit: TSMC)

Market speculations rumored that TSMC might cut its capital expenditure for next year to USD 28-30 billion. This potential reduction, ranging from 6.3% to 12.5% compared to this year, is attributed to the shared use of certain process equipment and the utilization of deferred budgets from the current year. If realized, this would mark the lowest capital expenditure point in nearly four years. Additionally, it could impact the order volumes for equipment & testing-related companies, influencing the overall order dynamics in the supply chain for the upcoming year, reported by UDN News.

Responding to the speculations about a decrease in next year’s capital expenditure, TSMC stated on the December 4th that regarding next year’s capital expenditure will be officially disclosed during the January 2024 conference. Despite the potential moderation in capital expenditure, industry observers anticipate continued growth in R&D investment, particularly in advanced process technology.

Industry sources suggest that TSMC’s R&D investment in advanced process technology will persist in its growth trajectory for the next year. Notably, approximately 80% of the equipment for the 3nm advanced process can be shared with the 5nm and 7nm processes. The focus of next year’s capital expenditure is expected to be on investments in the 3nm and below advanced processes and mask technology.

Meanwhile, mature processes will bring a rise in the share of specialty processes and equipment modifications for advanced packaging.

During 2023Q3 earnings call in October, TSMC set a cautious tone, citing uncertainties in the short-term market. The company maintained this year’s capital expenditure at nearly USD 32 billion, adopting a prudent approach to investment.

On the other hand, ASML, the global leader in semiconductor lithography technology, recently released its financial report. The forecast indicates that 2024 will be a transitional year, with expected revenue similar to that of 2023. This cautious outlook aligns with the semiconductor industry’s current phase of experiencing the bottom of the cycle.

(Image: TSMC)

According to TechNews’ report, TSMC and Samsung fiercely compete in the semiconductor foundry sector. Earlier market reports suggested that Qualcomm’s Snapdragon 8 Gen 4 mobile processor might adopt a dual-foundry strategy with TSMC and Samsung manufacturing simultaneously.

However, according to the latest industry information, due to Samsung’s conservative expansion plan for next year’s 3nm production capacity and unstable yields, Qualcomm has officially canceled the plan to utilize Samsung for next year’s processors. The dual-sourcing model is now postponed until 2025.

Samsung began mass production of its first-generation 3nm GAA (SF3E) process at the end of June last year, marking Samsung’s initial use of the innovative GAA architecture for transistor technology. The second-generation 3nm process, 3GAP (SF3), will utilize the second-generation MBCFET architecture, optimizing it based on the foundation of the first-generation 3nm SF3E. It is expected to enter mass production in 2024.

The dual-foundry strategy for Qualcomm was initially leaked by the reputable source Revegnus via the X platform (formerly Twitter). It was mentioned that the Snapdragon 8 Gen 4 processor would adopt TSMC’s 3nm (N3E) process, while Samsung’s 3GAP process would be used for the Snapdragon 8 Gen 4 supplying Samsung’s Galaxy series smartphones. Other sources suggested that due to limited capacity at TSMC’s 3nm production, Qualcomm had to seek Samsung as an alternative chip foundry.

As a result, Qualcomm originally anticipated dual-foundry production with both TSMC and Samsung in 2024, with hopes of being the first customer for the 3GAP process. However, considering Samsung’s conservative 3nm production capacity plan for next year and the instability in yields, Qualcomm decided to scrap the plan and exclusively rely on TSMC, pushing the dual-foundry strategy to 2025.

Currently, TSMC’s 3nm process technology capacity is on the rise, with expectations that by the end of 2024, monthly production capacity will reach 100,000 wafers, and the revenue contribution will increase from the current 5% to 10%.

(Photo credit: Qualcomm)

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Equipment is playing an indispensable role during the wafer manufacturing process. In response to market needs, the global EUV lithography supplier, ASML, has recently taken significant steps.

ASML’s Bold Move: Annual Investment of EUR 100 Million in Berlin Plant

As reported by the German media “Handelsblatt,” the Netherlands-based company ASML plans to invest EUR 100 million (USD 109 million) in 2023, with a similar annual investment in the subsequent years. This investment aims to enhance the production and development capabilities of ASML’s manufacturing plant located in Berlin, Germany.

Reports indicate that ASML’s Berlin plant primarily produced core components of EUV equipment, including wafer clamps, wafer tables, reticle chucks and mirror blocks. ASML acquired this facility, known as “Berliner Glas,” in 2020.

Foundries Actively Pursue EUV equipment

The EUV equipment plays a crucial role in manufacturing, utilizing specific wavelength light for radiation to precisely imprint images on wafers. Currently, the EUV equipment market is highly concentrated, with only a few global companies mastering this technology. Among them, Dutch company ASML stands out as the world’s largest and most advanced EUV company. Additionally, companies like Nikon, Canon, and Shanghai Micro Electronics Equipment (SMEE) are strategically positioning themselves in the EUV sector.

EUV technology, used for exposing semiconductor process, is indispensable due to its high cost, complex processes, and limited supply. ASML is the sole global supplier of EUV. For advanced processes below 7nm, EUV serves as an essential device. Developed over more than 20 years, EUV technology has become the cornerstone of advanced processes, enabling the continuation of Moore’s Law for at least another decade.

As a crucial EUV equipment supplier, ASML is working on a new generation of NA-EUV equipment, where “NA” represents numerical aperture. A higher NA value means a higher achievable resolution, allowing for more transistors on the chip. It is expected that by the year-end, ASML will unveil the world’s first high-NA EUV and deliver it to Intel.

Currently, both TSMC and Samsung utilize EUV equipment for manufacturing, covering TSMC’s 7nm, 5nm, and 3nm processes and Samsung’s EUV Line (7nm, 5nm, and 4nm) located in Hwaseong, Korea, along with the 3nm GAA process.

TSMC’s 2nm process will continue to leverage EUV technology. In a previous announcement in September, TSMC disclosed the acquisition of Intel’s subsidiary IMS for up to US 432.8 million, focusing on the research and production of electron beam lithography machines. Industry experts believe that TSMC’s move ensures the technical development of critical equipment and meets the supply demand for the commercialization of 2nm.

Following 2nm chips. Samsung plans to achieve mass production of 2nm processes in the mobile field by 2025, expanding to HPC and automotive electronics in 2026 and 2027, respectively. According to the report in September, Samsung is gearing up to secure the yield of the next-generation EUV equipment, High-NA, with the prototype expected to launch later this year and official supply next year.

After announcing its return to the foundry business, Intel revealed in October that it has commenced mass production of Intel 4 process nodes using EUV technology. Currently, both Intel 7 and Intel 4 have achieved mass production, and Intel 3 is progressing according to plan, with the goal of completion by the end of 2023.

(Image: ASML)