Advanced Manufacturing Technologies for Extending Microprocessor Availability
Proactive Solution to Military MicroprocessorAvailability and Affordability
Manufacturing Science & Technology DivisionEngineering Directorate, RDECOM
Commercial IP Soft Core
Advanced Retargeting/Cloning
On-Demand Chip Processing
On-Demand ASIC Packaging
•Microprocessor Availability Problem
•Overview of Microprocessor Cloning Initiative
•Demonstrate Aviation Application
•Summary
Briefing ObjectivesBriefing Objectives
Advanced Microprocessor Technologiesfor Military Systems
Problem StatementProblem Statement
• Missile Defense, Army Aviation, Tactical Missiles and other key weapon systems face critical microprocessor availability problems– Commercial processor lifecycles ~ 3 - 5 years– Military system lifecycles ~ 20 years and greater
• Current solution options are bridge buys or system redesign– Bridge buys are high-risk due to varying system lifecycles and
quantities. Also requires high up front investment cost and storageconsiderations.
– System redesign is costly due to:– Software is microprocessor specific; software regression testing
always required and is a major cost driver– Simply band aides the problem until next redesign required
Advanced Microprocessor Technologiesfor Military Systems
SolutionSolution• Employ advanced Microprocessor Cloning technologies
– Retargeting/Cloning tools based on commercial intellectual property (IP) soft core transfer and integrated processor design, simulation and hardware/software validation capabilities
• Use of advanced Microprocessor Manufacturing technologies– On-demand Application Specific Integrated Circuits (ASIC) and
Ball Grid Array (BGA) fabrication and robust packaging processes (including RAD-HARD devices) using commercial vendors or TAPO (Trusted Access Program Office)
• Conduct multiple Pilot demonstrations– Optimize IP soft core transfer business cases– Optimize design retargeting cloning capabilities – Optimize ASIC/BGA manufacturing and packaging capabilities– Enable technology insertions in multiple military systems
Advanced Microprocessor Technologiesfor Military Systems
•Prevention of complete CCA/LRU redesign requirements
•Combats market dependencies & enforced technology upgrades
•Better use of limited resources
•Another tool in obsolescence mitigation arsenal
BenefitsBenefits
Advanced Microprocessor Technologiesfor Military Systems
Get to Market Faster and
Typical Product Lifecycle
Stay There Longer!Stay There Longer!
Volu
me
Time
Use of intellectual property processor cores offers a new level of design flexibility and technology independence. The vision is to extend this best commercial practice to
military application.
Advanced Microprocessor Technologiesfor Military Systems
Advanced Microprocessor Technologiesfor Military Systems
• Now you can use a state-of-the-art processor and get the added benefit of long term availability.
• “The independent intellectual property provider market represents one of the most significant, exciting and rapidly changing segments in the entire semiconductor history for future evolution and growth of the overall electronics industry."
Advanced Microprocessor Technologiesfor Military Systems
Using This Technology TodayUsing This Technology Today
Aviation Pilot DemonstrationAviation Pilot DemonstrationPhase 1:• Acquire IP core, conduct design/retargeting/cloning exercises to
establish equivalent microprocessor• Conduct design for manufacturing/packaging exercises
Phase 2:• Synthesize design to technology independent VHDL/Verilog
libraries • Identify manufacturing and test process improvements for high
reliability/low volume die fabrication and ASIC/BGA packaging
Phase 3:• Fabricate processors (die) and package to demonstrate cloning
and improved manufacturing and test processes• Potential to use Trusted Foundry for die fabrication• Validate capabilities at multiple levels: microprocessor, board
level, and full system hardware/software compatibility
Advanced Microprocessor Technologiesfor Military Systems
TAPO Operational Flow
DoD PMAwards Contract
DoD PMAwards Contract
TAPO Establishes Linkage
with IBM
TAPO Establishes Linkage
with IBM
Trusted Access Program Office (TAPO)
Contract Activities
Trusted Access Program Office (TAPO)
Contract Activities
IBM/DoD ContractorGenerate Task OrderIBM/DoD ContractorGenerate Task Order
IBM Fills OrderIBM Fills Order
DoD Contractors/IBMTechnical Exchange
DoD Contractors/IBMTechnical Exchange
TAPOCompletes Admin Duties
TAPOCompletes Admin Duties
DeliverTo Contractor
DeliverTo Contractor
Notify TAPO Notify TAPO
DoD PMIdentifies Rqmts
Program/Contractors
DoD PMIdentifies Rqmts
Program/Contractors
COPY COPY
DoDContractor
DoDContractor
Contractor providesMask Files
IAW Task Order
Contractor providesMask Files
IAW Task Order
DoD PMValidates Task Order
Provides Funds
DoD PMValidates Task Order
Provides Funds
•Use of microprocessor IP cores is becoming mainstream in commercial industry to reduce time to market and increase availability
•Microprocessor Cloning is an enabling technology that can address all military systems
•Program plans and investment strategy built for flexibility and success
•Phase 1 Trade Study in Progress
SummarySummary
Advanced Microprocessor Technologiesfor Military Systems
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