> I assume they don't pattern the unused area, so the process should be quicker?
The primary driver of time and cost in the fabrication process is the number of layers for the wafers, not the surface area, since all wafers going through a given process are the same size. So you generally want to maximize the number of devices per wafer, because a large part of your costs will be calculated at the per-wafer level, not a per-device level.
> Yes, but isn't a big driver of layer costs the cost of the machines to build those layers?
Let's say the time spent in lithography step is linear the way you're describing. Even with that, the deposition step beforehand is surface area independent and would be applied across the entire wafer, and takes just as long if not longer than the lithography.
Additionally, if you were going to build a fab ground up for some specific purpose, then you might optimize the fab for those specific devices as you lay out. But most of these companies are not doing that and are simply going through TSMC or a similar subcontractor. So you've got an additional question of how far TSMC will go to accommodate customers who only want to use half a wafer, and whether that's the kind of project they could profitably cater to.
Yes, but my understanding is that the wafer is exposed in multiple steps, so there would still be less exposure steps? Probably insignificant compared to all the rest though. (Etching, moving the wafer, etc.)
EDIT: to clarify - I mean the exposure of one single pattern/layer is done in multiple steps. (https://en.wikipedia.org/wiki/Photolithography#Projection)
The number of exposure steps would be unrelated to the (surface area) size of die/device that you're making. In fact, in semiconductor manufacturing you're typically trying to maximize the number of devices per wafer because it costs the same to manufacture 1 device with 10 layers vs 100 devices with 10 layers on the same wafer. This goes so far as to have companies or business units share wafers for prototyping runs so as to minimize cost per device (by maximizing output per wafer).
Also, etching, moving, etc is all done on the entire wafer at the same time generally, via masks and baths. It's less of a pencil/stylus process, and more of a t-shirt silk-screening process.
> This goes so far as to have companies or business units share wafers for prototyping runs so as to minimize cost per device
Can this be done in production? Is there a chance that the portion of the wafer cerebras.ai can't fit their giant square in is being used for production of some other companies chips?
Yes, but isn't a big driver of layer costs the cost of the machines to build those layers?
For patterning, a single iteration could be (example values, no actual values used, probably only ballpark accuracy) on a 300M$ EUV machine with 5-year write off cycle, patterns on average 180 full wafers /hour. Excluding energy usage and service time, each wafer that needs full patterning would cost ~38$. If each wafer only needed half the area patterned, the lithography machine might only spend half its usual time on such a wafer, and that could double the throughput of the EUV machine, halving the write-off based cost component of such a patterning step.
Given that each layer generally consists of multiple patterning steps, a 10-20% reduction in those steps could give a meaningful reduction in time spent in the machines whose time spend on the wafer depends on the used wafer area.
This of course doesn't help reduce time in polishing or etching (and other steps that happen with whole wafers at a time), so it won't be as straightforward as % reduction in wafer area usage == % reduction in cost, but I wouldn't be surprised if it was a meaningful percentage.