Moving into pilot production for world-leading 2nm logic chips

Rapidus was founded to accomplish an extraordinary feat, which is to commercialize 2nm semiconductors. When we do this, it will have a major impact and benefit on the manufacturing industry in Japan and around the world. In this interview, CEO Koike shared his views, formed over the past 2.5 years since the company’s founding in August 2022.

We have progressed steadily without a single day’s delay

――All employees have worked as one team toward the launch of the pilot line.

The chip we are trying to produce has an unprecedented structure called GAA (Gate All Around) that helps to realize the ultra-fine precision required for 2nm semiconductors. In May 2021, IBM published its basic research on the GAA-based 2nm process node developed through many years of research. However, it has not progressed to mass production.

Seeing it as an opportunity, we sent about 150 engineers, mainly those with years of experience in semiconductors, to IBM’s R&D base in New York to develop technology for practical applications. Many of those responsible for advanced technology there returned to Japan to start the pilot production.

――What hurdles did you face throughout from basic research to practical applications?

Firstly, we are faced with a lot of technical challenges and issues, such as how to develop technology that can realize a complex 3D transistor structure and how to combine different materials and compositions.

Secondly, this pilot line alone contains over 200 new, state-of-the-art machines. In particular, EUV lithography systems, which provide key functionality for our process, have never been part of mass-production in Japan.

Given this, the engineers currently working in New York are getting hands-on opportunities to learn about the EUV lithography systems to promote research. Moreover, since Belgium’s IMEC has been jointly researching EUV technology with ASML, we sent engineers there to conduct research in this field.

We are dealing with many technical challenges and issues, and to be honest we’re encountering many obstacles. However, thanks to the enthusiasm and efforts of everyone involved, we are moving forward by taking steady steps and proceeding with the pilot production that’s about to begin.

Build the ecosystem to deliver pioneering chips two to three times faster

――Isn’t Rapidus also known for its rapid development?

The first thing I would like to highlight is that, in addition to the fast-processing speed, for all processes we apply single wafer processing, which enables us to capture a large amount of production data.

Furthermore, the chip industry currently divides the processing into three distinct parts: development/design process, pre-process and post-process. There are key technologies and established experts associated with each part. A challenge is that as the chip industry as a whole becomes more sophisticated, longer lead times will be necessary.

To address this, we are creating an unprecedented, all-new business model and ecosystem by combining all three processes and advancing development through intense collaboration with leading expert companies.

When the new ecosystem is realized, we will maximize the benefits of AI to quickly analyze production data captured from sensors and other sources. This will enable us to swiftly feed the data to semiconductor design companies to accelerate their chip design and development.

As a result, we expect the overall development lead time to be dramatically reduced. To be more precise, development will be two to three times faster than the current speed.

Not just a manufacturer, but a spirited team ready to tackle tough challenges

――Currently, 700 people work for Rapidus. Do they have any unique traits?

What all employees have in common is that they have been given a mission to create world-leading technologies and products. They are truly the type of people who are thrilled to be engaged in such kind of work. You might describe them as individuals who are eager to take on tough challenges and full of passion and energy.

Another trait is that we employ many older professionals. This is because many young engineers who played key roles in the late 1980s and 1990s, when the Japan’s semiconductor industry was once at its peak, have come to Rapidus to help realize leading-edge chip manufacturing. Japan used to be one of the world’s largest chip-producing countries, so there are many engineers who are well versed in not only basic technology but also mass-production technology.

――Please tell me about your communication style.

I’m a go-getter type of personality, always looking for new challenges. So, I’m often in the frontline watching what initiatives are being taken there. I encourage honest and open communication through active dialogue with our frontline workers.

The challenge we are facing is unprecedented, so every member is expected to make individual contributions, but more importantly, to contribute as part of a team. To foster teamwork, we, among other things, schedule milestone events and organize all-hands meetings for all employees.

Teamwork and collaboration are pivotal for Rapidus to develop an ecosystem for the future. We’re not aiming to become No. 1 for our own benefit, but to contribute to the global chip ecosystem.

Do not act like a component provider.
Truly understand what customers really want.
Visualize what the final delivery should look like before planning and designing.

These are the things I tell my employees when I have the opportunity. I strongly feel that the spirit of co-creation is indispensable.

――Please share some examples of excellent teamwork.

Last year, we had an company-wide celebration to commemorate the delivery of EUV lithography systems to the IIM-1, located in Chitose-city, Hokkaido. Since it happened on Christmas Day, a cake shaped like the EUV was distributed to not only IIM-1 members, but also to all employees in other locations. Of course, the individual cakes weren’t as big as the 10-meter wide EUV (laughs).

――Could you please make your final remarks.

Japan’s strong roots in manufacturing will enable it to overcome challenges, such as reduced momentum and market presence in the semiconductor industry in recent years. So, when our business becomes successful, it will invigorate all industries in Japan—not to mention across the world—because chips are essential to virtually every industry, just as rice is an essential staple to our diets.

We will continue to work together as one team toward our meaningful and rewarding goal.