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