The growing importance of advanced processes in wafer foundries is evident, propelled by innovations like AI and high-performance computing. While 3nm chips have entered the consumer market, efforts are underway in wafer foundries to advance to 2nm chips. Recent reports suggest progress in 1nm chips, further fueling the competition among wafer foundries.

2nm Chips: Unveiling in 2025

Anticipated by 2025, the race for 2nm chips is in full swing, with major players like TSMC, Samsung, and Rapidus actively pursuing mass production. TSMC plans to implement GAAFET transistors in its 2nm process by 2025, offering a 15% speed boost and up to a 30% reduction in power consumption compared to N3E, all while increasing chip density by over 15%.

Samsung is on a similar trajectory, planning to unveil its 2nm process by the end of 2025. As report by media in October, Samsung Foundry, said on Semiconductor Expo 2023 in South Korea, has already initiated discussions with major clients, expecting decisions in upcoming future.

Rapidus aims for trial production of 2nm chips in 2025, scaling up to mass production by 2027. Reports in September indicated that ASML plans to establish a technical support hub in Hokkaido, Japan in 2024. Approximately 50 engineers will be dispatched to Rapidus’ ongoing construction site for the 2nm plant, assisting in the setup of EUV lithography equipment on the trial production line, and providing support for factory activation, maintenance, and inspections.

When will 1nm chip arrive?

Apart from 2nm, the industry’s attention turns to 1nm-level chips. According to industry plans, mass production of 1nm-level chips is expected between 2027 and 2030.

Nikkei recently reveals collaboration between Japanese chipmaker Rapidus, Tokyo University, and the French technological research organization Leti to develop foundational technology for 1nm IC design. Talent exchange and technical sharing are slated to begin in 2024, aiming to establish a supply system for indispensable 1nm chip products, crucial for enhancing auto driving and AI performance.

On the other hand, collaborations with IBM for 1nm products are also being considered. The computing performance of 1nm products, anticipated to become mainstream in the 2030s, is expected to surpass 2nm by 10-20%.

TSMC and Samsung are also eyeing 1nm chip development. TSMC’s initial plan to build a 1.4nm process wafer fab in Taiwan faced delays after abandoning the original site selection in October. Samsung aims to launch its 1.4nm process by the end of 2027, with improved performance and power consumption through an increased number of nanosheets per transistor, promising enhanced control over current flow and reduced power leakage.

(Image: TSMC)

In the previous articles (China Strives to Break Through U.S. Restrictions in Mature Processes, Aiming for Over 30% Global Share by 2027 and China’s Wafer Fabs Hits 44 with Future Expansion 32, Mainly Targeting on The Mature Process) we explored the overall layout of Chinese wafer fab and developments in 12-inch and 8-inch wafer foundries. This article shifts to navigating the challenges of preventing oversupply while strategically pushing forward in the realm of mature processes.

Due to the counterattack of international giants in mature processes leads to fierce competition for orders, the recent surge in mature processes over the past two years in fact has brought pressure to Chinese wafer fabs. From the perspective of the industry chain, it may also cause industry overcapacity.

The popularity of mature processes can be traced back to its extensive application market, research and development of advanced processes approaching the limit of Moore’s Law.

No need to say it also reflects the regular operation of market dynamics. In the current economic downturn, the demand for automotive electronics and industrial control systems(ICS) is booming, with 80% of their demand falling under mature processes. As the AI trend rises, many high-end AI and computing chips in China cannot adopt advanced processes, prompting a reconsideration of design changes to use multiple mature process chips instead of a single high-end process chip. This not only ensures shipments but also indirectly increases the synchronous multiplier of mature process chips.

Can Specialty Processes Become a Blue Ocean for China?

With the emergence of new demands in downstream application scenarios, the variety of semiconductor products continues to increase. Industry insiders state that global foundries are competing to target mature process wafer foundries. In this context, Chinese wafer fabs should focus on creating differentiation.

Therefore, specialty processes are gradually gaining attention in the current development of wafer foundries. In comparison to advanced logic processes, specialty processes particularly emphasize the research, innovation, and application of new materials (SiC and GaN are currently popular), new structures, and new devices. Specialty processes highlight wafer processes with custom capabilities for special IP and diverse technological categories. This is considered an important development branch beyond Moore’s Law, which involves continually reducing the linewidth to enhance chip integration.

Specialty process product categories are extensive and can form a competitive advantage in specific areas. These mainly include embedded/independent non-volatile memory, power devices, analog and power management, sensors, and other process platforms.

Representative enterprises in China’s specialty process industry include SMIC, Huarun Microelectronics, and Huahong Group. These companies attach great importance to the development of specialty processes. To meet the differentiated demands for product functionality and performance in the market, enterprises continually research and innovate wafer manufacturing process technologies, evolving into differentiated manufacturing processes.

For example, Huahong Semiconductor’s specialty processes include power management, radio frequency, power devices, and other platforms, especially in wafer foundry for power devices; Huarun focuses on high-voltage power BCD, high-performance BCD, high-reliability BCD, high-precision analog, MEMS, and six major special power device simulation wafer foundry processes.

Major wafer foundries have always attached great importance to the development of specialty processes. TSMC’s specialty process is leading by far, while GlobalFoundries and UMC are also focusing on mature processes and specialty processes. It is not difficult to predict that there will be fewer and fewer participants chasing advanced processes in the future, and new entrants will compete for the market in specialty processes.
(Image: SMIC)

On August 7th, HuaHong Group officially went public on the Sci-Tech Innovation Board Market, Shanghai Stock Exchange (STAR Market, SSE). Combined with the return of SMIC to A-shares (China’s domestic shares) in the past two years and Nexchip’s listing in May, it brings together the three major players in China’s foundry sector on the STAR Market. Additionally, SMEC, closely linked to SMIC, also went public on the STAR Market without turning a profit. Overall, China’s foundry industry is steadily gaining strength.

As per TrendForce’s latest research, challenges in the economic outlook and ongoing inventory issues this year have led to a slowdown in demand. This is particularly noticeable in the automotive and industrial control, where inventory has been piling up after short-term fulfillment. Fabless and other IDM inventory digestion have faced severe restrictions. IDM foundries, launching new capacities, are consolidating outsourced orders and once again reducing orders to foundries. In 2024, given the expected unfavorable economic environment, the overall recovery of capacity utilization poses challenges.

While Chinese foundries have not been immune to these challenges, the losses have been mitigated thanks to the boost in China’s import substitution policies on semiconductors. According to TrendForce, the global ratio of mature (>28nm) to advanced (<16nm) processes is projected to hover around 7:3 from 2023 to 2027. Propelled by policies and incentives promoting local production and domestic IC development, China’s mature process capacity is anticipated to grow from 29% this year to 33% by 2027. Leading the charge are giants like SMIC, HuaHong Group, and Nexchip.

Exploring China’s Wafer Foundries Landscape

According to TrendForce, excluding 7 temporarily suspended fabs, China currently operates 44 fabs (25 fabs in 12-inch, 4 fabs in 6-inch wafers, and 15 in 8-inch fabs and production lines), additionally, 22 fabs are under construction (15 fabs in 12-inch, and 8 fabs in 8-inch). In the future, SMIC, Nexchip, CXMT, and Silan plan to construct 10 fabs (9 fabs in 12-inch, and 1 fab in 8-inch). Overall, by the end of 2024, China aims to establish 32 large fabs, and all of them are about to focus on mature processes.

Reviewing the distribution of wafer foundries across China, the Yangtze Delta region hosts nearly half of the total, with significant concentrations in provinces like Shanghai, Wuxi, Beijing, Hefei, Chengdu, and Shenzhen.

Nearly 4.14 million wafer capacity in 12-inch will be ongoing per month in China until 2026

In terms of capacity, the statistics showed that China currently operates 31 fabs in 12-inch, including those under construction with fixed capacity for 12-inch. The total monthly capacity is approximately 1.189 million wafer capacity. Compared to the planned monthly capacity of 2.17 million wafer capacity, the capacity utilization of these fabs is close to 54.48%, still a significant room for expansion.

Considering construction and future planning, it is anticipated that China will add 24 fabs in 12-inch in the next five years, with a planned monthly capacity of 2.223 million wafer capacity. Assuming all planned 12-inch wafer foundries achieve full production, by the end of 2026, the total monthly capacity of 12-inch in China will exceed 4.14 million wafer capacity, marking a 248.19% increase compared to the current capacity utilization rate.

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• TrendForce Foresees China’s Mature Wafer Processes to Expand to 33% by 2027, Japan Secures Advanced Processes

The demand for TSMC’s CoWoS advanced packaging is skyrocketing. Following NVIDIA’s expansion confirmation in October, there are reports in the industry that major clients like Apple, AMD, Broadcom, Marvell, and others are also placing additional orders with TSMC.

To meet the demands of these five major clients, TSMC is fast-tracking the expansion of CoWoS advanced packaging capacity. Next year, the monthly capacity will increase by about 20% more than the original doubling target, reaching 35,000 wafers, reported by UDN News.

TSMC has not commented on the capacity deployment for CoWoS advanced packaging. Industry sources believe that the substantial orders from TSMC’s major clients indicate a widespread growth in AI applications, driving the demand for chips such as GPU and AI accelerators.

In response to the continuous increase in AI demand, TSMC had previously announced the doubling of CoWoS advanced packaging capacity expansion for next year but did not disclose the monthly production capacity. Industry reports suggest that TSMC’s CoWoS advanced packaging capacity next year will not only double but will also increase by an additional 20% from the original target, resulting in a total monthly capacity of 35,000 wafers.

NVIDIA currently stands as the main large customer for TSMC’s CoWoS advanced packaging, securing almost 60% of TSMC’s related capacity, which is used in its AI chips such as H100 and A100. Additionally, AMD’s latest AI chip products are in the mass production stage, and the upcoming MI300 chip, expected to launch next year, will adopt both SoIC and CoWoS advanced packaging.

At the same time, Xilinx, a subsidiary of AMD, has been a significant customer for TSMC’s CoWoS advanced packaging. With the continuous growth in AI demand, not only Xilinx but also Broadcom has started increasing orders for TSMC’s CoWoS advanced packaging capacity.

(Image: TSMC)

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• [News] TSMC Deploys Manpower to Support Longtan and Tainan Facilities Amid CoWoS and 3nm Demand
• Exploring the Significance of 3D-SOC and 3D-IC in Cutting-Edge 3D Advanced Packaging

In TrendForce’s latest solar energy pricing, it is revealed that upstream polysilicon and wafer transactions have reached a standstill, while downstream cell and module prices continue to decline.

• Polysilicon

Polysilicon prices continue to decline throughout the week. The mainstream concluded price for mono recharge polysilicon is RMB 70/KG, while mono dense polysilicon is priced at RMB 68/KG and N-type polysilicon is currently priced at RMB 75/KG.

In terms of trading, this week has shown a slight improvement compared to the stagnation of the previous week. Some small orders have been placed, but the majority of companies are still in the negotiation process. Additionally, there are ongoing discussions about transaction prices for polysilicon and crystal pulling.

Examining the price trends, there’s a notable divergence between leading manufacturers and second-tier manufacturers, with the current prices approaching the cost threshold for the latter and older capacity.

When we analyze the supply and demand dynamics, it becomes evident that as polysilicon prices continue to decline, downstream manufacturers are considering production cuts, and new production capacity might face the challenge of running at a loss right after starting operations.

Moreover, considering the projected oversupply in the future and the potential for prices to hit rock bottom, some manufacturers have realized that the profits from new production capacity may differ significantly from their expectations, prompting them to adjust their production schedules.

However, in the short term, polysilicon output is showing a month-on-month growth trend this quarter. As downstream demand decreases, polysilicon prices will likely continue to face pressure. Overall, this week has seen a decline in quoted polysilicon prices, and the price gap between N-type and P-type polysilicon continues to narrow.

• Wafer

The prices of wafer have still reduced throughout the week. The mainstream concluded price for M10 wafer is RMB 2.30/Pc, while G12 wafer is priced at RMB 3.30/Pc. The current cell prices are causing significant losses in the cell business, leading to a substantial reduction in activation rates.

The overall market turnover is currently sluggish. Additionally, the quoted prices only reflect the trend of declining wafer prices and may not accurately represent the actual transaction prices for spot goods.

On the supply side, wafer prices have continued to decline over the past two weeks. If the prices of different types of wafers keep dropping, manufacturers may find themselves in a situation where their costs exceed their selling prices.

Consequently, wafer production schedules have seen a significant reduction, forcing some second and third-tier manufacturers to maintain OEM business for meager profits. The current wafer inventory level has decreased to 1.9-2.1 billion pieces, and there are indications that prices are reaching a bottom in the market.

On the demand side, downstream cell manufacturers are gradually reducing their production schedules, and inventory issues have not been effectively resolved. As a result, cell manufacturers are becoming more cautious when it comes to purchasing wafers. This week, wafer prices have continued to decline, but the rate of decline will narrow with cost support.

However, considering the price pressure imposed by downstream consumers, their high inventory levels, and other factors, wafer prices have yet to stabilize and are likely to continue falling in the future.

• Cell

Cell prices have still declined this week. The mainstream concluded price for M10 cell is RMB 0.48/W, while G12 cell is priced at RMB 0.52/W. The price of M10 mono TOPCon cell is RMB 0.49/W.

On the supply side, current cell inventory has remained high for more than seven days. Consequently, facing pressure from both the elevated inventory levels and downstream module manufacturers, cell prices have experienced a decline.

The current price of M10 P-type cells stands at 0.48 yuan per watt, which is approaching the production cost of leading integrated manufacturers. The reduction in cell production is the current scenario.

However, the shipment pressures haven’t been alleviated, and the price gap between N-type and P-type cells has narrowed, putting both types at risk of operating at a loss due to costs exceeding their prices. On the demand side, the domestic peak season for centralized cell procurement has concluded, and there has been no significant uptick in demand in overseas markets or the distributed PV sector.

As a result, the demand for cells has weakened. With module prices also under pressure, module manufacturers are inclined to push down cell prices. Although there has been some improvement in the rate of decline for cells this week, the accumulation of cell inventory, falling upstream material prices, and sluggish downstream demand continue to exert constant pressure on cell prices.

• Module

Module prices have gone down slightly throughout the week. The mainstream concluded price for 182mm facial mono PERC module is RMB 1.08/W, 210mm facial mono PERC module is priced at RMB 1.11/W, 182mm bifacial glass PERC module at RMB 1.09/W, and 210mm bifacial glass PERC module at RMB 1.12/W.

On the supply side, module prices are persistently decreasing and have come close to the cost price of integrated manufacturers. Specialized module manufacturers, in response to module prices falling below their cost, have had to reduce their production rates to avoid losses. This is evident from the reduced demand for various auxiliary materials associated with module production.

On the demand side, the primary driver of demand continues to be large domestic projects, whereas overseas demand has not shown any significant increase. The overseas market is still working through its high inventory. In domestic bidding projects, there’s a noticeable shift toward an increased proportion of N-type modules, indicating a faster transition in demand toward N-type technologies.

In the third round of centralized procurement for PV modules by Huadian Group, the quoted price stands at 0.9933 yuan per watt. In the same month, the bidding price for modules in the centralized procurement tender by CHN Energy is 0.945 yuan per watt, marking a record low within a single month.

This price trend underscores the inevitable intense competition within the module sector, as excess production capacity is evident throughout the entire industry chain. This week, module prices have continued their descent. In summary, it’s probable that module prices will remain volatile in the future, especially considering that bidding prices for modules are swiftly approaching the 1 yuan mark.

Read more

• PV Industry Supply Chain Price Update