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Fabless manufacturing

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Outsourced fabrication of semiconductors
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Fabless manufacturing is the design and sale of hardware devices andsemiconductor chips whileoutsourcing theirfabrication (orfab) to a specialized manufacturer called asemiconductor foundry. These foundries are typically, but not exclusively, located in theUnited States, mainlandChina, andTaiwan.[1][2][3][4] Fabless companies can benefit from lower capital costs while concentrating theirresearch and development resources on the end market. Some fabless companies andpure play foundries (likeTSMC) may offerintegrated-circuit design services to third parties.

History

[edit]

Prior to the 1980s, the semiconductor industry wasvertically integrated. Semiconductor companies owned and operated their own silicon-wafer fabrication facilities and developed their own process technology for manufacturing their chips. These companies also carried out the assembly and testing of their own chips.

As with most technology-intensive industries, the silicon manufacturing process presents highbarriers to entry into the market, especially for small start-up companies. Butintegrated device manufacturers (IDMs) had excess production capacity. This presented an opportunity for smaller companies, relying on IDMs, to design but not manufacture silicon.

These conditions underlay the birth of thefablessbusiness model. Engineers at new companies began designing and selling integrated circuits (ICs) without owning a fabrication plant. Simultaneously, the foundry industry was established by Dr.Morris Chang with the founding ofTaiwan Semiconductor Manufacturing Corporation (TSMC). Foundries became the cornerstone of the fabless model, providing a non-competitive manufacturing partner for fabless companies.

The co-founders of the first fabless semiconductor company, LSI Computer Systems, Inc. (LSI/CSI) LSI/CSI, worked together at General Instrument Microelectronics (GIM) in the 1960s. In 1969 GIM was hired to develop three full custom CPU circuits forControl Data Corporation (CDC). These CPU ICs operated at 5 MHz (state of the art at the time) and were incorporated in the CDC Computer 469. The Computer 469 became a standard CDC Aerospace Computer and was used in the Spy in the Sky Satellites in addition to other classified satellite programs.

GIM was reluctant to proceed with the next phase of the program, which it deemed to be too technically challenging. The GIM engineers who had worked on the project were encouraged by CDC to form their own company to provide five new custom circuits. This resulted in the formation of LSI Computer Systems, Inc. (LSI/CSI) in 1969. The new chips were power-efficientrandom logic circuits with extremely high circuit densities. These new circuits also operated at 5 MHz. These devices were designated LSI0101, LSI0102, LSI0103, LSI0104, and LSI0105 and were manufactured in compact 40-pin metal flat packs with 0.050 inches (1.3 mm) spacing.

In creating the fabless semiconductor industry, LSI/CSI had to do the following:

  1. Select a suitable and CDC certifiable wafer fab house.
  2. Monitor the process, and inspection of all wafers per Class S requirements and visuals.
  3. Perform all In-Process inspections of the wafers.
  4. Select a highly reliable packaging house capable of meeting CDC's Class S assembly requirements.
  5. Have CDC certify and approve the assembly facility and its processes.
  6. LSI/CSI successfully performed all required environmental testing at Class S approved facilities.
  7. LSI/CSI prepared and submitted all environmental test reports.

CDC's Aerospace Computer 469 weighed one pound, consumed a total of 10 watts and ran at 5 MHz. CDC ran a parallel program, developing a chipset of eight similar parts that were to operate at 2.5 MHz with the identical environmental and Class S requirements. CDC had initial difficulties with this project, but eventually awarded another contract to LSI/CSI to manage the processing, inspection, visuals, assembly, and testing of the ICs. These parts were given the designation LSI3201, LSI3202, LSI3203, LSI3204 and LSI3205. Another successful space program completed by LSI/CSI was the upgrade to class S of a Standard Brushless DC Motor Commutator/Controller Chip, LS7262, which was implemented in satellites.

In 1994,Jodi Shelton, along with a half a dozen CEOs of fabless companies, established theFabless Semiconductor Association (FSA) to promote the fabless business-model globally. In December 2007, the FSA transitioned to the GSA, theGlobal Semiconductor Alliance.[5] The organizational transition reflected the role FSA had played as a global organization that collaborated with other organizations to co-host international events.

Industry growth and success

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The fabless manufacturing model has been further validated by the conversion of major IDMs to a completely fabless model, including (for example)Conexant Systems,Semtech, and most recently,LSI Logic. Today most major IDMs includingApple Inc.,Infineon andCypress Semiconductor have adopted the practice of outsourcing chip manufacturing as a significant manufacturing strategy.

Sales leaders

[edit]

The top 5 sales leaders for fabless companies (IC Design Houses) in2023 were:[6]

RankCompanyHeadquartersRevenue (millionUS$)
1NvidiaUnited States55,268
2QualcommUnited States30,913
3BroadcomUnited States28,445
4AMDUnited States22,680
5MediaTekTaiwan13,888

The top 5 sales leaders for fabless companies in2020 were:[7]

RankCompanyHeadquartersRevenue (millionUS$)
1IncreaseQualcommUnited States19,407
2DecreaseBroadcomUnited States17,745
3SteadyNvidiaUnited States15,412
4SteadyMediaTekTaiwan10,929
5SteadyAMDUnited States9,763

The top 5 sales leaders for fabless companies in2019 were:[8]

RankCompanyHeadquartersRevenue (millionUS$)
1BroadcomUnited States17,246
2QualcommUnited States14,518
3NvidiaUnited States10,125
4MediaTekTaiwan7,962
5AMDUnited States6,731

The top 5 sales leaders for fabless companies in2017 were:[9]

RankCompanyHeadquartersRevenue (millionUS$)
1QualcommUnited States17,078
2BroadcomUnited States16,065
3NvidiaUnited States9,228
4MediaTekTaiwan7,875
5AppleUnited States6,660

The top 5 sales leaders for fabless companies in2013 were:[10]

RankCompanyHeadquartersRevenue (millionUS$)
1QualcommUnited States17,200
2BroadcomUnited States8,200
3AMDUnited States5,300
4MediaTekTaiwan4,600
5NvidiaUnited States3,900

The top 5 sales leaders for fabless companies in2011 were:[11]

RankCompanyHeadquartersRevenue (millionUS$)
1QualcommUnited States9,910
2BroadcomUnited States7,160
3AMDUnited States6,568
4NvidiaUnited States3,939
5MarvellUnited States3,445

The top 5 sales leaders for fabless companies in2010 were:[12]

RankCompanyHeadquartersRevenue (millionUS$)
1QualcommUnited States7,098
2BroadcomUnited States6,540
3AMDUnited States6,460
4MediaTekTaiwan3,610
5MarvellUnited States3,602

The top 5 sales leaders for fabless companies in2003 were:

RankCompanyHeadquartersRevenue (millionUS$)
1QualcommUnited States2,398
2NVIDIAUnited States1,716
3BroadcomUnited States1,610
4ATI TechnologiesCanada1,401
5XilinxUnited States1,300

See also

[edit]
Look upfabless in Wiktionary, the free dictionary.

References

[edit]
  1. ^"The UK manufacturer taking on China".BBC Online. 2012-05-07. Archived fromthe original on 2014-10-03.
  2. ^Blodget, Henry (2012-01-22)."This Article Explains Why Apple Makes iPhones In China And Why The US Is Screwed".Business Insider. Archived fromthe original on 2014-06-24.
  3. ^Pinto, Jim."Global Manufacturing – The China Challenge". Archived fromthe original on 2012-01-12.
  4. ^Jain, Rounak (2012-01-22)."Why Does Apple Manufacture iPhone in Asia?".iPhoneHacks.com. Archived fromthe original on 2013-04-01.
  5. ^"About the Global Semiconductor Alliance".GSA. Archived fromthe original on 2013-02-19.
  6. ^TrendForce."Press Center - Top 10 IC Design Houses' Combined Revenue Grows 12% in 2023, NVIDIA Takes Lead for the First Time, Says TrendForce | TrendForce - Market research, price trend of DRAM, NAND Flash, LEDs, TFT-LCD and green energy, PV".TrendForce. Retrieved2025-01-20.
  7. ^"Revenue of Top 10 IC Design (Fabless) Companies for 2020 Undergoes 26.4% Increase YoY Due to High Demand for Notebooks and Networking Products, Says TrendForce". Semiconductors.TrendForce (Press release). 2021-03-25. Retrieved2021-08-29.
  8. ^Manners, David (2020-03-23)."Fabless revenues fell 4% in 2019".Electronics Weekly. Retrieved2021-01-15.
  9. ^Manners, David (2018-01-05)."Over $100bn revenues for fabless for first time".Electronics Weekly.
  10. ^Manners, David (2014-05-08)."Fastest growing fabless companies".Electronics Weekly.
  11. ^Clarke, Peter (2012-04-12)."Spreadtrum, Dialog, MegaChips shine in fabless rankings".EE Times.
  12. ^"13 Fabless IC Suppliers Forecast to Top $1.0 Billion in Sales in 2010!".ICInsights.com. 2010-12-21.
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