Die-Level Transformation From 2D Shuttle Chips to 3D-IC With TSV for Advanced Rapid Prototyping Methodology With Meta Bonding

3D-IC technology, it may be more appropriate to refer to this as TSV (Through-Si Via) formation technology, has been maturing year by year and is increasingly utilized in advanced semiconductor devices, such as 3D CIS (CMOS Image Sensor), HBM (High-Bandwidth Memory), and SRAM-on-CPU (named 3D V-Cache) devices. However, the initial development costs remain prohibitively high, largely due to the substantial investment required for TSV formation at the wafer level. Meanwhile, conventional System on a Chips (SoCs) are transitioning from Fin-FET to GAA (Gate All Around) using the latest beyond 3-nm technology nodes, incorporating extreme ultraviolet (EUV) and other cutting-edge techniques. Meanwhile, the academic community is establishing an environment conducive to the utilization of nodes ranging from legacy 180 nm to 7 nm, making it feasible for designers to obtain 2D IC chips with their novel architectures at a reduced cost. Despite these advancements, foundry shuttle services employing TSV are still almost impossible to utilize, and performing proof of principle and functional verification using 3D-ICs remains extremely challenging. This article introduces recent advancements in technology that can transform 2D-ICs into 3D-ICs using shuttle chips for Multi-Project Wafers (MPWs) at a small scale to a large scale. This article mainly focuses on discussing the facilitation of die-level short-TAT (turnaround time) 3D-IC fabrication with key elemental technologies of multi-chip thinning and TSV/microbump formation. In addition, the effectiveness of Meta Bonding, such as fine-pitch microbump and direct/hybrid bonding, is described for future high-performance 3D-IC prototyping.