ASML, the Dutch leader in advanced photolithography systems for semiconductor fabrication, has made a significant advancement in the realm of manufacturing by establishing the world’s first qualified additive manufacturing (AM) supply chain specifically tailored for the semiconductor industry. This initiative, which involves stringent auditing of suppliers, is designed to meet the robust standards of ISO/ASTM 52920, alongside ASML’s internal guidelines, known as GSA-02-0001. The aim is to mitigate process variability that can compromise quality and improve the reproducibility of Class 3 critical components essential for semiconductor systems.
The company’s ambitious qualification process typically spans four to ten months, consisting of comprehensive audits, reports, and certification assessments. By standardising AM systems, materials, parameter sets, and human interactions, ASML seeks to establish a reliable production process that aligns with industry-critical requirements. The Qualified AM GmbH team conducted detailed evaluations focused on the powder bed fusion process via laser beam melting (PBF/LB-M), employing titanium alloy Ti6Al4V and stainless steel 316L as materials for assessment.
One of the pivotal challenges addressed by this initiative is the notable quality variations across the supply chain, which arise due to differing AM systems and human factors. ASML has recognised that, while the potential of AM is significant, achieving consistent quality across various production environments is critical. “Our goal has been to reduce the process variables that affect reproducibility, ensuring that all components meet the highest standards,” an ASML spokesperson noted.
The qualification process not only affects the manufacturability of high-stakes Class 3 components but also serves as a bellwether for the overall health and reliability of semiconductor manufacturing. The audits included rigorous evaluations related to manufacturability assessments, ensuring that suppliers could produce components that meet strict semiconductor-grade requirements. The programme also employed failure mode assessments to highlight inefficiencies and risk factors within the AM process, prompting suppliers to refine their assessments with expert insights.
ASML’s standardisation efforts are reflected in its alignment with a comprehensive assortment of industry standards, such as ISO/ASTM 52920:2023 and various others that set critical benchmarks for AM production. This systematic approach is anticipated to yield a more integrated and reliable national and international supply chain within the semiconductor sector.
As the semiconductor industry grapples with fluctuating demand and supply chain pressures, ASML has remained optimistic about the sector’s recovery prospects, particularly in light of the anticipated growth stemming from AI technologies. Despite a challenging first quarter in 2024, ASML’s leadership expressed confidence in a rebound during the latter half of the year. Chief Executive Peter Wennink described this period as a “transition year,” mentioning the significant potential embedded within emerging AI markets that may counterbalance more stagnant areas of semiconductor production.
Amid such a backdrop, ASML’s qualification initiative is emblematic of broader trends within the industry striving for heightened reliability and standardisation. Notably, other initiatives in the field, such as the establishment of Spain’s first centre dedicated to advanced manufacturing for military and defence applications by Sicnova—aiming to ensure component reliability through certification—illustrate a growing commitment to establishing rigorous quality standards across diverse sectors reliant on advanced manufacturing techniques.
As the demand for semiconductors continues to evolve, so too does the need for robust and reliable production processes. ASML’s latest undertaking not only sets a high benchmark for future practices in additive manufacturing but also reinforces the industry’s ongoing quest for excellence and innovation in semiconductor fabrication.
Source: Noah Wire Services
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