Dr. Maksym Plakhotnyuk, CEO, ATLANT 3D
With global demand for semiconductors showing no signs of abating, the industry remains somewhat of a paradox. On the one hand, semiconductors are vital to cutting-edge eco-friendly developments like electric cars and environmental sensors. But on the other, the current impact of the manufacturing process on the environment, and the size of its ecological footprint, are untenable.
This is especially true when considering the toxicity (heavy chemical use) of the process which, in addition to hurting the environment through the release of harmful particles and gases, also can have a direct negative impact on the health of workers and surrounding communities. Several commonly used chemicals are classified as carcinogens, while others are known to cause burns, respiratory problems as well as pose risks to reproductive health. In response, semiconductor manufacturers typically have stringent safety procedures in place including personal protective equipment (PPE) and ventilation systems, and must adhere to strict government standards regarding exposure monitoring and limitation.
New advanced manufacturing techniques hold promise
New advanced manufacturing techniques can help create more environmentally- and human health-friendly products, particularly by reducing chemical use and exposure. One technique is ATLANT 3D’s advanced atomic layer manufacturing technology, known as direct atomic layer processing (DALP®).
This technique accelerates processes along the entire value chain of manufacturing advanced micro and nano-devices. DALP® represents a major breakthrough in the atomic layer deposition (ALD) arena by combining the meticulous precision of materials deposition with accelerated deposition rates, all while operating in ambient conditions. DALP® has revolutionized prototyping, turning traditionally lengthy processes into rapid, precise operations. Key benefits include accelerated development cycles, atomic-level control for complex prototypes, versatile material and surface adaptability and cost-reductions due to increased efficiency.
Zero waste
But when it comes to reducing environmental and human health impacts, the true value of DALP® lies in the fact that it allows semiconductor manufacturers to skip a number of time-consuming steps (such as creating vacuum environments through time-consuming purge steps or eliminating cross-contamination, which again involves the use of chemicals). Simultaneously, manufacturers can accomplish a lot more in the individual steps that are taken.
By being more accurate and efficient, DALP® represents a sustainable, environmentally-conscious technology enabling zero-waste advanced manufacturing of nano- and microelectronics. Not only does this drastically reduce material waste, but it minimizes harmful emissions and energy requirements as well as limits chemical exposure. Ultimately, this allows semiconductor manufacturers to work faster, smarter and more ethically, while making it easier to comply with government standards.
Besides enabling a more environmentally- and human health-friendly approach, DALP® is good for society in other ways. It introduces a new way of working to developing countries and can help them manufacture new products and services, enhancing valuable economic opportunities. DALP® can also be used to create sensor-based products that further promote environmental and human health, like clean energy and clean water.
As a testament to the power of DALP®, ATLANT 3D recently won the semiconductor category of the Extreme Tech Challenge (XTC) 2024 at CES. As the world’s largest startup competition for entrepreneurs addressing global challenges, XTC showcases innovative tech founders addressing the United Nations’ Sustainable Development Goals (SDGs) list. Winning this award validates ATLANT 3D’s commitment to innovation and sustainability in the semiconductor industry.
As the magical materials powering advanced electronic gadgets, semiconductors are increasingly vital to our modern world. But the manufacturing process as we know it still has an outsized ecological impact. While this fact has been somewhat overlooked in recent years as the industry has prioritized supply security over environmental concern, the issues of climate and human health are becoming more urgent in light of global production-boosting initiatives. New advanced manufacturing techniques such as DALP® will be key to being able to satisfy demand while also protecting the environment and public health.
