WEBVTT

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I've spent most of my career trying to get into a chip Fab Samsung's a hard no

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Global foundaries was open to it in person then ghosted me when I followed

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up and Intel has said no to me every

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single time I've asked except one honestly I'm pretty overwhelmed today

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because I'm going to be taking three major items off my bucket list I'm

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visiting Israel for the first time I'm going to be going deep into the heart of

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Intel state-of-the-art Fab 28 and I get

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below my tour guide today couldn't be more experienced Danny is the co-general

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manager of worldwide semiconductor manufacturing and started at Intel

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working in Fab 8 in Jerusalem back when their state-of-the-art was the Pentium 1

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microprocessor fabrication experts can safely skip ahead a couple of minutes

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but for everyone else let's run through the basics every CPU die every one of

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these starts with a sliced up silicon Ingot like the one right here these are

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astonishingly pure and are exactly 300

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mm in diameter if they went any smaller they'd increase waist around the edges I

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mean look at this obviously this is not going to be a working chip if it's cut

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off by the edge of the circle fun fact by the way the reason that they run the

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non-working Edge dieses through all of the same fabrication processes is that

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it actually improves the uniformity of the full chips next to them consistency

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is key in CPU manufacturing because even though we talk about these chips in

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terms like 14 or 10 nanometer the

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components that make up these transistors are much smaller like on the

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order of less than a nanometer and a tiny eror or contaminant in any of the

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hundreds of manufacturing steps means that that die he no work I mean it's a

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modern miracle that any of this is possible and is basically unheard of to

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get an entire 300 mm wafer through the Fab without a single defective die on it

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before it can be sold however it needs to be transformed from melted sand like

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this into the brains of your PC silicon you see is neither an insulator nor is

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it a true conductor so to create all the little transistors or switches that

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control current flow through the logic gates and other micro structures on the

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chip the wafer needs to undergo many processes implantation fires dopent ions

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into the surface of the Silicon to alter its electrical characteristics so

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depending on what kinds of ions are implanted say phosphorus or Boron you

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might be laying the groundwork for an N type or a ptype transistor this

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determines if the voltage is negative or positive to open the gate diffusion

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furnaces create new combined materials by exposing the wafer to various gases

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at up to hundreds of De C lithography is one of the easiest steps to understand

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conceptually but also one of the most important within a single processor die

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there are billions of transistors and literally kilometers of tiny wires but

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they're obviously far too small to build them and solder them together by hand so

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the wafer gets coated with a material called photo resist then exposed to UV

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light through a mask anywhere the light passes through the mask the photo resist

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will be removed allowing the exposed portions to be processed then it's quite

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literally rinse and repeat Nikon who

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does a lot more than make cameras by the way has a great diagram on their site

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demonstrating this so one such potential processing step is etching where the

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goal is to selectively remove material from the top of the wafer creating

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trenches in it these can be overfilled with copper to create interconnects then

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the excess gets removed by polishing it off using brushes and slurry in a

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process called chemical mechanical planarization there are different kinds

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of etching but we can talk about that more once we get

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inside this is it point of no return here we go there there's no card or

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anything just yeah it's very good high

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security time to learn the procedure this is great this very inclusive they

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have child-sized gloves for people like me this is crazy so these are not the

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gloves we wear in the clean room these are the gloves to put put on the stuff

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that we're going to wear in the clean room that will be contaminated that then

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we will get rid of after wow man I'm

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looking sharp now time for stage two

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basically we grab a couple of little foot cover doodads here and this room is

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pressurized and the idea is that these these aren't like filtered like the

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clean room or anything like that but by having a little bit of pressure in this

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room we keep this super stanky air from outside out so when you walk into here

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you feel this gust of air coming out and then what you're supposed to do is

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you're supposed to have dirty stuff on this side and then clean stuff on this

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side so I got to put my little booties on did I do it right help okay so

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there's more positive pressure in here blowing that way right so the idea then

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I guess is the air gets cleaner and cleaner as we go okay what do I

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do yeahp top to bottom okay why do we go

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top to bottom so that the dust won't fall off our top onto our bottom better

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that um it will suit into the bunny suits oh got it cuz that's how the

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overlap I have a feeling our audio is not going to be um our finest ever for

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this video ladies and gentlemen you'll have to bear with us cuz my microphone

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is already under three layers of fabric

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now we're out of the Gown room into the

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Fab the Fab and it's already crazy okay you see these like robots on tracks up

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here apparently these are taking the fots and I checked that is actually what

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it's called f which is 25 wafers so

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that's 25 slices of the original silicon

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Ingot that fuk we just saw that little robot on the track had hundreds of CPU

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dies in it but we don't know how many of them are good because they're actually on their way to sorting where not only

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will they determine if they work but they'll determine how well so is it a

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COR i7 or a COR I9 every guy wants to

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live it sounds like a nerdy James Bond film I love

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it oh my God this place is a lot biger

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than it initially looked how many square feet is this four football

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fields diffusion over there and deposition was over there

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right and what on the other etching and

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and planing so we're going to look at all of that but there's no particular

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order for these steps because once a fop comes in here you guys can see they're

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whipping around all over the place there are hundreds of stages each older Lake

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CPU dive might go from lithography to

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planing to deposition back and forth

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hundreds of

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times every silicon wafer comes to

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diffusion land and basically what these machines do they're more like a a

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furnace and they will take that top layer of silic on the wafer and they

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will diffuse it with some kind of other material uh I asked for some examp

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examples but other than silicon oxide they wouldn't really tell me anything

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and in fact they wouldn't even tell me what the first material layer would be

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for the spirit processors that they're making here now there you go we can

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actually see the robot ARM inside that would take the Silicon Wafers out of the

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food and position them as needed for the machine this is the loading area down

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here that we can see through the window and then up top is the actual furnace

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where it reaches hundreds of degrees and then it has uh gases in there that help

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them to achieve whatever kind of chemical changes that they're going for

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on top of the wafer one thing Intel's been very particular about is don't

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touch anything because it's more than just you know not pressing the wrong

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button but actually even just bumping these machines when you're trying to

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build something that has structures in it that are on the size order of

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nanometers that means that the building blocks of that thing are sub nanometer

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in some cases so you you actually you cannot you cannot bump one of these

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machines while it's running and in fact they only build their Fabs on

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particularly stable parts of the world where they don't have to worry about

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excess seismic activity this is cool as we were walking

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through diffusion we actually got a great opportunity to show you guys the

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multi-level structure of the Fab so what we're walking on is only one of four

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total layers above us are filters and

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the air comes from there down to here then below us is where they're going to

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have pumps uh chemistry delivery you can

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see these punch outs in the floor here you can actually see there's like a foam

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like vent of some sort going up into the machine that's next to us and then the

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air flows from top to bottom so it goes down to that layer then it goes down to

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one more layer where they have uh water utilities like electricity as well as

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exhaust so that air goes back up the side of the building and recirculates in

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total Intel expects anywhere from Z to one particle per uh what was the unit of

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volume 1 M cubed and for context an

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operating room could have tens of thousands of particles per meter cubed

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so you you could conceivably perform surgery in here assuming you were

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qualified I asked about this sign and apparently it's just to make sure that

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if people are blowing through this Corridor they don't accidentally smoke

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someone coming out of the red this is one of the most secret Areas even here

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inside the Fab which is already a secret area because it contains some of the

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most expensive materials that they need for lithography it's also some of the

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most top secret now under normal circumstances every one of these

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stations would be occupied by someone in fact the entire Factory runs on four

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shifts a day 247 364 days a year only

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shutting down for Yam kaper so I didn't

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ask because I'm afraid to know the answer but I think it's probably costing

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Intel a fair amount to have Us in here poking around while they didn't sponsor

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the video or anything definitely shout out to Intel for how much it's costing

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them for us to make this video on that note here's something cool

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these tools are maybe not as sophisticated as some of the other tools

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here in the Fab got your flathead screwdriver but the process is what's

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fascinating because taking a machine like this offline for more than a few

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minutes at a time very very costly so

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they handle it kind of like a formula one pit crew they've got all their tools

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everything's arranged freaking ready to rock they go okay time we're shutting it

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off we're performing maintenance go go go go go go go fire it back up that's it

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don't worry I will not hit any buttons this is the emo button okay the machine

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will get very sad if you press it this machine right here is doing dry etching

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right now so the fops come down off of

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the track up there and then while they're waiting you can see they're

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actually sitting out they sit away from the machine and while they're being

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processed they come up right next to it here and then you can see there's the

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robot ARM inside grabbing Wafers

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whipping them around it just throws it on here for a span of I don't know five

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or 10 seconds boom it's dry etched it

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goes back in the fop and then that whole fop is going to head off to whatever the

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next step is for this particular processor we don't know exactly what

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it's making but everything here is Intel 7 so modern CPUs pretty much or maybe

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future CPUs for all I know not every drying machine is identical as you guys

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can imagine for all the different specialized processes that a wafer goes

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through there might be different Machinery so this is another example of

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a dry etching machine where the wafer actually sits in this chamber in here

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and does whatever the heck it's doing

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now we're heading back to the lithography area again which is why the lighting in the Fab has changed back to

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yellow and the reason for that is they use UV light to expose the w wers so if

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they had white light it could easily contain parts of the spectrum that could

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accidentally expose the wafer so they have to use these carefully controlled

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light sources that will not cause any damage to the Wafers as they're ripping

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around in the fuks or going in and out of the machines fun fact each of these

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machines costs on the order of 30 to4

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million and it doesn't take a rocket scientist to figure out or I should say

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a a chip architect to figure out that

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you put this many of them tap this tight into an area the size of four football

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pitches um that's going to cost a pretty penny and it's because of those costs

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that they actually have this entire sort

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of R of cabinets I guess you could call it in between the East and West sides of

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the fat this entire thing is full of poops that are just waiting to be

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processed because the second one of those machines is available you want to

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be loading it up with silicon so you can make more processors now we're at of

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phography again then we're in the east side of the Fab which is also freaking

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enormous and the first machines that we're encountering are deposition

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machines so what these do is they'll

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take the wafer and they'll apply some

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extraordinarily thin layer of something say for example metal okay then it comes

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back into the boof back up to the rails and off to the next step did I ever say

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we're going to go see the planers now depending on the stage of wait for

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processing cuz remember if you go back and forth hundreds of times for a single

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die you don't necessarily want the straight edges of a dry edch you might

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want this kind of curved shape of a wet

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Edge now the actual exact shape is apparently extremely important and

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extremely difficult to control because unlike a dry Edge there's actually you

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can actually hear the sounds of the pump you hear that right now so there's

00:14:23.560 --> 00:14:30.240
actually chemicals pumping inside another key consideration if you've got

00:14:27.320 --> 00:14:33.680
such expensive Machinery is training so one of the things that Intel wanted to

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show us is how they're using augmented reality practically right here in the

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Fab for a variety of purposes so one is due to covid-19 obviously some Personnel

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were not able to be here in person for an extended period of time so remote

00:14:46.240 --> 00:14:53.560
assist allows someone who is here in person to actually have someone else

00:14:51.040 --> 00:14:57.040
scribbling on a schematic or explaining it to them while it hovers in front of

00:14:55.000 --> 00:15:00.199
them pretty freaking cool it's also used as a training resource for maintenance

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for the machine Mach so that you can kind of learn by doing and they're

00:15:02.120 --> 00:15:08.399
actually going to do a practical demo for us hey here's our here's our test

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Penny Pig here and he gets to look at my mug that's

00:15:10.959 --> 00:15:17.680
unfortunate oh that's awesome so it shows you all the tools you need so

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there's a little instructional video for how to do it very cool hey look at me

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I'm a Fab equipment maintenance technician unfortunately the Windows on

00:15:24.720 --> 00:15:30.240
these machines are quite dark but we did manage to catch one that is being

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processed right now so we've got some footage to show you guys essentially

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after the deposition step you're going to end up with some inherent unevenness

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that needs to be polished off now in the past they might have actually submerged

00:15:40.959 --> 00:15:49.240
the Wafers for polishing but now it's actually done by a brush that has a

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slurry on it that Intel said is very proprietary they wouldn't even give me

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any hints as to what is in this this

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polishing liquid but they did tell me that the pressure as well as the motion

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of it has to be so precise that they could take off as little as a few atoms

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or molecules at a time so you can see the wafer moving back and forth on the

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like spinning bottom crazy one thing that's missing is I don't see where that

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trade that loads all the wers in is where the poop is it ha get it cuz it's

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a poop by the way something I didn't mention before is that each of the

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different types of machines actually has a number but it also has these animals

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because Intel found that especially in a multi-layer design like Fab 28 in order

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to make sure that the maintenance crew down below is actually you know shutting

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down the correct machine for maintenance up above it's much easier to communicate

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and much easier to remember oh we're working on a giraffe machine or a

00:16:48.759 --> 00:16:53.440
ladybug machine apparently most of the

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staff that we saw in there though were actually maintenance staff for the

00:16:55.040 --> 00:17:02.040
machines and the actual control center of rein of the operation is elsewhere so

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we're gonna head over there now this is the remote operational Center which is

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you could think of kind of like the brains of the Fab that we just saw so if

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something goes wrong it's going to pop up as an error on someone's screen so

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it's the job of everyone in this room to optimize the overall throughput of the

00:17:15.799 --> 00:17:22.120
Fab so instead of having technicians there on the Fab floor moving things

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around and looking at screens and turning dials everything is done right

00:17:24.919 --> 00:17:31.039
here to ensure that they're pumping as many chips out as possible because once

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you invest $0 $40 million in a machine

00:17:31.039 --> 00:17:37.240
times however many were in there you

00:17:34.640 --> 00:17:40.960
want them going as hard as you possibly can as often as you possibly

00:17:44.280 --> 00:17:51.080
can every shift they have to do two stretching sessions in order to you know

00:17:49.080 --> 00:17:55.640
minimize the risk of RSI because they're basically sitting at their computers all

00:17:52.760 --> 00:17:55.640
day every day

00:17:56.480 --> 00:18:02.760
right but like the friend who only invited you to dinner because he wanted

00:18:00.240 --> 00:18:06.480
to show off his new car Intel had a bit of an agenda for inviting us here and

00:18:04.600 --> 00:18:11.640
that is to show off the enormous investment that they're making into Fab

00:18:08.720 --> 00:18:17.679
38 so everything that we just saw is about to be doubled this roundabout see

00:18:14.720 --> 00:18:22.120
you later in about 2 weeks that entire construction site out there is going to

00:18:19.640 --> 00:18:25.919
be state-of-the-art new generation fabrication technology that will

00:18:23.720 --> 00:18:30.720
actually be integrated so tightly with the existing Fab that you could actually

00:18:27.760 --> 00:18:34.000
take a wafer from one utilize equipment in the other and then send it back if

00:18:32.720 --> 00:18:39.200
you really needed to although that's going to be quite a distance for the fops to travel to give you some idea of

00:18:37.679 --> 00:18:43.760
how enormous this construction project is Intel actually built their own

00:18:41.559 --> 00:18:48.880
concrete production in the corner of the lot over there which you can see at the

00:18:45.720 --> 00:18:50.960
very back unreal one of the big reasons

00:18:48.880 --> 00:18:55.559
Intel is building out Fab capacity so aggressively right now is a New Concept

00:18:52.960 --> 00:18:59.640
called IDM 2.0 where basically instead of only building their own products

00:18:57.840 --> 00:19:03.360
they're going to be Fab products for third party companies which I personally

00:19:02.280 --> 00:19:09.600
given that we're sitting in the middle of the largest ever Global silicon shortage am pretty excited about now

00:19:08.120 --> 00:19:13.400
unfortunately there are a couple of steps in the die creation process that

00:19:11.480 --> 00:19:16.559
we weren't able to see today the addition of the bumps that connect the

00:19:15.080 --> 00:19:21.120
die to the package through electroplating that doesn't happen here

00:19:18.799 --> 00:19:25.360
and quality control QC starts with an endof thee line e test which checks the

00:19:23.120 --> 00:19:29.320
functionality of fake debugging structures and transistors that are

00:19:27.360 --> 00:19:32.480
specifically meant to be there to ensure that everything went correctly

00:19:30.559 --> 00:19:35.760
manufacturing then it proceeds to binning which is the process of sorting

00:19:34.000 --> 00:19:40.080
the good dieses according to their capabilities obviously the best of the

00:19:37.840 --> 00:19:45.280
best will become core I9 the next best will be core i7 and so on and so forth

00:19:42.799 --> 00:19:48.919
other than that 12th gen core or Alder lake is a pretty unique product for

00:19:47.120 --> 00:19:53.520
Intel with much of the design and Manufacturing done here in Israel once

00:19:51.679 --> 00:19:58.080
the wafer's done Intel sends it to one of their other facilities for slicing

00:19:55.760 --> 00:20:03.159
and packaging and a second validation step called class where they basically

00:20:00.520 --> 00:20:07.760
burn in every single chip to ensure that no degradation took place and that the

00:20:05.240 --> 00:20:11.440
packaging was done properly this along with design phase testing that simulates

00:20:09.640 --> 00:20:15.400
the effects of CPU aging is where Intel's reputation for manufacturing

00:20:13.159 --> 00:20:19.200
quality comes from I mean think about it when you're troubleshooting a system

00:20:16.640 --> 00:20:23.480
that won't boot the CPU is the last thing you're going to check because

00:20:20.720 --> 00:20:26.559
unless you dropped it it probably works packaging by the way is going to be

00:20:24.880 --> 00:20:30.480
getting a lot more complicated over the next few years as multi- processors like

00:20:28.960 --> 00:20:34.559
the upcoming Sapphire rapid start rolling out and it's expected that the

00:20:32.480 --> 00:20:39.120
relatively basic packaging facilities of yester year are going to be getting a

00:20:36.280 --> 00:20:44.840
lot more fabike I mean a packaging error on a $10,000 server CPU is a pretty

00:20:42.840 --> 00:20:48.760
expensive mistake given that the whole thing needs to be thrown away at that

00:20:46.600 --> 00:20:52.640
stage if something goes wrong maybe that should be the next tour I request am I

00:20:51.000 --> 00:20:56.360
right actually I'm not going to push my luck at the moment this was a once in

00:20:54.120 --> 00:21:00.640
a-lifetime opportunity and I'm extremely grateful to Danny and his team shout out

00:20:58.400 --> 00:21:04.840
to Karen by the way for hosting me to you guys for coming and sharing it with

00:21:02.120 --> 00:21:08.440
me and of course to my sponsor Ting mobile Ting mobile has rates that make

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guys enjoyed this video maybe check out one of our previous tours it's been a

00:21:48.760 --> 00:21:52.760
little while but they're excellent videos