As the demands for AI and HPC processors keep their momentum, driving the usage of advanced packaging technologies, TSMC revealed plans to further expand its chip-on-wafer-on-substrate (CoWoS) capacity at a compound annual rate (CAGR) of over 60% until at least 2026, according to a report by AnandTech.

According to its latest roadmap revealed at the company’s European Technology Symposium earlier, TSMC would now be able to more than quadruple its CoWoS capacity from 2023 levels by the end of 2026, the report indicated.

Last year, the foundry leader announced plans to more than double its CoWoS capacity by the end of 2024, but now it needs to be more ambitious, not only to meet existing demand but also address the future market.

TSMC is also preparing additional versions of CoWoS (specifically CoWoS-L) to support building system-in-packages (SiPs) with up to eight reticle sizes, just in case that increasing CoWoS capacity four-fold over three years may still be insufficient, the report said.

In addition to CoWoS, TSMC also plans to expand its system-on-integrated chips (SoIC) capacity at a CAGR of 100% through 2026, indicating that its SoIC capacity will increase eight-fold from 2023 levels by the end of 2026, according to AnandTech.

When it comes to the latest overseas expansion plans regarding major Taiwanese foundries, TSMC’s Kumamoto Fab 1, a joint investment between TSMC, Sony Semiconductor Solutions Corporation, and Denso Corporation, was inaugurated in February. Construction of the second Kumamoto fab is slated to begin by the end of 2024, with operations starting by the end of 2027.

UMC, Taiwan’s second-largest wafer foundry, announced on May 21st the arrival of the first equipment tools for phase 3 expansion at its Fab12i located in Singapore. According to a report by CNA, UMC anticipates the construction of the facility will be completed by mid-year. However, due to adjustments in customer orders, mass production has been delayed by six months to early 2026.

In October, 2023, Powerchip Semiconductor Manufacturing Corporation (PSMC), in collaboration with SBI Holdings, Inc., announced plans regarding its first semiconductor wafer plant in Japan, which is expected to be located in the Second Northern Sendai Central Industrial Park in Ohira Village, Kurokawa District, Miyagi Prefecture (Second Northern Sendai Central Industrial Park).

Previous reports indicated that PSMC plans to construct multiple plants, with the first phase potentially starting construction as early as 2024, involving an investment of around JPY 400 billion (USD 2.6 billion).

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(Photo credit: TSMC)

Wafer foundries’ mature process continues to suffer from oversupply, facing further price reduction pressure. According to a report from Economic Daily News, industry sources from IC design companies revealed that in this quarter, prices for certain mature processes have dropped by single-digit percentages (1% to 3%). Given the current situation, prices in the third quarter may drop by another 1% to 3%, leading to a continuous correction in overall price trends starting from the third quarter of 2022, marking the ninth consecutive quarterly decline.

Industry sources cited by the same report pointed out that this wave of price reductions in mature process was triggered by Chinese foundries two to three years ago, with Taiwanese manufacturers subsequently following suit. Major Taiwanese foundries involved in mature processes, include UMC, Vanguard International Semiconductor (VIS), and PSMC, have all been closely monitoring the latest market changes.

Regarding rumors of further price cuts in the market, UMC stated that the company would not make further comments. VIS, on the other hand, mentioned during a recent earnings call that the price pressure from Chinese foundries has affected its operations, but the company will not engage in these price-cutting competitions. It is expected that as market inventory adjustments approach completion, prices should gradually stabilize without significant fluctuations. PSMC indicated that they have not particularly felt any price pressure.

Local foundries stated that even though customers from specific applications, including driver ICs and other IC design houses, turn to Chinese foundries in order to enjoy cheaper manufacturing prices, they will not engage in price-cutting. After all, price wars may never see an end. Instead, Taiwanese foundries will continue to increase orders from other applications to gradually boost capacity utilization rates.

In the third quarter of 2022, as market conditions reversed, Chinese foundries initiated price cuts, prompting some Taiwanese manufacturers to make slight concessions in pricing. The pricing gap between Chinese and Taiwanese foundries generally remained at double-digit percentages.

To cope with a period of market inventory adjustment, some foundries are more flexible in negotiations, while others hope for customers to “exchange volume for price.”

Overall, foundry pricing has experienced eight consecutive declines up to this quarter. However, with no significant recovery in most end-demand sectors, IC design companies assess that foundry pricing in the third quarter may continue to trend downward.

Industry sources cited by the report believe that Chinese foundries receive official subsidies, allowing them to disregard profit considerations. Previously, IC design houses’ price negotiations with Chinese foundries were mostly successful, which results in single-digit percentage price reductions recently. However, after the third quarter, the room for further price reductions may diminish, indicating that the price seems to be soon hit the bottom.

However, fin order to cope with the current macroeconomic fluctuations, some IC design companies mentioned that after suffering from being “burned” by high inventory in the past, they now tend to wait for clear demand from customers before starting production. In recent years, the proportion of production sent to Chinese foundries has been increasing due to cost considerations. With the continuous expansion of mature process capacity in Chinese foundries, the pressure of oversupply may persist for a while longer.

According to TrendForce’s previous report on the fourth quarter of 2023, global semiconductor foundry revenue rankings showed that the top three semiconductor foundries globally were TSMC, Samsung, and GlobalFoundries, which are all less exposed to mature nodes.

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(Photo credit: TSMC)

Powerchip Semiconductor Manufacturing Corporation (PSMC) held the inauguration ceremony for its new Tongluo plant on May 2nd. This investment project, totaling over NTD 300 billion  for a 12-inch fab, has completed the installation of its initial equipment and commenced trial production. According to a report from Commercial Times, it will serve as PSMC’s primary platform for advancing process technology and pursuing orders from large international clients.

Additionally, PSMC has ventured into advanced CoWoS packaging, primarily producing Silicon Interposers, with mass production expected in the second half of the year and a monthly capacity of several thousand units.

Frank Huang, Chairman of PSMC, stated that construction of the new Tongluo plant began in March 2021. Despite challenges posed by the pandemic, the plant was completed and commenced operations after a three-year period.

As of now, the investment in this 12-inch fab project has exceeded NTD 80 billion, underscoring the significant time, technology, and financial requirements for establishing new semiconductor production capacity. Fortunately, the company made swift decisions and took action to build the plant. Otherwise, with the recent international inflation driving up costs of various raw materials, the construction costs of this new plant would undoubtedly be even higher.

The land area of Powerchip Semiconductor Manufacturing Corporation’s Tongluo plant exceeds 110,000 square meters. The first phase of the newly completed plant comprises a cleanroom spanning 28,000 square meters. It is projected to house 12-inch wafer production lines for 55nm, 40nm, and 28nm nodes with a monthly capacity of 50,000 units. In the future, as the business grows, the company can still construct a second phase of the plant on the Tongluo site to continue advancing its 2x nanometer technology.

Frank Huang indicated that the first 12-inch fab in Taiwan was established by the Powerchip group. To date, they have built eight 12-inch fabs and plan to construct four more in the future. Some of these fabs will adopt the “Fab IP” technology licensing model. For example, the collaboration with Tata Group in India operates under this model.

According to a previous report from TechNews, Frank Huang believes that IP transfer will also become one of the important sources of revenue in the future. “Up to 7-8 countries have approached PSMC,” including Vietnam, Thailand, India, Saudi Arabia, France, Poland, Lithuania, and others, showing interest in investing in fabs, indicating optimism for PSMC’s future Fab IP operating model.

PSMC’s Fab IP strategy, according to the same report, leverages its long-term accumulated experience in plant construction and semiconductor manufacturing technology to assist other countries, extending from Japan and India to countries in the Middle East and Europe, in building semiconductor plants while earning royalties for technology transfers.

Looking ahead to the second half of the year, Frank Huang indicated that the current issue lies in the less-than-stellar performance of the economies of the United States and China. While the United States is showing relatively better performance in AI and technology, China’s performance is not as strong.

Huang believes that after the fourth quarter of this year, there is a chance for accelerated deployment of AI application products such as smartphones, PCs, and notebooks. With the explosive demand brought about by AI, 2025 is expected to be a very good year for the semiconductor industry, and PSMC has already seized the opportunity.

In addition, PSMC also mentioned that since last year, there has been a continuous tight supply of advanced CoWoS packaging. In response to the demands of global chip clients, the company has also ventured into CoWoS-related businesses, primarily providing the Silicon Interposer needed for advanced CoWoS packaging. Currently in the validation stage, mass production is expected to commence in the second half of the year, with an initial monthly capacity of several thousand units.

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(Photo credit: PSMC)

Recently, according to sources from an official platform of Shanghai Construction No.4 (Group), Huahong Group has topped out the main building of FAB9 of the Huahong Manufacturing (Wuxi) project. This is reportedly the second phase project with a total construction area of about 530,000㎡, which is projected to construct a 12-inch characteristic process production line with a monthly capacity of 83,000 wafers.

It can be seen that the 12-inch wafer field is greeted by high enthusiasm. Previously, companies such as Renesas Electronics, PSMC, TSMC, and UMC have all announced plans to build new 12-inch fabs. As for China, as per earlier industry reports, 12-inch fabs scheduled to start production in 2024 include CR Micro, ZenSemi, and CanSemi, all located in Guangdong Province.

• Investment Enthusiasm in 12-Inch Fabs Unabated

On April 11, Renesas officially restarted its previously closed factory in Kofu. It was announced in 2022 that Renesas would invest JPY 90 billion to convert the plant into a 12-inch fab in a bid to meet the increasing demand in the power semiconductor sector.

The fab has a cleanroom with an area of 18,000㎡, and it will start mass production of IGBTs, power MOSFETs, and other power devices in 2025, which is expected to double Renesas’ overall power semiconductor capacity.

On March 13, PSMC and India-based Tata Group held a groundbreaking ceremony for their joint 12-inch fab. The fab comes with a total investment of INR 910 billion (Around USD 11 billion), which is estimated to produce a monthly capacity of 50,000 wafers, covering various mature nodes such as 28nm, 40nm, 55nm, 90nm, and 110nm.

On February 24, TSMC’s Japan Kumamoto fab (JASM) was officially opened, marking TSMC’s first plant (Fab23) in Japan. TrendForce stated that the plant will possess a total capacity of up to 40~50Kwpm in the future, with the process mainly focusing on 22/28nm and a small amount of 12/16nm. This will pave the way for developing the main process of the Kumamoto Fab2 later.

Previously, TSMC had announced that in response to customer demand growth, construction of JASM’s second fab in Japan is planned to commence at the end of 2024 and start operation in late 2027. Media reports stated that TSMC would invest JPY 2 trillion in the second fab in Kumamoto, which will adopt advanced processes of 6nm and 7nm. The monthly total capacity of 12-inch wafers in JASM Kumamoto fab is expected to exceed 100,000 pieces in the future.

In January, it was reported that UMC’s new fab in Singapore is scheduled to complete construction by mid-2024 and start mass production in early 2025. UMC said that to meet the demand for capacity construction, its board of directors approved a capital budget execution proposal of USD 39.8 million. The first phase of the new fab, with a total investment of USD 5 billion, is expected to deliver a monthly capacity of 30,000 wafers, providing 22/28nm processes.

UMC has been operating the 12-inch fab in Singapore for over 20 years. In February 2022, UMC’s board of directors approved the plan to expand a new advanced fab in the Fab12i area in Singapore. At that time, UMC expected the new fab to start mass production in late 2024, but the latest news indicates that the date of mass production will be in early 2025.

• Several Guangdong-Based 12-Inch Fabs Set to Start Production in 2024

According to a local official report from Zengcheng, Guangdong, ZenSemi held a lithography machine introduction ceremony for the project of 12-inch advanced intelligent sensors and characteristic process wafers mass production lines, marking that the project has smoothly entered the debugging and production preparation phase.

It is reported that the first phase of the project covers an area of 370 acres, with a planned investment of CNY 37 billion. It is expected to start production in June 2024, with the first batch of high-yield products scheduled to be completed in late December and delivered to customers.

According to official information from CanSemi, the third phase of CanSemi’s project will establish a 12-inch integrated circuit analog characteristic process production line with a capacity of 40,000 wafers per month. Currently, the first and second phases have been put into production successively, and the company are accelerating the construction of the third phase project, striving to achieve a fixed asset investment of over CNY 4 billion in 2024 and ensure the third phase to complete construction and start production in 2024.

According to the Wechat Account “Binhai Baoan”, Huahong’ 12-inch characteristic process integrated circuit production line project is also expected to start production this year.

It is reported that the first phase of Huahong’ 12-inch power chip production line project has a total investment of CNY  22 billion, with a total construction area of 238,000㎡, and an annual production capacity of 480,000 wafers after completion. The products will mainly be used in automotive electronics, new energy, industrial control, consumer electronics, and other fields.

As per stats from Wechat Account “Global Semiconductor Observation”, there are currently 31 operating 12-inch fabs in China (Inclusive of under-construction 12-inch fixed-capacity fabs), with a total monthly capacity of approximately 1.189 million wafers.

Compared with the planned monthly capacity of 2.17 million wafers, the capacity utilization rate of these fabs is close to 54.48%, indicating significant expansion potential. Considering construction and future planning, it is estimated that China will add 24 new 12-inch fabs in the next five years, with a planned monthly capacity of 2.223 million wafers.

Assuming all planned 12-inch foundries achieve full production, the total monthly capacity of 12-inch wafers in China will exceed 4.14 million wafers in late 2026, representing a 248.19% increase in capacity utilization compared to the present.

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(Photo credit: TSMC)

The Taiwanese semiconductor foundry Powerchip Semiconductor Manufacturing Corporation (PSMC) has held its earnings call and released its Q1 financial report. According to a report from Liberty Times Net citing information, with increasing capacity utilization, idle capacity costs decreased, boosting gross margin to 15.4%, up 12.3 percentage points from the previous year’s Q4. The net loss narrowed to NTD 439 million after tax, translating to a loss of NTD 0.11 per share.

Looking ahead to a potential turnaround this year, PSMC’s General Manager, Brian Shieh, highlighted that while large-size panel driver ICs are performing relatively well, Chinese foundries are exerting significant pricing pressure on mature processes, impacting average selling prices unfavorably. This remains a key variable affecting profitability.

In response to inflation-driven equipment cost adjustments and market demands, PSMC is revising its product portfolio. They also announced an increased capital expenditure of NTD 32 billion for 2024, which represents a 30% increase from the previously disclosed amount of NTD 24 billion. Powerchip’s Tainan fab has initiated trial production, with future investments focusing on power management IC, memory, and copper processes in the interposer.

Brian Shieh mentioned that PSMC’s capacity utilization rate was around 65% in the fourth quarter of last year. In the first quarter of this year, the utilization rate for logic products improved slightly, while memory product utilization reached 95% to 98%.

He expects memory product utilization to remain at first-quarter levels in the second quarter, with logic product utilization around 65% to 70%. Overall gross margin is anticipated to remain stable or improve compared to the first quarter.

According to TrendForce’s previous report on the fourth quarter of 2023, global semiconductor foundry revenue rankings showed that Intel Foundry Services (IFS), which ranked ninth globally in the third quarter of 2023, was pushed out of the top ten by PSMC and Nexchip due to factors such as the transition between old and new CPU generations and lackluster inventory momentum. At the same time, the top three semiconductor foundries globally were TSMC, Samsung, and GlobalFoundries.

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(Photo credit: PSMC)