A semiconductor factory, also known as a semiconductor fabrication facility or “fab,” is a high-tech manufacturing facility that produces integrated circuits, microprocessors, and other electronic components.
Here are the basic steps involved in how a semiconductor factory works:
Wafer fabrication: The first step in semiconductor manufacturing is wafer fabrication. This involves creating a wafer of pure silicon that will serve as the substrate for the integrated circuits. The wafer is typically created using a process called Czochralski crystal growth, which involves melting a small amount of silicon and slowly pulling a single crystal out of the molten material.
Photolithography: Once the wafer is created, it is coated with a layer of photosensitive material called photoresist. A mask is then used to selectively expose certain areas of the photoresist. The exposed areas become either more or less soluble, depending on the type of photoresist used.
Etching: After the photoresist is exposed, the wafer is treated with a chemical solution that selectively etches away the exposed areas of the wafer, leaving behind a patterned layer of material. This process is repeated multiple times to create the different layers that make up the semiconductor chip.
Deposition: Once the layers are etched, they are coated with a layer of metal or insulating material, which is deposited using techniques such as chemical vapor deposition or physical vapor deposition.
Metallization: Finally, the chip is metallized, which involves depositing a layer of metal on top of the wafer to create the interconnects that connect the different components of the chip together.
Testing and packaging: Once the chip is fabricated, it undergoes a series of tests to ensure that it is functioning correctly. The chip is then cut into individual dies, which are packaged in a protective material and shipped to customers.
A semiconductor factory is a highly automated and controlled environment that requires specialized equipment and facilities. The entire process is carefully monitored to ensure high yields and consistent quality. The process can take several weeks to several months, depending on the complexity of the chip design and the number of layers involved.