How a CPU is made

DIY with Ben

4 Feb 201310:16

Summary

TLDRThis video script takes viewers on a journey through the intricate world of semiconductor manufacturing. It showcases the creation of integrated circuits at a global foundry's chip factory, detailing the process from circuit diagram design to the final packaging of microchips. The script highlights the extreme cleanliness of the environment, which is 100,000 times cleaner than an operating theater, and the precision involved in photolithography and ion implantation. It also emphasizes the use of copper for interconnects and the monitoring of atomic structures using electron microscopes. Global foundries, with facilities in the USA and Germany, are presented as pioneers in semiconductor innovation, producing state-of-the-art multicore processors.

Takeaways

📈 The script outlines the journey of semiconductor manufacturing, highlighting the complexity and precision involved in creating integrated circuits.
🌟 Design centers worldwide collaborate to create sophisticated integrated circuits such as microprocessors, high graphic processors, and wireless communication ICs.
💠 Silicon wafers, the substrates for microchips, are made from quartz sand and are crucial for the semiconductor industry.
🔍 The manufacturing process requires an extremely clean environment, with clean rooms being over 100,000 times cleaner than an operating theater to prevent impurities.
📚 Circuit structures are transferred to silicon wafers using photolithographic techniques, akin to slide projection, with a strong emphasis on mastering light.
💧 The silicon disc is coated with a photosensitive resist, and UV light is used to transfer circuit structures onto the wafer, which is then developed to create a template.
🤖 Ion implantation is used to specify the electrical properties of the transistors, leveraging silicon's semiconductor properties to change its conductivity.
🔩 Copper is used to create the finest interconnect wires, linking billions of transistors to form integrated circuits, with a focus on cleanliness to avoid short circuits.
🏭 GlobalFoundries is recognized as the first company to adopt copper in volume production, laying a foundation for state-of-the-art multicore processors.
🔬 Electron microscopes are used to constantly monitor every step of the manufacturing process, down to the atomic structures of individual transistors.
📦 The final production step involves packaging the chips, with tins and silver pellets applied to link the chip to the frame, and the use of the flip chip method for bonding.

Q & A

What is the initial step in the creation of integrated circuits?
-The initial step is the creation of circuit diagrams at design centers around the globe, where experts collaborate to design sophisticated integrated circuits like microprocessors, high graphic processors, and wireless communications ICs.
What are the substrates for microchips made from?
-The substrates for microchips are made from quartz sand and are called silicon wafers.
How is a silicon wafer produced?
-A silicon wafer is produced by drawing a huge monocrystal from purified silicon melt, resulting in a perfect silicon lattice into which transistors will later be fitted.
Why is it crucial to maintain a clean environment during the wafer fabrication process?
-A clean environment is crucial because impurities pose a threat to the flawless silicon crystals. Wafers are fabricated in an environment that is more than 100,000 times cleaner than an operating theater, completely free of dust.
What is the purpose of the photolithographic techniques used in the semiconductor industry?
-Photolithographic techniques are used to transfer the circuit structures to the wafers, similar to slide projection. This process involves using UV light to transfer the circuit structures depicted on a mask to the wafer.
What happens during the ion implantation process in semiconductor manufacturing?
-During ion implantation, the electrical properties of the transistors are specified. Engineers use the property of silicon as a semiconductor to change its conductivity by precisely implanting dopant atoms.
How do high temperatures affect the dopant atoms during the manufacturing process?
-At high temperatures, the doping atoms become flexible and take on a fixed position in the atomic structure of the silicon.
Why is copper used in the interconnect process of semiconductor manufacturing?
-Copper is used because it dominates the next process step, linking up billions of separate transistors to form integrated circuits. It also helps to avoid short circuits and guarantees reliability.
Which company is recognized as the first to adopt copper in volume production for microchips?
-GlobalFoundries is recognized as the first company in the world to adopt copper in volume production.
How does electron microscopy play a role in the semiconductor manufacturing process?
-Electron microscopes constantly monitor every step in the manufacturing process, down to the atomic structures of each individual transistor, ensuring quality and precision.
What is the final step in microprocessor manufacturing according to the script?
-The final step in microprocessor manufacturing is the packaging of the chips, which involves applying tins of silver pellets on the wafer, cutting the chips off the wafer, and using the flip chip method to bond the chip to the frame, which is then sealed with a cover.

Outlines

00:00

🛠️ Semiconductor Manufacturing Process

This paragraph introduces the intricate process of semiconductor manufacturing, focusing on the creation of integrated circuits within a global foundry's chip factory. It starts with the design of circuit diagrams by experts worldwide, leading to the production of sophisticated integrated circuits such as microprocessors, high graphic processors, and wireless communication ICs. The manufacturing process involves the creation of silicon wafers from quartz sand, ensuring a flawless silicon lattice for fitting transistors. The paragraph highlights the importance of clean rooms, which are over 100,000 times cleaner than an operating theater, to prevent impurities from affecting the silicon crystals. The wafers undergo photolithographic techniques to transfer circuit structures, akin to slide projection, and this process relies on a solid mastery of light. The silicon disc is coated with a photosensitive resist, and UV light is used to transfer the circuit structures onto the wafer, followed by a development process to etch away the unprotected parts, creating billions of small transistors on each wafer.

05:00

🔬 Advanced Transistor Manufacturing and Packaging

The second paragraph delves into the detailed steps of transistor manufacturing, emphasizing the use of silicon's semiconductor properties. Engineers exploit silicon's ability to change its conductivity through the precise implantation of dopant atoms. These atoms are injected into the silicon structures and, at high temperatures, take on fixed positions in the atomic structure. The paragraph mentions the necessity of a large, clean room environment for monitoring complex processes within automated production lines. It then describes the process of linking billions of separate transistors using the finest interconnect wires made of copper, preceded by a crucial cleaning step to avoid short circuits. The paragraph also touches on GlobalFoundries' pioneering use of copper in volume production, which laid the foundation for state-of-the-art multicore processors. The manufacturing process is constantly monitored using electron microscopes to ensure the quality down to the atomic level. Finally, the paragraph outlines the last steps of microprocessor manufacturing, which include packaging the chips with silver pellets and using the flip chip method to bond the chip to the frame, sealing it with a cover.

Mindmap

Keywords

💡Semiconductor

A semiconductor is a material that has electrical conductivity between that of a conductor and an insulator. It is the foundation of modern electronics, including integrated circuits and microprocessors. In the video's context, semiconductors are the core material used to create chips, with silicon being the most common semiconductor material due to its ability to control the flow of electrical current.

💡Integrated Circuits (ICs)

Integrated circuits are miniature electronic circuits etched on a semiconductor material, usually silicon. They are the building blocks of modern electronics, combining multiple electronic components into a single chip. The video discusses the design and manufacturing process of these sophisticated ICs, such as microprocessors, high graphic processors, and wireless communication ICs.

💡Silicon Wafers

Silicon wafers are thin slices of semiconductor-grade silicon used as the substrate for integrated circuits. They are crucial in the manufacturing process of microchips. The script mentions that these wafers are made from quartz sand and are the base upon which transistors and other circuit components are fabricated.

💡Clean Room

A clean room is a controlled environment designed to minimize contaminants, such as dust, which could affect the quality and performance of sensitive equipment or processes. In the context of the video, clean rooms are used for fabricating silicon wafers in an environment that is significantly cleaner than an operating theater, ensuring the flawless creation of silicon crystals.

💡Photolithography

Photolithography is a process used in the manufacturing of integrated circuits where circuit structures are transferred to a silicon wafer using light-sensitive materials. It is akin to slide projection, as mentioned in the script, where UV light transfers the circuit patterns onto the wafer. This technique is essential for creating the detailed structures of billions of small current switches on each wafer.

💡Ion Implantation

Ion implantation is a process used to alter the electrical properties of semiconductor materials by adding impurity atoms into the silicon lattice. The script describes how dopant atoms are injected into the silicon structures, which then take on a fixed position in the atomic structure at high temperatures, specifying the electrical properties of the transistors.

💡Dopant Atoms

Dopant atoms are impurities intentionally added to semiconductors to modify their electrical properties. Silicon, being a semiconductor, can have its conductivity changed by the precise placement of these dopant atoms. The video explains how this property is utilized in the ion implantation process to create the necessary electrical characteristics for the transistors.

💡Interconnects

Interconnects are the conductive pathways that link the various components within an integrated circuit. The script describes the use of copper for creating the finest interconnect wires, which are essential for connecting billions of separate transistors to form integrated circuits.

💡GlobalFoundries

GlobalFoundries is a semiconductor foundry company that produces chips for a wide range of industries. The video highlights GlobalFoundries as the first company to adopt copper in volume production for interconnects, which was a significant innovation in the manufacture of state-of-the-art multicore processors.

💡Electron Microscopes

Electron microscopes are high-resolution imaging tools that use a beam of electrons to create an image of a sample. In the video, these microscopes are mentioned as being used to constantly monitor every step in the manufacturing process, down to the atomic structures of each individual transistor, ensuring quality and precision in chip production.

💡Packaging

Packaging in the context of microprocessor manufacturing refers to the final step where the chips are prepared for use. The script describes the application of silver pellets on the wafer and the use of the flip chip method to bond the chip to the frame, which is then sealed with a cover. This step is crucial for protecting the chip and facilitating its integration into electronic devices.

Highlights

The journey begins with the design of sophisticated integrated circuits like microprocessors, high graphic processors, and wireless communication ICs at global design centers.

Microchips are manufactured from silicon wafers, which are made from quartz sand and are created through a process involving a huge monocrystal drawn from a purified silicon melt.

To protect the flawless silicon crystals, extensive precautions are taken in dust-free clean rooms, which are over 100,000 times cleaner than an operating theater.

The photolithographic process transfers circuit structures to the silicon wafers, akin to slide projection, requiring a solid mastery of light.

Silicon's semiconductor properties allow its conductivity to be modified through the precise implantation of dopant atoms.

The complexity of manufacturing tiny transistors necessitates a clean room as large as two soccer pitches and constant monitoring by engineers.

Copper is used to create the finest interconnect wires that link billions of separate transistors to form integrated circuits.

GlobalFoundries was the first company to adopt copper in volume production, laying a foundation for state-of-the-art multicore processors.

Electron microscopes are used to constantly monitor every step in the manufacturing process down to the atomic structures of each individual transistor.

The wafer is ready in two months, with huge integrated circuits consisting of conductors with a length of multiple kilometers and 100 billion transistors on numerous levels.

GlobalFoundries, located in the USA and Germany, is the first truly global semiconductor foundry with Fab 1 in Dresden and the future Fab 2 in Malta, New York.

The company serves as a testing ground for the latest microelectronic innovations from around the globe.

The final production step involves the packaging of the chips, where tins of silver pellets are applied on the wafer to link the chip to the frame.

The flip chip method is used to bond the chip to the frame, which is then sealed with a cover.

The manufacturing process is highly automated and takes place within hermetically sealed production lines.

A barrier layer is applied before copper is poured into the trenches for interconnects to avoid short circuits and ensure reliability.

The excess copper is ground down to the edges of the trenches to insulate each interconnect from the others.

The silicon discs are packed into hermetically sealed containers for a journey through hundreds of manufacturing steps.

The process involves etching away the unprotected parts of the water surface to generate structures of billions of small current switches on each wafer.