Reduce SWaP with Multi-physics Aware 3D Heterogeneous Package Design for A&D

We sat down with Marc Swinnen, product marketing director at Ansys and Kenneth Larsen, 3DIC solution director at Synopsys, to learn the importance of SWaP (Size, weight, and power ) and the benefits of using best-in-class solutions from Ansys and Synopsys for aerospace and defense systems.

Marc Swinnen:

Size, weight, and power – SwaP – have been an important consideration in aerospace and defense systems for decades. With each successive semiconductor node and generation, the complexity of chips increases substantially, and, often, the space in which it can process decreases, especially in challenging environments like those on the sea, in the desert, or up in space.

This increasing integration density has been a great benefit for realizing more capable and more portable systems but has also raised some serious Multiphysics challenges. The famous Moore’s Law is key to increasing the density of digital logic on silicon, but a complete system involves many more interactions along many different physical mechanisms.

Kenneth Larsen:

With 3D Heterogeneous Integration, it is possible to take an entire high-performance computing rack and shrink all computation, interconnect, and memory into a small package fitting in a backpack, or nose cone of a fighter, perhaps implanted one day. 

It has been more than 55 years since Moore's law came into being. We know that the geometric size of components on a chip cannot be reduced without a limit, meaning that one day, the number of transistors that can be integrated on a chip will reach the limit. We are not at the limit, but each technology shrink takes longer, at an enormous cost.

From a cost perspective splitting up a large chip into smaller chiplets, optimizing each chiplet in their most suitable technology and material, and combining them in a small semiconductor package is advantageous.  Smaller chips tend to yield better, chiplets can be reused in different applications, and with 3D Heterogeneous Integration, the various chiplets can be stacked, creating new possibilities in A&D designs.

Kenneth Larsen:

There are multiple concerns that 3DHI solutions need to address. In summary, they need to address (1) the computing performance and heat dissipation per unit volume, (2) the latency/bandwidth of the interconnect, (3) the environmental concerns, including power dissipation in extreme environments, and (4) application-specific capabilities like security and safety.

Regarding compute/volume, 3D packages have a significant advantage over traditional 2.5D and 2D designs due to die stacking using direct bonding and through-silicon vias bonding approaches, high-bandwidth, ultra-short latency, and incredibly power efficient bit transfers due to the proximity of the chiplets. Synopsys tools are unique (see Figure 1) because they can do multi-chip and package design together, along with system and chiplet signoff analysis. This is unlike legacy EDA solutions that start from the PCB realm.

Marc Swinnen:

Environmental concerns are a key challenge for our A&D customers who have high-performance semiconductors in very compact form-factors or that need to dissipate heat in challenging environments like space. The joint Synopsys-Ansys solutions address thermal management from chip through package to full system simulation. 

This also includes access to Multiphysics solvers like fluid dynamics simulation to establish the impact of fans and heatsinks, or mechanical solvers to predict thermo-mechanical stress and warpage of the multi-die package.

And with the ultra-high-speed signals in these advanced platforms, other physical design considerations like electromagnetic interference and coupling are absolute must-do analyses. With these joint solutions, customers get the state-of-the-art in 2.5D or 3DIC design and Multiphysics co-simulation of chip and package.

A&D companies build and deploy advanced systems that exceed mission requirements and challenging application demands, including security, safety, longevity and reliability in harsh environments from sea to space. Synopsys provides comprehensive solutions across the development lifecycle, including design and verification tools, software integrity solutions, IP, and services. Synopsys solutions enable our customers to automate silicon, optics, and software development, optimize design for silicon manufacturing, and digitally validate a design, prior to the creation of costly physical prototypes.

Synopsys’ US-based services are ITAR capable for radiation-hardened space designs. Our collaborations with Defense Prime Contractors, the Department of Defense, the Department of Energy and other agencies has enabled unique innovations in areas like security, AMS emulation and superconducting electronics.