Intel Struggles With Key Manufacturing Process For Next PC Chip

According to two sources Reuters spoke with, Intel is struggling with low yields in its next-gen 18A chip manufacturing process for its next PC chip, Panther Lake. Internal data suggests the company is far from reaching commercially viable production levels, leading some insiders to describe the effort as a 'Hail Mary.' Reuters reports: For months, Intel has promised investors it would increase manufacturing using a process it calls 18A. It spent billions of dollars developing 18A, including the construction or upgrades of several factories, with the goal of challenging Taiwan's chipmaking heavyweight, TSMC. Intel wants to round out its business designing chips that it largely makes in-house and TSMC helps it produce, with a contract manufacturing business that can compete with this key supplier. But whether Intel revives advanced chip production in the U.S. and gets its contract foundry on solid footing depends on closing the technology gap with TSMC. Early tests disappointed customers last year, but Intel has said its 18A is on track to make its 'Panther Lake' laptop semiconductors at high volume starting in 2025, which include next-generation transistors and a more efficient way to deliver power to the chip.

The chipmaker has hoped that producing such an advanced in-house chip would grow external interest in its foundry, at a time when new CEO Lip-Bu Tan has explored a major shift to course-correct that fledgling business, Reuters previously reported. Yet only a small percentage of the Panther Lake chips printed via 18A have been good enough to make available to customers, said the two people, who were briefed on the company's test data since late last year. The sources spoke on condition of anonymity because Intel did not authorize them to disclose such information. This percentage figure, known as yield, means Intel may struggle to make its high-end laptop chip profitably in the near future.

Intel in the past has aimed for a yield north of 50% before ramping production because starting any earlier risked damaging its profit margin, three of the sources said. Intel typically does not make the lion's share of its profit until yields reach roughly 70% to 80%, key for a chip as small as Panther Lake where many defects would make it a tough sell, the three people said. Profit also flows from market expansions and building up factory output, Intel said. An immense yield increase would be a tall task by Panther Lake's fourth-quarter launch, the two people with knowledge of Intel's manufacturing operation said. But without such a jump, Intel may have to sell some chips at a lower profit margin or at a loss, the two sources briefed on test data said. The company has warned it could exit leading-edge manufacturing entirely if it does not land external business for 14A, which is 18A's next-generation successor.

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