Source: DIGITimes

Will ASML be affected with the geopolitical uncertainties in the future, given the world’s most advanced high-NA EUV machines is touted to be the ultimate weapon for a technological leapfrog for its customers. 

1. Dan Hutcheson, vice chair of TechInsights, who has covered ASML since the 1970s, when it was still a subsidiary of Philips, and Marc Hijink, the author of Focus – the ASML Way and a reporter at Dutch newspaper NRC, joined DIGITIMES Asia for an insightful talk to address these questions.

Navigating Geopolitical Uncertainties

Although ASML and other semiconductor equipment providers benefit from the demand driven by export controls imposed by the United States to China, geopolitics may have long-lasting implications on the industry as extra capacities and ecosystems are built.

Hutcheson and Hijink see ASML following their customers’ footsteps to decentralise their productions from the Western Pacific corridor to the United States and Europe. Still, the efficiency of its customers’ fab operations may be a concern.

“We’re in a new world where the utilization of the tools is lower,” said Hutcheson, “The problem is, if you can’t find the workers to run the tools or to repair them, keep them running, your wafer fab is useless.”

Hijink observed that Asia will remain an important center for chip production in the future despite the onshoring efforts of various countries and the talent shortage issue since South Korea and Taiwan remain an important part of ASML’s expansion.

ASML’s Monopoly Status Unlikely To Be Challenged

Yet, Hijink cautioned, “ASML’s biggest fear is that the current restrictions on Chinese technology might even stimulate it in the long term and create an even bigger problem.” He pointed out that the less China gets access to these Western lithography tools, the more the Chinese companies are inclined to build their own. “Even though they might not be able to compete with ASML and Nikon now, you see more room for growth and R&D money in the long term.”

Yet, Hutcheson believes no company can challenge ASML lithography monopoly without massive government subsidies.

“Five decades ago, I developed this maxim that the number of unsubsidised competitors a market can sustain is equal to 1/5 the total market size divided by the cost to develop a new generation of technology, and then you subtract 1.5 times that cost,” said Hutcheson. “To attract another competitor in the market, the risk bar must be low enough that there’s enough available R&D to support the development of at least 1.5 more tools than what exists in the market at that time.”

Over those five decades, that maximum is held across 100, or there have been more sub-markets of semiconductor equipment, and that explains the market consolidation of the market from more than 20 semiconductor equipment makers in the 1980s to just a handful right now for lithography, explained Hutcheson.

As a semiconductor industry veteran, Hutcheson witnessed how ASML survived over the past four decades of vicissitudes through better management and technological development. Hijink added that ASML survived because it out-invested in R&D during the low cycles despite being on the brink of bankruptcy several times and cleverly invited its customers TSMC, Intel, and Samsung to invest in it and co-develop the EUV machine.

By getting the investments, ASML managed to get the money to acquire Cymer, the light source company based in San Diego, and establish a strategic alliance with ZEISS, the German lens maker. Those key components and e-beam technology created ASML’s secret sauce of success that competitors cannot copy.

However, repeating such success is getting harder.

“No single company can afford to do it alone, as R&D becomes more and more expensive,” Hutcheson quoted John Chen of Nvidia, who was the first R&D president at TSMC, that,” IC no longer means integrated circuit going forward, IC means industry collaboration.”

Hutcheson estimates that the cost of developing a new EUV tool from scratch would require multiple trillions of dollars, which is equal to the Gross Domestic Product for some countries, and that’s assuming that one gets around all the IP barriers in place. “To some extent, it levels the geopolitical playing field. So maybe EUV should receive the Nobel Peace Prize because no country can attack any other country unless they have the EUV,” quipped Hutcheson.

Can High-NA Machines Help Technology Leapfrog?

As Intel, Samsung, and TSMC are aiming to mass produce 2nm chips in the next few years and advance towards 1.4-1.6 nm, the ASML’s high-NA EUVs are making the headlines of semiconductor industry newspapers.

As always, ASML ships the US$300 million High-NA machines to customers according to the timetable agreed with customers and does the laborious adjusting and error corrections with customers. The media has been describing high-NA EUVs as the key for technology catch-uppers to leapfrog the incumbent. However, Hutcheson delved deeply into the intricacies involved in the complex processes of semiconductor manufacturing beyond lithography.

“There’s a lot of technology issues in the 2nm and 1.4nm era. And we will have to see if they can pull it off and turn it into an advantage,” Hutcheson explained that lithography is not the only factor at stake, there are also issues with the gate-all-around (GAA) structures, due to the leakage problems with that. “There’s also reliability problems, and the epitaxial layer is pretty poor. So really, there are more material and systems engineering problems than lithography problems.”

Though Intel has seemingly bought up all available high-NA machines for the year, TSMC is not in a hurry to apply it to its 1.4-1.6nm process. However, ASML said all of their customers who have bought EUVs are going to upgrade to High-NA EUVs.

“I think that Intel has to do more, try to leapfrog TSMC, which is a daring move, but that’s just one part of Intel’s challenge,” said Hijink. “Their biggest challenge is not the technology, but the fact that they want to do foundry business because they have to create enough wafer footprint or enough scale to be economically viable with huge competitors like Samsung and TSMC. So that adds to the problem of adopting a new technology where they’re not as experienced.”

Hutcheson cautioned that it is too early to judge the outcome of technology competitions. Yet seeing from the history of the semiconductors industry, decades of research, blood, sweat, and tears, and fixing tonnes of errors, plus making the right decisions at the right timing and building deep trust with customers made ASML and TSMC what they are today.

ASML, a blend of European, Asian, and American cultures as the result of acquisitions, can be a great teacher for TSMC, which is just starting to expand its footprints to the US and Europe. With such a close bond between the two, with AI being the main driving force for semiconductor’s future growth, one can be sure there will not be short of fascinating stories in the future.

Editor’s note: For more insights and analysis from Hutcheson and Hijink on the industry, watch DIGITIMES Asia’s new GeoWatch video, ‘Decoding Excellence: ASML’s Evolution Towards Leadership and Beyond.’ Click the link here to access this informative video: https://dgt.ms/geowatch0516

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GROB is a pioneer of electromobility: The manufacturing technology and process expertise of the Bavarian family-owned company are used by over two-thirds of all EV suppliers. GROB earned this market leadership not only through courage and foresight, but also through high quality standards with ZEISS’ commitment towards enhanced standards and productivity.

Electrification is a key economic and ecological success factor – especially in the mobility sector. It is often said that Germany is a lagger on electromobility. However at GROB, a supplier of manufacturing and automation systems, they only smile at such statements. Martin Negele, Head of Quality Assurance says:

“At GROB, we recognised several years ago that the future belongs to e-drives. Despite being a controversial topic then, we took the plunge. This has paid off: today, we have a 67% market share in stator technology alone. If you look at an e-drive train, it is very likely that our production technology is behind it,” Martin Negele explains.

GROB earns this leading role mainly by striving for uncompromising quality, enabled by a close partnership with ZEISS. With its Industrial Quality Solutions division, ZEISS is the only provider to offer a complete portfolio of state-of-the-art quality solutions.

“We combine microscopic, tactile and optical measurement technology to achieve optimum results,” Martin Negele noted.

This means producing a demanding part such as a stator can be fully executed with maximum certainty and productivity.

Stator: Challenges In Manufacturing And Quality Assurance

In addition to many other advantages, the drive technology of EVs impresses with its fundamentally simple design: In an electric motor, a rotating electromagnet, the rotor, turns in the magnetic field of an immovable permanent magnet, the stator. 

However, producing these components, especially the stator is anything but simple in spite of consisting a sheet metal housing, laminated core, and induction coils made of coated copper. Even with such a “simple” component, there are high performance requirements today. For this reason, automotive manufacturers are also increasingly using hairpin technology, i.e. plug-in coils, instead of winding wire coils for their stators.

Read more here at page 39

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With these products and quality in mind, the aim is to increase the safety of vehicles and at the same time reduce their weight. The German site in Hagenbach produces ready-to-install assemblies of high-strength steel for this purpose and supplies them to global vehicle manufacturers and automotive suppliers. To keep the quality of the complex parts at a consistently high level, production processes must be monitored constantly.

Automated 3D measurement technology solutions from ZEISS support the tier-1 supplier throughout the entire manufacturing process: Three integrated ScanBox systems scan measuring data and submit it directly to upstream production using ZEISS PiWeb. Deviations are thus detected quickly and appropriate corrective measures are initiated.

Growing Quality Requirements And High Monitoring Rates

As a close partner of the automotive industry, LINDE + WIEMANN has been faced with increasing customer demands and ever more complex geometries for many years. This development requires constant adaptation of production and quality assurance processes.

The automotive supplier regularly shares its measuring data with customers. The parallel operation of the ScanBox systems accelerates the measuring procedures significantly.

Quality management already receives valid information on part quality during ongoing production.

“We pass on our measuring results to the manufacturing department promptly, so that decisive measures can directly be taken. This way, unnecessary quality costs can be avoided,” explains Peter Kluge, Head of Quality Management of LINDE + WIEMANN.

Flexibility During The Inspection Of Large Structural Components And Change Processes

ZEISS optical measuring machines offer significant advantages for automotive suppliers in terms of accuracy. ATOS sensors digitize the entire surface of the structural components to be inspected within seconds via fringe projection.

Every measurement identifies possible deviations between the actual 3D coordinates and the CAD data, which are displayed through a color comparison in the GOM Inspect Pro software.

Read more here 

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Headquartered in Rorschacherberg, Switzerland, the Starrag Group manufactures machining centers for production solutions that handle turbine blades, blisks, and more, with a major focus on aerospace applications. Precision powers the aerospace industry, and accuracy requirements have grown far stricter in recent years.

In serving the expanding and widely varying demands of its global customer base, Starrag must perform high-efficiency measurements that deliver very fast, highly accurate, and easily reproducible results. The pilot project thus saw the new-generation ZEISS PRISMO 7/12/7 fortis deployed in a vital and highly visible role in the quality lab – and Starrag was wowed by the results.

Starrag’s Head of Quality Management, Roland Ziltener, sums it up neatly: “In the field of measuring technology, accuracy is usually slow. With ZEISS PRISMO 7/12/7 fortis equipped with ZEISS CMM Acceleration Mode for Aerospace Applications, the opposite is the case.”

As Ziltener notes with a smile, his customers are always “fascinated and somewhat shocked” at how this new-generation CMM combines accuracy and speed on a whole new level.

A Fresh Approach To Rotary Table Applications

The new-generation ZEISS PRISMO 7/12/7 fortis boasts a highly dynamic rotary table for sharply reduced measuring times, while the ZEISS Acceleration Mode for Aerospace Applications package combines a pair of rotary table measurement options known as ZEISS VAST Rotary Table (ZVR) and ZEISS VAST Rotary Table Axis (ZVRA).

These promote a fresh approach to rotary table applications by boosting the rotary table positioning speed and axis definition speed respectively. Indeed, ZVRA cuts the axis definition period from 60 to 12 seconds – a remarkable 80% time saving on a process performed for each workpiece at Starrag.

Read more here https://rb.gy/3hvp6

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Digitalization and Industry 4.0 are changing manufacturing processes and quality assurance. Customers’ expectations call for both tactile and optical measurement on a coordinate measuring machine.

The multisensor platform translates to ZEISS CONTURA’s compatibility with a variety of sensors from the ZEISS portfolio: sensors on the continuous articulating unit, star styluses or long styluses, optical or tactile, scanning or with single point measurement. ZEISS’ mass technology offers the user maximum flexibility.

Simple Sensor Switch

ZEISS mass technology — where sensors operated on the continuous articulating unit are switched automatically. This applies to all optical sensors as well as the ZEISS VAST XXT and XDT tactile sensors.

During the switch, the continuous articulating unit aligns itself in a 90° position, with the sensor pointing downwards. The unit moves to a free place in the sensor magazine usually attached to the reverse end of the measuring stage, pushes the safety flap back, moves downwards into a groove and releases the magnetic locking mechanism in order to unlock the sensor.

The new sensor is picked back up magnetically: the continuous articulating unit moves backwards and opens the safety flap, moves downwards and retrieves the sensor. On the sensor holding plate sits three cylinder-shaped rollers which ensure the counterpart is precisely positioned.

Despite after frequent switches, the sensor reproducibly remains accurately positioned. The sensor bracket minimises measurement uncertainty; giving users the assurance of table accuracy. Its high repetition accuracy during the sensor switch, eliminates sensor recalibrating. With the automatic exchange happens within seconds, ZEISS mass technology offers an enormous productivity boost saving time and cost.

The continuous articulating unit and tactile probes from ZEISS VAST XT gold series, are attached to the ZEISS CONTURA via a dovetail mechanism. This is a groove which the counterpart on the sensor or on the continuous articulating unit is pushed into and whose shape and precise processing disallow deviations.

The technician loosens a screw and pulls the sensor or the continuous articulating unit out of the groove and replaces the new sensor; completing within seconds. However, a repeated calibration is crucial during a sensor switch and useful when using an active tactile sensor such as ZEISS VAST XT gold which offers high measuring accuracy, short measurement times and long stylus lengths.

All other sensors – passive, tactile and optical – are ideally operated on the continuous articulating unit – with all the advantages of the automatic sensor switch of ZEISS mass technology.

Read more here —–> https://t.ly/Cjpg

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The post ZEISS CONTURA With Mass Technology: Versatility In Focus appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Racing places high demands on engine makers – also regarding measuring technology. At its Bruck site Pankl Racing Systems therefore replaced almost manual measuring equipment with ZEISS measuring machines and saved up to 80% of measuring times.

Pankl Racing Systems AG is headquartered in Kapfenburg, Austria, specialises in lightweight components designed to withstand extreme mechanical stress. The company has around 1150 employees around the world who develop, produce and distribute engine and drive systems, as well as chassis parts for motorsport, luxury cars and helicopters.

Pankl manufactured its first connecting rods for motorsport back in 1985. Today, the company’s racing division is the market-leading supplier of engine and drive systems.

The Challenge: Demanding Requirements, Complex Measurement

“Lighter, more reliable and better quality,” says Mario Pichler, Head of Quality Assurance at Pankl Engine Systems, describing the constantly growing demands of Formula 1 motorsport teams on engine components. The engineers at Pankl are therefore tasked with designing parts so that they are as light as possible, yet able to withstand extreme forces on the track: “It is often a thin line between weight and sustainability,” says Pichler.

To push the boundaries of technology, a lot also has to be measured – not least during the production process. Until a few years ago, Pankl mainly used manual measuring equipment for these in-process measurements.

“This took a lot of time and was largely dependent on the skills of the employees,” remembers Pichler.

Read more about it here —–> https://t.ly/51fM-

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The post ZEISS Reduces Measurement Time By 80% appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Since December 2020, MRB Guss GmbH Herzogenburg has been assuring the quality of iron castings with the ZEISS BOSELLO MAX 450kV machine. With this X-ray inspection machine, the company is able to guarantee the quality of the castings faster and more comprehensively.

These help the firm produce more efficiently and attract new customers. In the composition hall of MRB Guss GmbH, 12 to 13 tonnes of metal are melted in two medium-frequency ovens in tandem processing every hour.

With the volume of material, the red-hot molten mass from the holding furnace is poured several times an hour into a huge temperature-resistance treatment and transportation container (GF converter), which is then mounted onto a forklift. This happens so precisely that not a single drop of the approximately 1,530 deg C hot mass falls to the ground.

Before the operator drives the hot load to the casting plant, he inspects the temperature for quality purposes using an approximately 2 m long measuring probe. Afterwards, he adds pure magnesium or a master alloy to the reaction chamber.

The ensuing exothermic reaction, where the magnesium evaporates and the melted mass desulferizes and amalgamates, creates a fireball that rises from the so-called converter, lasting around a minute. Following this infernal noise, the forklift driver moves forward and dumps the mass for the cast iron together with ductile iron into the casting furnace at the molding plant.

Read more here —–> https://t.ly/c81l

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Given the construction of electric powertrains differs significantly from that of combustion engine vehicles, companies are being forced to adapt the production and assembly of critical electric vehicle components as well – with a focus in eMobility precision.

Achieving more power, less weight and longer range are important targets in the design and construction of electric vehicles. At the same time, manufacturers are faced with the question of how to manufacture electric powertrains efficiently.

Flexible Quality Solutions

Production requirements are bringing about changes to the traditional dimensional measurement of components of the electric motor. While tolerance margins are in fact widening in some cases, production is also complicated by limited accessibility and a high number of properties.

New critical requirements for weld seams, such as the need for them to be free of defects, and even the thickness characteristics of impregnation coatings are likewise important contributors to the difficulty of manufacturing electric engines, which can make eMobility precision more challenging.

While mechanical processes such as milling, rotating and grinding prevail in the manufacture of combustion engines, the predominant methods used in the production of electric motor stators are punching, bending, welding and impregnation. This has implications on the quality assurance process.

Read more here —-> https://rb.gy/0mpqa7

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Up to 400,000 motorcycle chassis components are produced annually at by 170 employees at VMG Dambauer in Vöcklabruck, Austria. Each individual part has to fulfill rigorous quality requirements given it concerns people’s safety.

In order to identify good and bad parts swiftly and accurately, the company relies on the 2D Xray device ZEISS BOSELLO MAX. Its excellent image rendition made it easier for the staff at this aluminum foundry to make the right decision.

Demand For Quality

Quality demands for components in the automotive industry are extremely high. There is perhaps no better example for that than the chassis parts for motorcycles, such as the wings of the rear wheels and the wheel hubs.

Whether during acceleration or going around a curve, these parts endure continuously high forces throughout their entire product life cycle. A breakdown of material due to undiscovered defects would most likely have drastic consequences for both user and machine.

End-customers therefore trust that the manufacturers of their choice will do everything in their power to install flawless components into the product. In order not to erode customers’ trust, manufacturers demand the highest possible standards in quality assurance from their suppliers — without exceptions or compromises.

Read on for more —-> https://rb.gy/g5rwq7

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The Volkswagen plant in Salzgitter manufactures important components for the new APP 310 electric drive destined for the VW ID.3, including an innovative hairpin stator. To assure the quality of this sophisticated engine design, ZEISS worked collaboratively with Volkswagen(VW) to develop a convincing measuring solution.

The VW ID.3 is the first-ever vehicle to be designed purely as an electric car. This compact model went into production in 2021, with up to 500,000 units expected to roll off the factory floor in Germany. In addition, plans to set up more production plants in other countries are already in place.

The Challenge >> https://bit.ly/3O0BWdD

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The post E-Mobility: ZEISS Accelerates Volkswagen’s EV Production appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.