How Disruptive will Chiplets be for Intel and TSMC?

By Daniel Nenni

January 15, 2024

Chiplets (die stacking) is not new. The origins are deeply rooted in the semiconductor industry and represent a modular approach to designing and manufacturing integrated circuits. The concept of chiplets has been energized as a response to the recent challenges posed by the increasing complexity of semiconductor design. Here are some well documented points about the demand for chiplets:

Complexity of Integrated Circuits (ICs): As semiconductor technology advanced, the complexity of designing and manufacturing large monolithic ICs increased. This led to challenges in terms of yield, cost, skilled resources, and time-to-market.

Moore’s Law: The semiconductor industry has been following Moore’s Law, which suggests that the number of transistors on a microchip doubles approximately every two years. This relentless scaling of transistor density poses challenges for traditional monolithic designs.

Diverse Applications: Different applications require specialized components and features. Instead of creating a monolithic chip that tries to cater to all needs, chiplets allow for the creation of specialized components that can be combined in a mix-and-match fashion.

Cost and Time-to-Market Considerations: Developing a new semiconductor process technology is an expensive and time-consuming endeavor. Chiplets provide a way to leverage existing mature processes for certain components while focusing on innovation for specific functionalities. Chiplets also aid in the ramping of new process technologies since the die sizes and complexity are a fraction of a monolithic chip thus easing manufacturing and yield.

Interconnect Challenges: Traditional monolithic designs faced challenges in terms of interconnectivity as the distance between components increased. Chiplets allow for improved modularity and ease of interconnectivity.

Heterogeneous Integration: Chiplets enable the integration of different technologies, materials, and functionalities on a single package. This approach, known as heterogeneous integration, facilitates the combination of diverse components to achieve better overall performance.

Industry Collaboration: The development of chiplets often involves collaboration between different semiconductor companies and industry players. Standardization efforts, such as those led by organizations like the Universal Chiplet Interconnect Express Consortium (UCIe) for chiplet integration.

Bottom line: Chiplets emerged as a solution to address the challenges posed by the increasing complexity, cost, time-to-market, and staffing pressures in the semiconductor industry. The modular and flexible nature of chiplet-based designs allows for more efficient and customizable integration of chips, contributing to advancements in semiconductor technology, not to mention the ability to multi source die.

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