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Semiconductor Fabrication Process

A semiconductor is a crucial component in many electronic devices. In fact, semiconductors are present in most modern electronics. Semiconductors contain the properties of both a conductor and an insulator.

Semiconductor Materials

Common semiconductor materials include silicon, selenium, boron, tellurium and germanium. Sometimes semiconductors are made from a combination of these materials. Since semiconductor materials are abundant in nature, they are often inexpensive. The use of these materials allows technology to remain affordable for the general public.

Silicon is the most common semiconductor material used today. This substance is extracted from sand, making it easily accessible and environmentally-friendly.

Semiconductor Fabrication

Semiconductor fabrication involves an extremely intricate process in which circuits are created on top of a wafer made from semiconducting material. Although small, these circuits contain a large number of electronic components. These components must all work simultaneously to perform functions that are vital to the operation of an electronics device.

Semiconductor circuits are assembled by skilled professionals is facilities referred to as “fabs”. The process involves the assembly of hundreds of layers of different materials, each containing their own circuit pattern, on top of a semiconducting material. The entire fabrication process takes approximately six to eight weeks to complete.

Preparation of Semiconductor Material

The semiconductor material must be properly prepared before it can be used. This involves melting and forming it so that it can be sliced into wafers. The size of the wafer varies depending on the type of semiconductor circuit being created.

Once sliced, the wafer undergoes a process to prepare it for photolithography. This process involves the growth of an oxide layer, a cleaning process to remove all contaminants and the application of photoresist to the wafer. The wafer is then spun, baked and exposed to intense UV light to develop the photoresist. Once prepared, a developer is added, the remaining oxide is etched away and the photoresist is removed.

Cleanroom Environment

The entire semiconductor fabrication process takes place inside a dedicated cleanroom. This ensures that dust and other contaminants are not able to come in contact with the parts of the semiconductor circuit. Because of their delicate nature and small size, even microscopic contaminants can render semiconductors ineffective.

Evolution of AS9100 from Rev C to Rev D

AS9100 is the internationally adopted Quality Management System (QMS) for the aerospace industry. It is currently being updated from Rev C to Rev D. The latest changes to AS9100 reflect the needs of a changing marketplace.

After September 15, 2018, AS9100 Rev C will no longer be valid. All organizations are required to transition to AS9100 Rev D by this time. The revisions incorporate changes made by ISO TC176 to the embedded ISO 9001 standard.

Improving Quality and Reliability

The overall performance and success of an organization relies on the quality of its products and services. Customer expectations in regards to quality and reliability are getting more and more stringent in the aerospace and defense sector. This is reflected by the importance being placed on AS9100 to drive consistent quality and reliability through the supply chain.

In today’s competitive business environment, evolution of the QMS is quickly becoming necessary as executives attempt to improve quality and performance. The new AS9100 is based on the updated ISO9001 with the addition of aviation, space and defense industry requirements. The focus of the revision is to add clarity and enhance ease of use.

Preparing for the Update

Rev D represents a major change. As such, it requires leadership and facilitation. It’s important for organizations to think about the required changes, prepare for them being continuous and manage any resistance within their organization.

Organizations must identify any organizational gaps that need to be addressed in order to meet the new requirements. Appropriate training should be given to all parties that have an impact on the effectiveness of the organization. The existing QMS must also be updated to meet the revised requirements.

Benefits of AS9100 Rev D

When implemented and managed well, there are many benefits to AS9100 Rev D. It allows organizations to produce and improve safe and reliable products that meet and exceed customer and regulatory expectations. The processes necessary to perform day-to-day business are well defined and managed and documentation accurately reflects the work being performed.

Semiconductor Fabrication Process