Within fabrication plants, it takes about three months to manufacture hundreds of microchips from a single wafer of pure silicon using light and significant quantities of electricity, water, and hazardous chemicals.

Watch a tour of an integrated circuit fabrication plant

Explore the protocols in place to ensure clean rooms have no dust to jeopardize the integrity of silicon wafers as they are transformed into working microchips. Layering, photolithography, etching, and chemical vapor deposition are shown alongside digital visualizations.

Lasers help build the layers of circuit components in microchips

During the photolithography process, light is projected through a blueprint onto a light-sensitive chemical layer on silicon wafers, etching patterns that become transistors through a series of successive reactions. These processes require significant electricity, as only about 2% of photons reach the wafer.

Microchip fabricators create light by heating tin droplets to over 220,000 Kelvin

Every second, lasers strike 50,000 droplets moving at 250 kilometers (155 miles) per hour, vaporizing the tin in supernova-like miniature explosions that produce ultraviolet light. Knowing this light will spread via diffraction as it passes through a filter during manufacturing, designers reverse-engineer the filter design based on the required final microchip pattern.

Silicon must be 99.9999999% pure to be used in creating microchips

After the mined quartz is processed in an electric-arc furnace to remove oxygen from the silica, it undergoes the Siemens process, where it is bathed in hydrochloric acid. The liquid produced in the reaction undergoes multiple distillations to produce ultra-pure silicon in the end.

Photolithography etches circuit components into a semiconductor wafer

A high-energy laser is fired at molten tin droplets, turning them into plasma that releases the ultraviolet light needed to burn the wafer's photoresist layer. A mask controls what parts of the wafer are etched for subsequent chemical processing.

Semiconductor chips are electronic devices that store and process information

They can contain billions of microscopic switches on a chip smaller than a fingernail. An article provides a quick overview of how the devices work and how they’ve provided the backbone of the computer age.

Solar panel manufacturing begins with silicon extracted from sand

The silicon is purified and shaped into wafers less than 0.2 millimeters thick, coated and connected through a criss-cross pattern of narrow and wider metal, followed by multiple rounds of lamination before bonding to a weatherproof panel.

Some graphics processing units advertised under different product names, such as Nvidia's RTX 5070-Ti and RTX 5080, are identically manufactured microchips with different defect counts.

A simple explanation of semiconductors

Semiconductor chips are electronic devices that store and process information. Today they can contain billions of microscopic switches on a chip smaller than a fingernail. The article provides a quick overview of how the devices work and how they've provided the backbone of the computer age.

An integrated circuit combines major circuit components onto a single device

Before 1958, these components were fabricated separately before manual assembly, introducing human error, delays, and higher costs. The invention of the IC laid the foundation for automated manufacturing, miniaturization, and improvements to speed and energy efficiency.

There is a limit to how small transistors can become because they rely on being able to allow or block the flow of electrons, but quantum effects allow electrons to leak through these barriers, generating heat, current loss, and potential data errors.

Watch a tour of a battery manufacturing gigafactory

Inside Contemporary Amperex Technology Limited's facility, China's largest EV battery manufacturer uses slurry mixing, "jelly rolling," electrolyte injection, and other techniques and equipment to transform raw metals such as lithium and magnesium into approximately 2.2 million electrochemical cells daily.

Since computers rely on the distribution of electrons in microchips to represent binary code, cosmic rays and ionizing radiation from radioactive elements can introduce software errors by detaching electrons from atoms.

Chip-based 3D printers can be pocket-sized and involve no moving parts

Researchers have demonstrated a proof-of-concept version of a chip-based 3D printer that emits visible light onto light-sensitive resin to construct solid shapes. The technology may provide a portable, low-cost solution for future, small-scale fabrication needs.

During manufacturing, lithium-ion and alkaline batteries are tested for short-circuiting

Lithium-ion batteries are made by manufacturing anodes, cathodes, and electrolytes via chemical processes, assembling these components into cells, and enclosing multiple interconnected cells within a protective casing. Disposable alkaline battery production involves filling steel containers with preforms—rings of powdered cathode material—paper-based separators, electrolyte solution, and an anode gel.

Transistors are the foundational components of integrated circuits and microchips and manage the processing of electronic signals by controlling the flow of electricity.

How TSMC, the world's biggest chip manufacturer, makes money

Taiwan Semiconductor Manufacturing Company has more than 500 clients across the world, but none are bigger or more consequential to its business than Apple. The iPhone maker accounts for 25% of TSMC's total revenue. TSMC controls more than 60% of the global market share in semiconductor manufacturing. Dive into the economics and outlook of this important company here.

Watch a microscopic tour of an Intel i486 microprocessor

Released in 1989 for $950, the chip contained over a million transistors on a piece of silicon the size of a postage stamp, much less packed than today’s chips. The layering of components makes the chip resemble a network of structures—not unlike a city—when zoomed in.

Clean energy technologies are more mineral-intensive than burning fossil fuels

Solar panels use silver due to its high conductivity, hydropower plants use chromium in their steel alloys, and geothermal plants need titanium to withstand abundant heat and pressure. Lithium—used in energy storage—is expected to see over 500% increased demand from 2020 to 2025.

During wash cycles, synthetic fabrics shed millions of plastic microfibers, making them a significant source of global microfiber pollution.

Data centers can be kept cool by circulating fluid over plates atop high-temperature components or by submerging equipment in non-corrosive oil that does not conduct electricity.

Shenzhen, China is known as the 'Silicon Valley of Hardware'

The "Silicon Valley of Hardware" is a major manufacturing hub. This WIRED documentary from 2016 does a deep dive into how this Chinese city's practice of copycat manufacturing alongside its innovative culture has made it China's own Silicon Valley.

Synthetic diamonds may be used to cool microchips

The strong carbon bonds in diamonds efficiently carry vibrations, allowing them to conduct heat several times faster than copper, a metal commonly used in heat sinks. AI and high-performance computing have pushed researchers to investigate alternative materials for cooling solutions.

Microreactors are 100 to 1,000 times smaller than traditional nuclear reactors but still generate thermal energy for heating or electricity by splitting atomic nuclei.

Photonic integrated circuits use light instead of electrons within circuit components

Instead of processing electric signals, photons in the visible and near-infrared serve as optical signals between chips made of electro-optical crystals. PICs can enable lower power consumption and heat generation by eliminating the friction from electrons moving along wires.

Watch how metals are extracted from rechargeable devices during recycling

Recyclable batteries found in cars, phones, power tools, and other electronics contain lithium, cobalt, nickel, and other precious metals, whose reuse generates 70% fewer emissions than during their initial mining. Upon shredding these devices, a filter press squeezes the pieces through a proprietary fluid, which separates them for future reuse.

Glass can be endlessly recycled without losing quality

Sand from specialized mines is thoroughly cleaned and melted at more than 1,600 degrees Celsius before being poured onto liquid tin and evenly spread out to form glass sheets. Some factories are designed to reprocess 100% of glass scraps created when cutting glass with diamond-tipped blades or lasers.

Additive manufacturing consists of seven different process categories

Although 3D printing has become synonymous with the term, objects can be fabricated without filaments of hot plastic or light-sensitive powders. For example, during sheet lamination, ultrasonic waves—high-frequency vibrations—can join metal sheets by creating molecular bonds through friction.

Flexible integrated circuits can be built from carbon nanotubes and elastic materials

Stanford researchers arranged the nanotubes in fishnet-like networks that allow deformation without loss of function. The stretchable ICs have been shown to power micro-LED displays and may be used in smart clothing.

Microchips in payment cards improve security by generating unique transaction codes

Magnetic strips store unchanging data that is easily cloned, but microchips act as miniature computers that encrypt sensitive data. They also resist fraud by creating data unique to each transaction, preventing duplication.

Taiwan's semiconductor dominance

Taiwan is a leader in the production of semiconductors. In the event of a Chinese invasion, what happens if China controls the supply chain for these indispensable materials? How would it affect the United States as well as other nations already dealing with disruptions due to Russia's invasion of Ukraine? This blog explores these questions and more.

NASA purchased about 60% of all integrated circuits from 1961 to 1965

The US government adopted the new technology to support the development of the Apollo Guidance Computer, which would help astronauts fly to the moon. This drove manufacturing up and costs down, setting the stage for the modern computing era.

When users prompt AI chatbots, both cooling systems that support data centers and power plants that rely on steam cycles to generate electricity for data centers contribute to water use.

All clean energy technologies rely heavily on critical minerals

Although many of these minerals have been used for decades, such as copper in electrical wiring, the accelerating demand for them has strained existing extraction and processing systems. Supply chain disruptions for these materials may delay and increase the cost of transitioning to solar, wind, hydroelectric, and geothermal power.

Watch how graphics cards are fixed in a workshop by replacing faulty components, including graphics processing units and memory, located atop printed circuit boards.

Transistors in traditional computers are physically limited to atomic scales

As computer parts shrink, transistors—tiny switches that control the path of electrical signals—become obsolete because electrons can quantum tunnel through switch barriers. This makes quantum computers, which take advantage of quantum effects, an enticing alternative.

Although PFAS, or forever chemicals, are intentionally designed to be extremely stable and long-lasting because of their strong carbon-fluorine bonds, these bonds can be broken by heat, plasma, and supercritical water.

Microplastics are entering human food chains through carrots, wheat, and other foodstuffs grown in farmlands fertilized by sewage sludge.

The world's first commercial biological computer combines neurons with silicon

Australian start-up Cortical Labs unveiled CL1, a hybrid chip designed to help scientists study brain function in real-time. The 800,000 lab-grown neurons on the chip are kept viable for six months via a built-in life support system.

Methods for disposing of nuclear waste include melting it into a liquid to create glass, dumping it into graphite blocks, storing it in lead-lined rooms, and submerging it in deep pools of water.

Multi-material 3D printing produces filament waste if only one nozzle is used

When swapping between colors or materials in a fused deposition modeling system, a considerable amount of filament is purged from the nozzle before introducing a new filament. Filament extruders can create new filament from purged elements, but the device combines colors and produces filaments of inconsistent diameter.

As of 2022, only about 5% of lithium-ion batteries are recycled globally

Traditional recycling methods have been inadequate for lithium batteries, prompting manufacturers to explore more sustainable battery designs, alongside robotic disassembly and ultrasonic techniques to improve recycling rates. Studies have shown that mining for new lithium requires significantly more water and energy than recycling and results in declining vegetation near mines.

Indigenous women crafted the integrated circuits for the Apollo Guidance Computer

Applying their blanket-weaving skills, over 1,000 Navajo women in New Mexico were hired to connect circuit components in intricate patterns using a microscope. Outside Boston, "rope mothers" at the Raytheon facility wove the AGC's core memory using threaded metal wires.

The prevalence of microplastics came from plastic’s affordability and versatility

Microplastics' durability and overuse have led to massive pollution that overwhelms the planet's ecosystems. Avian, terrestrial, and marine life have been observed to contain microplastics in their bodies, but reverting to paper, cotton, and other materials in manufacturing also brings environmental challenges.

Nearly all of China's construction sand is artificial

Roughly 50 billion tons of sand are used in construction every year, mostly extracted from oceans, beaches, and rivers. To avoid depleting natural sand deposits, China crushes rocks and used materials to create an artificial sand, which it uses in 80% of its construction projects.

Stereolithography uses light to fabricate objects in layers via chemical reactions

Specific locations in a tank of light-sensitive liquid resin are exposed to projected light, causing them to cure onto a build platform. The resulting cross-section of hardened plastic is moved slightly away from the light source, exposing it to resin once more, and the process repeats to produce successive layers.

Integrated circuits come in digital, analog, or mixed types

Each type can be further divided based on application, technology, and integration level. Digital ICs are used in computer memories and microprocessors, while analog ICs process continuous signals within sensors, including temperature, light, and sound.

Graphics processing units, which process large amounts of data in parallel, have become the foundational hardware for AI systems that rely on hardware capable of processing millions of text parameters simultaneously.

Lasers, semiconductors, medical imaging, and atomic clocks rely on quantum mechanics

Semiconductors, crucial in electronics, operate based on quantum superposition. Lasers use stimulated emission, a quantum process, and MRI machines leverage the quantum spin of hydrogen atoms for imaging. Atomic clocks measure time with unprecedented precision using quantum transitions.

Your iPhone started with a Cold War secret

Silicon Valley wasn't supposed to happen. A stretch of California orchard land somehow became the place that built the modern world: chips, PCs, the internet, the smartphone, and now AI. But the real story isn't the garage myth. It's a series of contradictions hiding in plain sight.