Ultra Thin Silicon Manufacturing

Why Can’t We Simply Build Bigger Wafers?

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November 22, 2024

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Thanks to their capabilities, silicon wafers are a fundamental element in today’s electronic devices, fostering or enabling our technology. Due to that, silicon manufacturing has grown incredibly these last few years. However, silicon does offer some limitations that make it unsuitable for applications in harsh environments, like high-speed trains, satellites, and quantum computing.

To enhance its capabilities and prevent damage, one could think about making bigger wafers as an alternative—but this is also not a solution. When it comes to semiconductors, diameters matter. Let's go over why.

Challenges of Scaling Up Wafer Size

Silicon wafers offer adequate functionalities for standard home appliances. Still, circumstances change when it comes to complex applications such as electric vehicles (EVs). Semiconductor devices have a maximum voltage threshold, and exceeding it can cause dielectric breakdown and device damage.

While increasing wafer size could enhance resistance to dielectric breakdown, practical and technical obstacles prevent this approach:

  • Space Constraints: Larger wafers require significantly more space, making them impractical for many applications.
  • Perfomance Trade-offs: Bigger wafers tend to have slower switching speeds, limiting their functionality.
  • Material Limitations: Improved materials are essential to achieve both high resistance to breakdown and minimal power loss in larger wafers.

The Role of Power Semiconductors

Power semiconductors are used to address these challenges. These specialized devices can efficiently switch under high-voltage conditions without experiencing dielectric breakdown, enabling advancements in EVs and other high-demand applications.  

Learn More About Silicon Manufacturing

For several years, the size of silicon wafers has been decreasing to adapt to new, advanced devices that are progressively smaller and more practical. Because of that, manufacturers prefer exploring alternative materials over increasing the size of silicon wafers.

Still, silicon is a great semiconductor material that can find applications in several industries. If you’re interested in learning more about our substates, reach out to Wafer World!

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