As the U.S. Department of Commerce finalizes subsidies for Intel and TSMC, the two major semiconductor manufacturers will enter a new competitive landscape in the United States.

In preparation for these new challenges and with the first fab trial production imminent, sources cited by a report from Liberty Times has revealed that TSMC will dispatch Vice President of Manufacturing Operations, Arthur Chuang, to oversee the Arizona site in May. He will collaborate with TSMC’s vice president of fab operations Dr. Y.L. Wang, signaling TSMC’s accelerated efforts to establish and produce at U.S. fabs concurrently, aiming to achieve a competitive advantage in advanced manufacturing processes in the United States.

Arizona Fab to Begin Trial Production of 4,000 Wafers by Month’s End

Following the confirmation of subsidies for Intel and TSMC by the U.S. Department of Commerce, subsidies for Samsung are also rumored to be announced soon. Industry sources cited in the report from Liberty Times believe that the United States, through these subsidies promoting domestic chip manufacturing and with major clients gathering, will become the primary battlefield for investment in advanced manufacturing processes.

However, with high production costs and the need to rebuild supply chains, TSMC has adjusted its strategy following a series of setbacks at its first fab. After more than a year of installation work, the fab is nearing completion and preparing to embark on a new phase with trial production of approximately 4,000 wafers using 4-nanometer processes by the end of this month. The target is to ramp up production by the first half of 2025, making this facility the most advanced semiconductor fab in the United States.

TSMC’s U.S. fab is facing new challenges as it continues to build and produce concurrently. According to the same report citing industry sources, unlike the previous director-level executive overseeing operations at the U.S. fab, TSMC will be assigning a vice president-level executive to lead the site, with experienced fab construction veteran Arthur Chuang slated for a long-term assignment in the United States starting in May.

Arthur Chuang holds a Ph.D. in Civil Engineering from National Taiwan University and joined TSMC 35 years ago as an equipment engineer. He transitioned to fab operations over 25 years ago and has overseen the construction of nearly 20 fabs, including Fab 15 in Tainan, Fab 18 in Southern Taiwan, and the advanced 2-nanometer fab sites in Hsinchu and Kaohsiung.

TSMC’s second semiconductor fab in the United States is currently under construction, with plans announced on April 8th to commence production of next-generation 2-nanometer process technology in 2028. Additionally, a third fab is scheduled to begin mass production of 2-nanometer or more advanced process technologies by the end of 2030.

The total area of TSMC’s U.S. fab is 1,100 acres, which is more than half of its area in the Hsinchu Science Park. Estimates from the supply chain suggest that this site could accommodate up to six fabs, indicating that TSMC’s expansion plans may go beyond just building a third fab. If collaboration with U.S. partners proceeds smoothly, further expansion is also possible in the future.

TSMC’s Kumamoto Fab Phase 2 to Commence Construction by Year-End, Production Set for 2027

Additionally, TSMC’s Japan Kumamoto Fab (JASM) announced yesterday that its Phase 2 facility will be located adjacent to Phase 1 on the east side, covering an area of approximately 320,000 square meters, which is about 1.5 times the size of Phase 1. Construction is scheduled to commence by the end of this year, with production expected to start by the end of 2027.

TSMC is scheduled to hold an earnings call on April 18th, and ahead of the conference, positive news has emerged regarding the new US fab. It is anticipated that the related topics will also be the focus of attention on the day of the conference.

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• [News] TSMC Receives USD 6.6 Billion for Chipmaking from the US Government, Commits to Constructing Third Fab
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(Photo credit: TSMC)

Japan and the EU are reportedly set to launch formal cooperation in the research and development of advanced materials, such as chips and electric vehicle batteries. According to a report from NIKKEI, this initiative aims to decrease their high reliance on suppliers from China. Iliana Ivanova, Commissioner for Innovation and Research at the EU, revealed that the two parties will establish a collaborative framework in April.

As per the same report, Commissioner Ivanova stated during an interview that both Japan and the EU remain globally leading in advanced materials innovation. In 2020, the EU’s investment in this industry totaled EUR 19.8 billion, while Japan’s amounted to EUR 14 billion.

Under the framework tentatively named “Dialogue on Advanced Materials,” Japan and the EU plan to hold regular meetings to discuss collaboration proposals. Institutions engaged in advanced materials research from both sides will also participate. Commissioner Ivanova highlighted that the areas of cooperation include renewable energy, transportation, construction, and electronic materials. She also expressed hope for Japan and the EU to jointly develop international standards for advanced materials.

The report highlights a specific area of focus: the development of sodium-ion batteries, which are seen as the most promising next-generation power source for electric vehicles.

In recent years, the rapid growth of the global electric vehicle and energy storage markets has driven robust demand for lithium-ion batteries. As per TrendForce’s data, with further expansion expected in these sectors, the demand for lithium batteries is projected to continue growing, surpassing 3200GWh in global shipments by 2027.

Currently, China dominates the global lithium battery supply chain system, including battery metal refining, battery material processing, and battery manufacturing. Per TrendForce, more than 75% of lithium batteries worldwide are currently produced in China, making it the global leader in lithium battery manufacturing capacity.

In regard to China’s competitive advantage in the LiBs field today, it’s difficult for Japanese and South Korean companies to surpass. And it’s even more challenging for the US and Europe to catch up with China, due to the weak foundation of LiB industry locally. However, the emergence of inexhaustible and inexpensive sodium batteries may have offered a solution for the world to reduce its reliance on China.

Sodium-ion batteries do not require the use of rare metals controlled by China and have lower production costs compared to traditional batteries. The EU hopes to make progress in this area to meet the increasing demand brought about by the transition to electric vehicles.

Additionally, the EU aims to leverage Japan’s leading knowledge in metal nanoparticle technology, which can enhance solar energy conversion efficiency. Nanoparticle materials can also help smartphones save energy. In the future, the EU plans to allocate significant funding to advanced materials research, fully supporting related research and large-scale production.

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• [News] Japanese Semiconductor Equipment Sales Smashed the JPY 300 Billion Threshold in February
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On March 25, the Semiconductor Equipment Association of Japan (SEAJ) disclosed its latest statistics.

The data revealed that in February 2024, the sales of Japanese semiconductor equipment (3-month moving average, including exports) reached JPY 317.418 billion, representing a growth of 7.8% compared to the same month last year. This also marked a second back-to-back month of growth, achieving the largest increase in 10 months (9.8% growth since April 2023).

Moreover, monthly sales crossed the 300 billion-yen threshold for the fourth consecutive month, hitting a new high over the 10 months (JPY 336.162 billion since April 2023).

Compared to the previous month, Japanese semiconductor equipment sales rose by 0.8%, marking the fourth consecutive month of monthly growth. In the cumulative period from January to February 2024, its sales stood at JPY 6,322.93 billion (+6.4% YoY), setting a new record high in the same period of previous years.

Semiconductor equipment manufacturers from Japan include Tokyo Electron (TEL), Advantest, Screen, Kokusai Electric, Hitachi High-Tech, Nikon, and Canon, etc.

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• [News] Subsidies to TSMC from Japan and China Increase Over Fivefold Annually
• [News] Semiconductor Equipment Sales in Japan Reach Nearly JPY 3.3 Trillion in 2023

(Photo credit: SEAJ Official Website)

According to sources cited by Reuters,  TSMC is reportedly considering plans to establish a production line for its CoWoS technology in Japan. However, TSMC has yet to make any further decisions, and they have declined to comment on the matter.

CoWoS is an advanced packaging technology that stacks chips to enhance computing power, reduce energy consumption, and save space. Currently, TSMC’s CoWoS production capacity is entirely located in Taiwan.

With the booming development of artificial intelligence, global demand for advanced semiconductor packaging has surged, prompting chip suppliers like TSMC, Samsung, and Intel to strengthen their advanced packaging capabilities.

Previously, TSMC’s CEO, C.C. Wei, stated that the company plans to double its CoWoS output by the end of 2024 and further increase it in 2025. With TSMC recently completing the first phase of construction for its Kumamoto fab in Japan and announcing plans for the second phase, which will involve collaboration with Japanese companies SONY Semiconductor Solutions and Toyota Motor Corporation, with a total investment exceeding USD 20 billion and utilizing 6/7-nanometer advanced processes.

However, Joanne Chiao, an analyst at market research firm TrendForce, suggests that if TSMC establishes advanced packaging capacity in Japan, it may face limitations in scale. It remains unclear how much demand there is in Japan for CoWoS packaging, but most of TSMC’s CoWoS customers are currently in the United States.

Additionally, sources cited by Reuters’ report indicate that TSMC’s competitor, Intel, is also considering establishing an advanced packaging research facility in Japan to deepen ties with local chip supply chain companies.

Meanwhile, Samsung, another competitor of TSMC, is setting up advanced packaging research facilities in Yokohama, Japan, with government support. Furthermore, Samsung is in discussions with Japanese and other companies regarding material procurement, preparing to launch its packaging technology similar to that used by SK Hynix.

Regarding the development of the semiconductor industry in Japan, as mentioned in a previous report from TrendForce, Japan’s resurgence in the semiconductor arena is palpable, with the Ministry of Economy, Trade, and Industry fostering multi-faceted collaborations with the private sector. With a favorable exchange rate policy aiding factory construction and investments, the future looks bright for exports.

However, the looming shortage of semiconductor talent in Japan is a concern. In response, there are generous subsidy programs for talent development. Japan is strategically positioning itself to reclaim its former glory in the world of semiconductors.

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• [News] Subsidies to TSMC from Japan and China Increase Over Fivefold Annually
• [News] High Efficiency in TSMC Kumamoto Plant Construction Sets Stage for Potential Advanced Packaging Investment in Japan

(Photo credit: TSMC)

Geopolitical factors are driving countries to actively establish semiconductor manufacturing locally and offer subsidies. According to TSMC’s annual report, subsidies received from Japan and China amounted to NTD 47.545 billion in 2023, signaling a 5.74-fold increase from the previous year, reaching a record high. In contrast, the report also suggest the subsidies from the US government have yet to materialize.

TSMC did not specify the individual amounts of subsidies from the Japanese and Chinese governments. However, estimations cited by the report suggest that the Japanese government, aiming to revitalize the semiconductor industry, subsidized TSMC’s Kumamoto plant with up to JPY 476 billion, likely serving as the primary driver behind the substantial increase in TSMC’s subsidies in 2023.

The construction of TSMC’s Kumamoto Fab began in April 2022, with full assistance from the Japanese central and local governments. Recently, the opening ceremony was held, and trial production has commenced, with mass production expected in the fourth quarter of this year.

The subsidies from the Japanese and Chinese governments to TSMC are mainly used to subsidize the costs of real estate, buildings, and equipment purchases, as well as some of the costs and expenses associated with building construction and production operations.

On the other hand, TSMC’s US fab began construction in early 2021, with a grand tool-in ceremony held in December 2022, attended by the US President. Initially planned to invest USD 12 billion, the facility aims to build a N5 process fab with a monthly capacity of 20,000 wafers. Construction was scheduled to commence in 2021, with mass production slated to begin by the end of 2024, creating approximately 1,600 job opportunities in the local area.

However, it was previously reported by the TechNews that due to the delay in the first phase’s production timeline from the end of 2024 to the first half of 2025, the production schedule for the second phase will also be postponed to start after 2027. Subsequently, the production schedule has been pushed from this year to next year.

Despite the US government’s declaration to reinvigorate manufacturing and the introduction of the “CHIPS Act,” totaling USD 52 billion in subsidies, only three US companies have been subsidized so far.

These include BAE Systems, Microchip, and the third-largest foundry, Global Foundries, with Global Foundries receiving the most substantial subsidy of USD 1.5 billion. As of now, subsidies for TSMC have yet to be finalized.

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(Photo credit: TSMC)