9 rue Alfred Kastler - BP Nantes Cedex 3 - France Phone : +33 (0) website :

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1 9 rue Alfred Kastler - BP Nantes Cedex 3 - France Phone : +33 (0) info@systemplus.fr - website : January Version 1 Written by: Sylvain HALLEREAU DISCLAIMER : System Plus Consulting provides cost studies based on its knowledge of the manufacturing and selling prices of electronic components and systems. The given values are realistic estimates which do not bind System Plus Consulting nor the manufacturers quoted in the report. System Plus Consulting is in no case responsible for the consequences related to the use which is made of the contents of this report. The quoted trademarks are property of their owners by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 1

2 Table of Contents Glossary Overview / Introduction Executive Summary Comparison of the Analyzed LEDs Reverse Costing Methodology GW5BTF27K00 2. Physical Analysis About the Physical Analysis Physical Analysis Methodology Package Characteristics Package X-Ray Package Connection Dam and Fill Phosphor LEDs in the package Package synthesis Semiconductor Die Patterned Sapphire Substrate Epitaxial Structure Structure Passivation Cathode Anode Active Layers GaN die Blue LED Structure 3. Manufacturing Process Flow. 39 LED Die Process Flow Description of the Wafer Fabrication Units 4. Cost Analysis Synthesis of the Cost Analysis Yields Explanation Yield Hypotheses LED Front-End Cost Front-End : Epitaxy Hypotheses Front-End : Epitaxy Cost Front-End : Epitaxy Cost per Steps Front-End : Other Front-End Cost Front-End : Other Front-End Cost per Steps Front-End Cost per Equipment Family Front-End Cost per Consumable Family Dies per Wafer & Probe Test Back-End 0 : Probe Cost Back-End 0 : Dicing Cost LED Wafer & Die Cost (FE + BE 0) Back-End 1 : Packaging Hypothesis Back-End 1 : Packaging Process Flow Back-End 1 : Packaging Cost Details Back-End 1 : Final Test Cost Component Manufacturing Cost (FE+BE0+BE1) Cost Analysis Evolution 5. Estimated Manufacturer Price Analysis 70 Price definitions Manufacturers financial ratios Binning Impact on Manufacturing Price Ideal manufacturer Price Manufacturing Price with Binning Yield Conclusion by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 2

3 Package X-Ray Anode Ceramic substrate Optical view of the LED module Phosphor limit Blue LED die Cathode Plan view X-RAY image shows the 45 blue LEDs. No resistor or protective diode are used in this LED module by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 3

4 UV view Optical view under UV light : the 45 blue LED are visible 2010 by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 4

5 Wire bonding SEM views : wire bonds in gold of 25µm of diameter. Ball bonds on the LEDs and stitch bonds on the substrate by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 5

6 Semiconductor die Optical image of one LED 2x Protective diodes, 420x420µm SEM view : dimension 500µm x 250µm = 0.125mm² 2010 by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 6

7 Cathode SEM top view : N-GaN electrode SEM cross-section view : Gold Bump Gold electrode 1µm 2010 by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 7

8 Anodes SEM tilt view : P-GaN electrode Gold Bump The anode and cathode have the same structure. A gold layer of 1µm is deposited by lift-off on the GaN. A passivation layer of 0.13µm of SiO2 is deposited and patterned. Gold electrode 2010 by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 8

9 LED Die Process Flow 1/ by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 9

10 LED Front-End Cost 2010 by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 10

11 Front-End : Other Front-end Cost per Steps 1/ by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 11

12 Front-end Cost per Material family Details of the material cost per step are given in the Excel Spreadsheet. Front-End cost per Material Family 2010 by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 12

13 Component Manufacturing Cost (FE+BE0+BE1) The component cost is between $xxx and $xxxx according to yield variations. The blue LED cost represents 82% of the total manufacturing cost. It includes the costs of Front-End and Back-End level 0 (Probe test & Dicing). The packaging cost represents 14% of the total manufacturing cost. Final test cost and yield losses represent 4.6% each of the total manufacturing cost. The Back-End level 1 (BE 1) includes the steps Packaging & Final Test by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 13

14 Conclusion Reverse costing analysis represents the best cost/price evaluation given the publically available data, completed with industry expert estimates. These results are open for discussion. We can re-evaluate this circuit with your information. Please contact us: 2010 by SYSTEM PLUS CONSULTING, all rights. reserved. Sharp Zenigata LED GW5BTF27K00 Warm White LED 14