During the Semicon Taiwan 2024 summit event, TSMC VP of Advanced Packaging Technology, Jun He, spoke about the importance of merging AI chip memory and logic chips using 3D IC technology. He predicted that by 2030 the worldwide semiconductor industry would hit the $1 trillion milestone with HPC and AI leading 40 percent of the market share. In 2027, TSMC will introduce the 2.5D CoWoS technology that includes eight A16 process chipsets and 12 HBM4. AI processors that use this technology will not only be much cheaper to produce but will also provide engineers with a greater level of convenience. Engineers will have the option to write new codes into them instead. Manufacturers are cutting the SoC and HBM architectural conversion and mass production costs down to nearly one-fourth.

Nevertheless, the increasing production capacities of 3D IC technology remain the main challenge, as the size of chips and the complexity of manufacturing are decisive factors. However, the higher the size of the chips, the more chiplets are added, and thus the performance is improved, but this now makes the process even more complicated and is associated with more risks of misalignment, breakage, and extraction failure.TSMC uses automation and standardization of tools, process control and quality instruments, and a 3DFabric manufacturing platform to tackle these challenges. 3DFabric is a unique, fully incorporated solution that guarantees stronger construction by optimizing the use of 1,500 different material types within the supply chain.

The company collaborates with up to 64 suppliers for the manufacturing of advanced packaging tools like high-resolution PnP tools and AI-driven quality control.