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Eight and a half years ago, I unboxed a pabyte of storage. It weighed over 150

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pounds, required multiple servers, and used an ungodly amount of power. Theo

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Joe asked me, "Why not simply use one pabyte drive?" We're not quite there,

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but we're getting very close. Each of the Kiosia LC9 SSDs in my hand holds 245

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terab of data. That means with just four drives, I can hold nearly a pabyte of

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storage [music] in the palm of my hand. That's thanks to the chonyy thick NAND

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packages that it uses that each contain a whopping 32 stacked dyes all wired

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together with gold. And behind me is the Kioskia fab that made them alongside the

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cutting edge nan flash that you might find in your other favorite electronics,

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mobile devices, and memory cards. It is one of the most advanced manufacturing

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facilities on Earth. And Kyogia was kind

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enough to sponsor this video and give us unprecedented access to their facility

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from the very top to the very bottom. I'm ready. Let's just see if Kyokia is

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ready. [laughter]

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Maybe I'm not ready.

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We're going to be taking you step by step through Kyokia's sprawling [music]

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Yokai plant that spans seven fabs over

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694,000 m [music] and even has its own tennis

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court. All so we can turn this into

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this. Every semiconductor's story begins

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with purified silicon. It gets melted in a vat into which a single seed crystal

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is inserted. [music] The vat gets turned while the seed crystal is pulled out,

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creating an enormous mono crystal. Now, the full-sized one would be too large

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and too cumbersome for me to carry, but I've actually got the top of one where

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you can see how a teardrop shape is formed as it is pulled out of the molten

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vat until it gets wide enough to grind down into the 300 mm diameter wafers

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that are used to make semiconductor devices. In the fab behind me are

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thousands upon thousands of these wafers ripping around on automated tracks in

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carrier pods called foops. Over the course of several months, each wafer

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will travel many kilometers, often over skyways between completely separate

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buildings and will go through thousands of manufacturing steps before becoming a

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finished chip. These fads take years to build, cost billions of dollars, and

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contain some of the world's most closely guarded secrets. The basics of

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semiconductor manufacturing are wellknown. Branch Education has an

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outstanding video on the subject. We'll have that linked down below. But what I

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want to focus on today are some of the specifics that make this fab especially

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tuned for crafting high density storage chips.

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Welcome to Y7. It's one of the cleanest

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places on the planet with so little airborne contamination that it would be

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about like having a single bee in a giant baseball stadium. This is

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incredibly important because just one single particle of foreign matter can

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spoil months of costly work. To create their cutting edge Bix Flash Generation

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8 memory cells, Kyioxia uses a process called plasma-enhanced chemical vapor

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deposition or PECBD. This allows them to

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turn chemical vapors in the vacuum chamber behind me into the 218

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intricate storage layers that give these chips their incredible data density.

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Plasma CBD operates at lower temperatures compared to conventional

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chemical vapor deposition, allowing its use on substrates that can't withstand

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higher temperatures. You probably noticed that this isn't the only machine

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here. For mass production, semiconductor fabs contain hundreds of machines, many

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performing the same functions, and they pack them in tight. That makes sense

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because clean rooms are extremely expensive to both build and operate. So

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the less you have to build, the more you save. So, how do they pack things so

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tight? To find [music] out, we'll be going somewhere I've never been before.

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Below the Fab.

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We're in the belly of the beast. Now, you know what they say, behind every

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great fab clean room is an almost as

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clean subf that contains the ancillary

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equipment that supports the manufacturing equipment above, including

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power, chemical supply lines, and in this case, a dry pump that creates the

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vacuum needed for our plasma CEVD machine that is right above us. But what

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about sub subf to optimize the layout of

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their fab? Kyokia is using an unusual second subfab which helps them avoid

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spreading their ancillary equipment out so much which improves equipment density

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and helps them avoid long ciruitous runs

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that can make maintenance more challenging. In this case, we're looking

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at gas neutralizing equipment, which treats the toxic gas that's exhausted

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from the CEBD equipment that is above us before it gets vented. Since we're down

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here, clean room air flow goes top to bottom. So fresh air comes in way up

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above where our plasma CVD machine was, then down through the fab, the subfab,

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and then ultimately gets drawn up down the sides of our sub subf before being

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sent back up to be filtered and reused. Coming back up to the main fab floor,

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we've got another really special treat for you guys. See, in traditional nan

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flash, your seamos logic layers would be manufactured on the same wafer below the

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flash memory cell layers. That sounds pretty good to me. Approved. But there's

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a small problem. The best conditions for manufacturing high performance SMOS

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circuitry and highdensity NAND are quite

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different. Kioxia solution. What about

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second wafer? That's right. [music] They produce the SMOS on an entirely separate

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silicon wafer and then literally sandwich them together with a nice

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shmear of copper that bonds the two layers together. It's called CBA or

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SIMOS directly bonded to array. And thanks to some very complex and precise

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engineering, Hya is able to create a lowresistance, high reliability bond,

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providing increased data density and performance. But wait, with two wafers,

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won't it be twice as thick? Yeah, it will. In fact, you can see it. And it's

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even noticeable just picking them up with my hands. How's that going to help

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with storage density? Don't worry, they thought of that. Once the two are joined

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together, they quite literally grind off

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the excess silicon on the top of the sandwich right down to [music] the flash

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cells. And then the processing continues. Wait, what? Surely this has

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got to go wrong [music] sometimes, right? Well, yeah. Let's visit the

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factory narc, the scanning electron microscope, and talk about AI.

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I'm not talking no content slop. It's actually super legit. I probably don't

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have to tell you guys that one of these wafers is worth a heck ton of money. So

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minimizing defects is the difference between huge profits and happy customers

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and rapid bankruptcy. That is where AI

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data analysis comes in. Kioxia is collecting data around the clock about

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35,000 data points per second and analyzing all of that manually is

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impossible. So, they've been using AI since well before the current trend to

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gain insights into how to improve their processes and maximize quality. Let's

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have a look at how this works. On this laptop are some example defects from the

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scanning electron microscope grouped up by AI according to their type. I'm going

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to try and guess what caused them. Wormhole fragments.

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>> Okay. Easter bunny tears.

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>> Dodo dandruff.

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Unfortunately, the real answers are very critical to Kyopsia's operations. So,

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they shall remain a mystery. You win this time, AI, this time. But next time,

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I'll challenge you to show me a seahorse emoji. Then, we'll see. Anywh who, by

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using this information about defects, [music] Kyokia can simulate fixes in

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their Fab's digital twin and then roll that into production to improve their

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product quality. Enough about the small stuff, though. I think the most

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impressive aspect of this facility is how big it is. We're standing on one of

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the Y7 FAD loading dock where FAD equipment can be lifted up to seven

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stories on cranes for deployment inside.

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It's 3 million square ft. And [music] that's not enough. They've already got

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plans to add even more capacity. [music] Mind-blowing. Of course, when you're

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operating at this scale, you run into all kinds of challenges that most people

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don't even need to think about. Below me, for instance, [music] is their on-site storage and management of gases

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and chemicals for semiconductor fabrication. Smells kind of like nail

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polish. And this is one of their on-site solar panel deployments that's part of

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Kioxia reaching their goals for green energy and sustainability. This one

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deployment has over 7,000 solar panels

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and can reach a peak power generation of over 2 and 12 megawatt. Another major

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environmental consideration for Kioxia is water. It's not the most intuitive

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thing in the world, but semiconductor manufacturing uses far more water than

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you'd think. And not just any water. In this glass is some of the purest water

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on the entire planet. It is so pure, in fact, that it is classified as a

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solvent. And in large enough quantities, it will actually extract minerals from

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my bloodstream. I asked Kyokia if I could drink some. And even though small

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quantities are unlikely to cause permanent damage, they forbade me. I was

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forbaded. So what do they use it for? Well, kind of everything from cooling to

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wet etching to the many, many washing steps. If you need computer chips, you

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need ultra pure water and you need ultra

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lots of it, which sadly means an ultra lot of waste.

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This is what it looks like after it's been used. The water behind me is full

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of acids, solvents, heavy metals, and

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all kinds of nasty things. But here's the thing, water is expensive, and also

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the environment is pretty cool. So, Kioxia puts a lot of effort into water

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reclamation. This tank is actually part of their

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older water filtration system for their older fabs, but it's a little bit more

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uh visual, so we thought we'd take you through it. This first stage agitates a

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mixture of waste water, biochemicals, and soil to facilitate easier filtration

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in the following stages. You know, they said I couldn't drink the ultra pure

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water, but they never said I can't drink this.

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No, no, I I I won't. I won't. The next

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stage is this gigantic mechanical skimmer vat that features a conicle

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shape, allowing all of the sludge to easily make its way towards the bottom

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while taking off the purest water at the top. And it's amazing what a difference

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it makes. This is the before, which you just saw me scoop out. And this is the

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after, which we pull right out of the

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edge of this tank. Next, it goes through a second stage of mechanical filtration

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where it becomes so clean that fish can

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live in it. But don't take my word for it. Take their word for it. This is the

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same water that is coming from that filtration station. And as you can see,

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there are koi living in it right now. Sort of like water canaries living in a

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silicon coal mine. But as cool as the old water treatment system is, the

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reclamation rate is only around 80%.

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which is okay, but it's not nearly as good as the new system that came

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alongside the new Fab. It's all enclosed, so we can't really show it to

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you, but it reclaims over 90% of all the

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water that's used that can be sent back into production for various purposes.

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Now, let's jump back inside. So, now that it's out of the fab, our wafer is

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done and ready for human consumption, right? Well, not so much. See, using

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Kyokia's Bix Flash Generation 8, this little square right here is up to 2

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terabt of storage, which means that if

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we wanted to make an 8 terbte package

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like their latest dies, we would need 32 of these stacked on top of each other,

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which would get pretty thick pretty fast. That is where [music] backside

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grinding comes in. We take this wafer and put a protective layer on top of it

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to keep all of our precious nan flash safe. Then we put it in the machine

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behind me and grind away the back until

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it goes from being stiff like this to being middle-aged like me. In total, we

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go from about8 mm down to anywhere from

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30 to 40 microme depending on the process. Much better for stacking.

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Stacked on what, you might ask? On the substrate, of course. On the bottom of

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this is what will ultimately be the BGA interface that will allow this nan flash

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to be soldered to a phone or laptop or SSD. And then on the top is where we're

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going to create stacks of these dyes up to 32. Oh my god, it's beautiful.

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Of course, before we can do that, we need to cut them up. And that's where

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dieing comes in. The thinned wafer gets mounted to one of these frames. And then

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a diamond blade is used to cut out all the individual dyes. Now, let's talk

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about wiring them up. Every one of those stacks is connected using dozens of tiny

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golden wires, about a quarter of the

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thickness of a human hair. It's fed off

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of a spool like this, into a tiny sewing

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needle-ike capillary that touches every contact point. You barely bake out what

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it's all connected to with the naked eye. So, I won't try. Kioska helpfully

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provided this microscope to give us a much much better look. And you can see

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[music] where every wire connects to the substrate. And then look at this. We

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turn it this way. Wow. We get a really good view of the stack. That's

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incredible. Incredibly fragile. How do we keep this safe?

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Inside this machine, trays get loaded with resin. It starts in a powdered form

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like this. Then our bonded dyes go face

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down onto the resin and the whole thing gets moved into these high temperature

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waffle irons. Then after a short cooling cycle, our now resin protected die

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stacks are shoved out the front of the machine. In a mass production

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environment, these would move to the next stage in an automated fashion. But

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this is a small scale prototyping lab. So, our trays of very expensive

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bookmarks comes out of the machine onto the cart and then off to our next step.

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Behind me is a shaker tray that's full of these tiny little solder balls. This

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vacuum head comes over it, sucks up

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solder balls, and then carries them back to the backside of our substrate,

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precisely placing them on what will be the contact points where our nan flash

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will be soldered to a board. The solder balls get melted in the oven behind me.

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Then our trays get cleaned and dried.

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Laser engraving. Every one of these packages gets etched with the batch

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number except oh, one of them is actually missing its markings. That's

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because at some point that package was tested and found to be defective.

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Whether it's one of the dyes, one of the stacks, or one of the wire bonds, we

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don't know. But it's no bueno. So it doesn't get a name. These machines are

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wild. They can do a whole one of those trays in 60 seconds.

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Now it's party time. This machine slices, she dices, she cleans with ultra

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pure water, and even takes the dice packages and arranges them nicely on a

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tray. Pretty much ready for final delivery. What about the bad ones with

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no engraving? They get dumped down the garbage shoot

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right here. See you later.

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Now, it's time to turn our tray of packages into a final product. Now,

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these could go directly onto the motherboard of, say, for example, a

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phone or a laptop, but in this case,

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it's going onto a high-performance SSD.

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Step one, we load in our blank PCBs. Then, it goes through the PCB cleaner

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and into this bad boy, which lowers a metal screen over top of the PCB and

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then slides a squeegee across it, depositing just the right amount of

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solder paste onto all of the pads. Next, it goes into this machine for a machine

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vision inspection. You can actually see it spotted one little tiny error in the

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solder paste. So, that's no big deal for this kind of thing. We can just pull it

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out and run it through again. Once our paste is perfect, our board goes into

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this line of pick and place machines. And they said, I can press the start button. They're not the latest on the

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market, but they'll do about 2,000 components in 10 minutes, which is fine

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for the prototyping line that we're looking at today. And you can actually

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see where the reels of tiny surface mount components are fed in and then

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placed rapid fire. Down at the end, we find the biggest components. So, right

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here we have our DRAM caches. And then in these two bays are trays of nan

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flash. Now, it's time for another inspection before our boards go into

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what I call the world's fanciest pizza oven. This mamajama has 10 heat zones

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slowly ramping up and then towards the

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end ramping down. This is because rapid changes in temperature can make BGA

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solder joints more brittle and a brittle solder joint is a bad solder joint. Next

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comes the pizza cooler. Then a third machine vision inspection. Finally, the

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finished boards come over to assembly where you load your chassis onto the

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assembly jig and zippity zappity fancy

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SSD. But there's one other environmental consideration for Kyia and it's a big

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one. Earthquakes. With such high precision manufacturing, how do they

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deal with the roughly 1,500 earthquakes that hit Japan every year? To find out,

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we've ventured all the way down to the basement of one of the FABs to take an

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in-person look at the gigantic footings that suspend the entire building above

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the ground. They're made out of four different types of materials. This one's

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made of natural rubber, I think, and these softest ones go around the outside

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perimeter of the building. And [music] then there are three other kinds that

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play different roles in maintaining the seismic stability of the entire fab

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because you never know what kind of earthquake you're going to get. Some are more up and down, some are more side to

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side, and you got to be ready for anything. The building we're under is

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supported by nearly 400 of these footings that allow it to move up to 60

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cm or about 2 ft in any given direction.

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Now, obviously, they're going to have to recalibrate their equipment to make sure everything's running correctly, but it's

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meant to dramatically reduce the impact. Maybe the coolest part though is if you

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look carefully in the basement, you can see a little slit of daylight. And this

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is where it's coming from, where this entire building is completely decoupled

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from the foundation by those dampers here. Check this out.

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You can't see it, but I moved it a little bit. Like just a little. Massive

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thanks to Kioxia for having us out here. It really puts into perspective the hard

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work that goes into bringing these products to life. I don't think I'll

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ever take for granted the performance or storage density of Nan Flash ever again.

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If you guys want to learn more, you can check them out at kioxia.com. We'll have

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them linked down below. If you guys are looking for another video to watch, why

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not check out the time we collaborated with Kyia to break a Guinness World

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Record calculating more digits of pi than anybody ever has before.