An Economic Comparison of PSM4, PAM, and LR4

Transcription

1 An Economic Comparison of PSM4, PAM, and LR4 Brian Welch

2 Supporters Chris Bergey Luxtera Tom Palkert Luxtera John Petrilla Avago Jon Anderson Oclaro Arash Farhood Cortina Sudeep Bhoja Inphi Scott Kipp Brocade Brad Booth Dell Oren Sela Mellanox David Warren - HP 2

3 Overview Uses Silicon Photonics as a basis for all comparison. Compares costs for all critical components constituting a Silicon Photonics Chipset and module. Silicon Photonics CMOS Light Source(s) Assumes equivalent total volume for either solution Depends on market acceptance and chipset reuse in other markets Compares assembly processes and yields And effects on product costs Comparison to contemporary solutions SR10 and LR4 Result: PSM4 and PAM solutions are approximately 1/5 th the cost of LR4. 3

4 Silicon Photonics Module Design Housing and Mechanical Passive Optics Silicon Photonics Chipset Note: QSFP Shown. Power Consumption of LR4 would likely mandate larger form factor 4

5 Silicon Photonics Chipset BOM Comparison 5

6 Silicon Photonics Building Blocks Silicon Photonics Packaged Light Source 300 mm CMOS 150 mm 300 mm 6

7 PSM4 Area / Count per Wafer Silicon Photonics Area 68 mm CMOS Area 17 mm Light Source(s)

8 PAM Area / Count per Wafer Silicon Photonics Area 62 mm CMOS Area 18 mm Light Source(s)

9 LR4 Silicon Photonics Area Area / Count per Wafer 98 mm CMOS Area 19 mm Light Source(s)

10 Chipset BOM Comparison DPW PSM4 PAM LR4 Silicon Photonics IC CMOS IC Light Source(s) Relative Cost PSM4 PAM LR4 Silicon Photonics IC CMOS IC CMOS Total Area Light Source(s) Uses ½ the number of process steps as full flow CMOS process Hereafter defined as Unity CMOS Cost 10

11 Chipset BOM Comparison Relative Chipset Cost LR4 (no TEC) PSM4 PAM Relative Light Source Cost (Light Source Cost / Unity CMOS Cost) 11

12 Chipset BOM Comparison - Normalized 3.50 Relative Total Chipset Cost LR4 (no LR4 TEC) (with TEC) PSM4 PAM PSM4 PAM Relative Light Source Cost (Light Source Cost / Unity CMOS Cost) 12

13 Chipset BOM Comparison with TEC - Normalized Relative Total Chipset Cost LR4 (with TEC) 3.70 PSM4 PAM Relative TEC Cost (TEC Cost / Unity CMOS Cost) 13

14 Silicon photonics Modules Assembly Comparison 14

15 Module Comparison - BOM Component(s) PSM4 PAM LR4 CMOS Total Light Source(s) 1 (x1) 1 (x1) 4 (x1) TEC(s) (x0.5) Optical Coupler 8 Fiber 2 Fiber 2 Fiber Optical Connector 8 Fiber 2 Fiber 2 Fiber PCB Housing

16 Optical Assembly Steps Alignment of Light Source to IC: Active alignment in seconds (X, Y, θ) Fixation by transparent adhesive Alignment of Coupler to IC: Active alignment in seconds (X, Y, θ) Fixation by transparent adhesive Task Force, Jan /17/2013 Page 16

17 Module Assembly Steps Assembly Steps PSM4 PAM LR4 CMOS Bonding PCB Attach Light Source Attach Coupler Attach Packaging Chipsets into modules incurs a cost adder Due to passive BOM and transformation costs Cost adder can vary due to BOM complexity and assembly steps Duplex vs. arrayed passive optics Number of optical attaches : Processing time / Throughput Housing and test complexity Cost Adder (Un-Yielded) PSM4 PAM LR4 Chipset Multiplier Net Relative Cost (Normalized) Task Force, Jan /17/2013 Page 17

18 Module Assembly Comparison - Yield Total Assembly Yield 110% 100% 90% 80% PAM / PSM4 90% 77% 70% 60% 50% LR4 40% 30% 20% 10% 0% 89% 90% 91% 92% 93% 94% 95% 96% 97% 98% 99% 100% Yield Per Optical Attach 18

19 Module Assembly Yielded COGS Relative Module Cost LR PSM PAM % 90% 91% 92% 93% 94% 95% 96% 97% 98% 99% 100% Yield per Optical Attachment 19

20 Yielded COGS Comparison - Variability Total Cost Variability (Normalized) PSM4 PAM LR4 20

21 From Nicholl_01_0112_NG100GOPTX Consistent with Current Findings 21

22 Comparison to Industry Contemporary Solutions 22

23 Comparison to Industry SR10 per Wafer Total CMOS Area 21 mm Light Source (s) 12x VCSEL Array N/A Photodiodes 12x PD Array N/A SR10 Chipset 23

24 Comparison to Industry = SR10 Relative Cost PSM4 PAM LR4 SR10 Silicon Photonics IC CMOS IC CMOS Total Area Light Source(s) x Array Discrete PD x Array 24

25 Comparison to Industry SR Relative Chipset Cost (sans PD) Relative Chipset Cost Relative Light Source Cost Relative PD Array Cost PAM PSM4 LR4 1x VCSEL Array / Light Source Cost 2x 3x 4x 25

26 Module Assembly Comparison Component(s) PSM4 PAM LR4 SR10 CMOS Total Light Source(s) 1 (x1) 1 (x1) 4 (x1) 1 (12x Array) Discrete PD(s) (12x Array) TEC(s) (x0.5) 0 Optical Coupler 8 Fiber 2 Fiber 2 Fiber 24 Fiber Optical Connector 8 Fiber 2 Fiber 2 Fiber 24 Fiber PCB (CXP MSA) Housing Cost Adder (Un-Yielded) PSM4 PAM LR4 SR10 Chipset Multiplier Net Relative Cost (Normalized) Yielded Relative COGS PSM4 PAM LR4 SR10 At 95% Attachment Yield

27 Comparison to Conventional LR4 LR4 Cost Relative to PAM Cost , , Conventional LR4 Cost Relative to SR10 Cost 27

28 Summary PSM4 and PAM offer significantly lower BOM costs than LR4. Approximately 1/5 th the cost PSM4 and PAM are much less sensitive to assembly yields and supply chain variability than LR4 solutions. Fewer BOM components and Assembly steps PSM4 and PAM are lower cost than contemporary solutions PAM solutions are about 30% lower cost than SR10 Assuming contemporary LR4 is 5x SR10, PAM is approximately 85% lower cost 28