Terawatt fab + chip props

Sources/RealLibrary/Props/ChipLab/BondWireMacro.swift

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+import simd
+import Foundation
+
+/// Bond wire macro display, about 160x scale, 0.4 x 0.1 x 0.2 m: black plinth, silicon die with aluminium pad rows on the
+/// right edge, ABF substrate with gold finger rows, and parametric gold wire loops with squashed ball bonds (neck) on the
+/// die pads and wedge bonds (foot and tail) on the fingers. Alternating wires use the far pad and finger row.
+public struct BondWireMacro: RealAsset {
+    public static let id = "bond-wire-macro"
+    public static let summary = "Parametric gold bond wire loops between die pads and substrate fingers with ball and wedge bonds at macro scale."
+    public static let tags = ["prop", "chiplab"]
+    public static let budget = 10500
+    public static let author = "realityhd"
+    public static let preview = PreviewHint(azimuth: 20, elevation: 25, distance: 0.8, studio: true)
+
+    /// Overall size in meters.
+    public var size = V3(0.4, 0.1, 0.2)
+    /// Wire count.
+    public var wires = 8
+    /// Wire radius (m).
+    public var wireRadius: Float = 0.0020
+    /// Loop height above the pads (m).
+    public var loopHeight: Float = 0.050
+    public var wire: MaterialKey = "metal.gold"
+    public var pad: MaterialKey = "metal.aluminum-brushed"
+    public var die: MaterialKey = "silicon.die"
+    public var dieEdge: MaterialKey = "silicon.die-edge"
+    public var substrate: MaterialKey = "laminate.abf"
+    public var plinth: MaterialKey = "metal.anodized-black"
+    public init() {}
+
+    func flat(_ w: Float, _ d: Float, _ t: Float, _ mat: MaterialKey) -> Surface {
+        Prim.extrude(Shape2D.rect(w, d), depth: t, bevel: 0.0003, bevelSegments: 1, material: mat)
+    }
+
+    public func build(seed: UInt64) -> LODModel {
+        var rng = SeededRNG(seed: seed)
+        var m = Model(name: Self.id)
+        let W = size.x, D = size.z
+        let pl: Float = 0.012
+        m.add(Prim.roundedBox(V3(W, pl, D), radius: 0.003, bevelSegments: 2, material: plinth), Xform(translation: V3(0, pl / 2, 0)))
+        let dieT: Float = 0.016, subT: Float = 0.008
+        let dieX0: Float = -W / 2 + 0.012, dieX1: Float = -0.045
+        m.add(Prim.roundedBox(V3(dieX1 - dieX0, dieT, D - 0.03), radius: 0.0012, bevelSegments: 2, material: dieEdge),
+              Xform(translation: V3((dieX0 + dieX1) / 2, pl + dieT / 2, 0)))
+        let dTop = pl + dieT
+        m.add(flat(dieX1 - dieX0 - 0.002, D - 0.032, 0.0005, die), Xform(translation: V3((dieX0 + dieX1) / 2, dTop + 0.00025, 0), rotation: simd_quatf(degrees: 90, axis: V3(1, 0, 0))))
+        let subX0: Float = -0.02, subX1: Float = W / 2 - 0.012
+        m.add(Prim.roundedBox(V3(subX1 - subX0, subT, D - 0.03), radius: 0.0012, bevelSegments: 2, material: substrate),
+              Xform(translation: V3((subX0 + subX1) / 2, pl + subT / 2, 0)))
+        let sTop = pl + subT
+        let pitch = (D - 0.07) / Float(wires - 1)
+        let xr = simd_quatf(degrees: 90, axis: V3(1, 0, 0))
+        for i in 0..<wires {
+            let far = i % 2 == 1
+            let z = -(D - 0.07) / 2 + Float(i) * pitch
+            let px: Float = dieX1 - (far ? 0.024 : 0.009)
+            let fx: Float = subX0 + (far ? 0.095 : 0.060)
+            m.add(flat(0.011, 0.0135, 0.0008, pad), Xform(translation: V3(px, dTop + 0.0009, z), rotation: xr))
+            m.add(flat(0.020, 0.0105, 0.0008, wire), Xform(translation: V3(fx, sTop + 0.0004, z), rotation: xr))
+            // Ball bond (squashed sphere) and wedge bond foot.
+            let y0 = dTop + 0.0014 + 0.0022, y1 = sTop + 0.0008 + wireRadius * 0.7
+            m.add(Prim.superellipsoid(V3(0.0100, 0.0042, 0.0100), exponent: 2.6, subdivisions: 6, material: wire), Xform(translation: V3(px, dTop + 0.0009 + 0.0021, z)))
+            m.add(Prim.superellipsoid(V3(0.0140, 0.0030, 0.0070), exponent: 3, subdivisions: 5, material: wire), Xform(translation: V3(fx, y1 - 0.0005, z)))
+            // Loop: steep neck then arc; slight per-wire height and sway variation.
+            let h = loopHeight * rng.float(0.85...1.2) * (far ? 1.25 : 1)
+            let sway = rng.float(-0.002...0.002)
+            var pts: [V3] = []
+            let n = 22
+            for k in 0...n {
+                let t = Float(k) / Float(n)
+                let x = px + (fx - px) * t
+                let arc = h * pow(sin(.pi * pow(t, 0.72)), 0.9)
+                let y = y0 + (y1 - y0) * t + arc
+                pts.append(V3(x, y, z + sway * sin(.pi * t)))
+            }
+            let radii = [Float](repeating: wireRadius, count: pts.count)
+            m.add(Prim.tube(pts, radii: radii, sides: 8, seamTile: 0.02, material: wire))
+        }
+        groundAO(&m)
+        return LODModel(m)
+    }
+}

Sources/RealLibrary/Props/ChipLab/ChipPackageFinal.swift

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+import simd
+import Foundation
+
+/// Finished AI accelerator package, 100 x 100 mm: nickel-plated lid (separate part) with laser marking and
+/// sealant bead, two compute dies and four HBM stacks on a glass-core interposer, ABF substrate with decoupling
+/// capacitor arrays and a BGA ball grid underneath. Parts: lid, dies, interposer, balls.
+public struct ChipPackageFinal: RealArticulated {
+    public static let id = "chip-package-final"
+    public static let summary = "AI accelerator package: nickel lid with laser mark, compute dies and HBM on glass interposer, ABF substrate, BGA balls; explodes."
+    public static let tags = ["prop", "chiplab", "electronics", "articulated"]
+    public static let budget = 12500
+    public static let author = "realityhd"
+    public static let preview = PreviewHint(azimuth: 28, elevation: 38, distance: 1.0, studio: true)
+
+    /// Substrate edge length (m).
+    public var edge: Float = 0.1
+    /// BGA ball grid per side.
+    public var ballCount = 10
+    public var lidMaterial: MaterialKey = "metal.nickel"
+    public var substrateMaterial: MaterialKey = "laminate.abf"
+    public init() {}
+
+    func box(_ s: V3, _ r: Float = 0.00003, _ mat: MaterialKey) -> Surface {
+        r < 0.0001 ? cuboid(s, material: mat) : Prim.roundedBox(s, radius: r, bevelSegments: 1, material: mat)
+    }
+
+    public func rig(seed: UInt64) -> Rig {
+        var rng = SeededRNG(seed: seed)
+        var rig = Rig(name: Self.id, lods: 1)
+        let W = edge
+        let ballH: Float = 0.0016, subT: Float = 0.0016, ipT: Float = 0.0004
+        let subBot = ballH - 0.0002, subTop = subBot + subT          // 0.0014 ... 0.0030
+        let ipTop = subTop + ipT
+        let dieH: Float = 0.0007, hbmH: Float = 0.0008
+        let lidWall: Float = 0.002, lidOuter: Float = 0.084, lidT: Float = 0.0012
+        let lidTop: Float = 0.006, lidBot = lidTop - lidT
+
+        // ---- base: substrate, caps, pads
+        var base = Model(name: Self.id)
+        base.add(box(V3(W, subT, W), 0.0002, substrateMaterial), Xform(translation: V3(0, subBot + subT / 2, 0)))
+        // Solder-mask-edge copper-clad strip along the underside rim.
+        base.add(box(V3(W - 0.001, 0.00012, W - 0.001), 0.00003, "metal.copper"), Xform(translation: V3(0, subBot + 0.00006 - 0.00002, 0)))
+        // Gold bond-pad rows outside the lid footprint.
+        for k in 0..<2 {
+            let o = W / 2 - 0.0016 - Float(k) * 0.0018
+            base.add(box(V3(W - 0.012, 0.00012, 0.0009), 0.00002, "metal.gold"), Xform(translation: V3(0, subTop + 0.00004, o)))
+            base.add(box(V3(W - 0.012, 0.00012, 0.0009), 0.00002, "metal.gold"), Xform(translation: V3(0, subTop + 0.00004, -o)))
+        }
+        // Edge decoupling capacitors (0402 class): ceramic body with solder terminals.
+        func cap(_ x: Float, _ z: Float, _ rot: Float) {
+            let q = simd_quatf(degrees: rot, axis: V3(0, 1, 0))
+            base.add(box(V3(0.0011, 0.0005, 0.0006), 0.00004, "plastic.underfill"), Xform(translation: V3(x, subTop + 0.00025, z), rotation: q))
+            for s in [Float(-1), 1] {
+                let d = q.act(V3(s * 0.00046, 0, 0))
+                base.add(box(V3(0.00022, 0.00052, 0.00062), 0.00004, "metal.solder"), Xform(translation: V3(x + d.x, subTop + 0.00026, z + d.z), rotation: q))
+            }
+        }
+        // Outside the lid: two rows on each side of the package.
+        for k in 0..<14 {
+            let t = (Float(k) - 6.5) * 0.0042 + rng.float(-0.0001...0.0001)
+            let o = W / 2 - 0.0058
+            for row in 0..<1 {
+                _ = row
+                cap(t, o, 0); cap(t, -o, 0); cap(o, t, 90); cap(-o, t, 90)
+            }
+        }
+        // Inside the lid: rows between interposer and lid wall (visible with the lid off).
+        for k in 0..<12 {
+            let t = (Float(k) - 5.5) * 0.0042
+            cap(t, 0.0305, 0); cap(t, -0.0305, 0)
+        }
+        for k in 0..<4 {
+            let t = (Float(k) - 1.5) * 0.0042
+            cap(0.0408, t, 90); cap(-0.0408, t, 90)
+        }
+        // Fiducials and pin-1 triangle.
+        for (sx, sz) in [(Float(-1), Float(-1)), (1, -1), (1, 1)] {
+            base.add(Prim.lathe([V2(0.0007, 0), V2(0.0007, 0.00012), V2(0, 0.00012)], segments: 10, seamTile: 1, material: "metal.gold"),
+                     Xform(translation: V3(sx * (W / 2 - 0.0018), subTop, sz * (W / 2 - 0.0018))))
+        }
+        base.add(Prim.extrude([V2(0, 0), V2(0.003, 0), V2(0, 0.003)], depth: 0.00012, bevel: 0.00002, bevelSegments: 1, material: "metal.gold"),
+                 Xform(translation: V3(-W / 2 + 0.0012, subTop + 0.00006, W / 2 - 0.0012), rotation: simd_quatf(degrees: -90, axis: V3(1, 0, 0))))
+        rig.base[0] = base
+
+        // ---- balls (BGA): own part so the grid can drop away.
+        _ = rig.part("balls", pivot: V3(0, 0, 0), joint: .slide(axis: V3(0, -1, 0), 0...0.03, duration: 0.8))
+        let pitch: Float = 0.0092
+        for i in 0..<ballCount { for j in 0..<ballCount {
+            let x = (Float(i) - Float(ballCount - 1) / 2) * pitch, z = (Float(j) - Float(ballCount - 1) / 2) * pitch
+            if abs(x) < 0.0095 && abs(z) < 0.0095 && (i + j) % 2 == 0 { continue }
+            let b = Prim.lathe([V2(0, 0), V2(0.0006, 0), V2(0.0008, 0.0008), V2(0.0004, 0.0015), V2(0, 0.0016)], segments: 7, seamTile: 1, material: "metal.solder")
+            rig.add(b, Xform(translation: V3(x, 0, z), rotation: simd_quatf(degrees: rng.float(0...50), axis: V3(0, 1, 0))), to: "balls")
+        } }
+
+        // ---- interposer
+        _ = rig.part("interposer", pivot: V3(0, subTop, 0), joint: .slide(axis: V3(0, 1, 0), 0...0.03, duration: 0.8))
+        let ipW: Float = 0.078, ipD: Float = 0.047
+        rig.add(box(V3(ipW + 0.0016, 0.0002, ipD + 0.0016), 0.0001, "plastic.underfill"), Xform(translation: V3(0, subTop + 0.0001, 0)), to: "interposer")
+        rig.add(box(V3(ipW, ipT, ipD), 0.00004, "glass.substrate"), Xform(translation: V3(0, subTop + ipT / 2 + 0.00004, 0)), to: "interposer")
+        // Copper RDL bus runs between each die and its HBM neighbours.
+        let dieW: Float = 0.022, dieD: Float = 0.032
+        for sx in [Float(-1), 1] {
+            for zi in [Float(-1), 1] {
+                for l in 0..<5 {
+                    let z = zi * 0.0075 + (Float(l) - 2) * 0.0013
+                    rig.add(box(V3(0.0030, 0.00005, 0.00040), 0.00001, "metal.copper"),
+                            Xform(translation: V3(sx * 0.0232, ipTop + 0.00004, z)), to: "interposer")
+                }
+            }
+            for l in 0..<5 {
+                rig.add(box(V3(0.0012, 0.00005, 0.00040), 0.00001, "metal.copper"),
+                        Xform(translation: V3(0, ipTop + 0.00004, (Float(l) - 2) * 0.0013 + 0.0)), to: "interposer")
+            }
+        }
+        _ = dieW; _ = dieD
+
+        // ---- dies: two compute dies, four HBM stacks
+        _ = rig.part("dies", pivot: V3(0, ipTop, 0), joint: .slide(axis: V3(0, 1, 0), 0...0.04, duration: 0.8))
+        for sx in [Float(-1), 1] {
+            let cx = sx * 0.0125
+            let cy = ipTop + dieH / 2 + 0.00006
+            rig.add(box(V3(0.022, dieH, 0.032), 0.00008, "silicon.die-edge"), Xform(translation: V3(cx, cy, 0)), to: "dies")
+            rig.add(box(V3(0.0215, 0.00004, 0.0315), 0.00002, "silicon.die"), Xform(translation: V3(cx, cy + dieH / 2 + 0.00001, 0)), to: "dies")
+            // Floorplan blocks: 2 x 3 core tiles raised 30 um.
+            for a in 0..<2 { for b in 0..<3 {
+                let px = cx + (Float(a) - 0.5) * 0.0100, pz = (Float(b) - 1) * 0.0098
+                rig.add(box(V3(0.0092, 0.00004, 0.0090), 0.00002, "silicon.die-edge"), Xform(translation: V3(px, cy + dieH / 2 + 0.00004, pz)), to: "dies")
+            } }
+            // Underfill fillet skirt.
+            rig.add(box(V3(0.0232, 0.00028, 0.0332), 0.00012, "plastic.underfill"), Xform(translation: V3(cx, ipTop + 0.00014, 0)), to: "dies")
+            // HBM stacks: base logic die plus slices, mold-grey sides, polished cap.
+            for zi in [Float(-1), 1] {
+                let hx = sx * 0.0315, hz = zi * 0.0102
+                let hy = ipTop + 0.00006
+                rig.add(box(V3(0.0112, 0.00018, 0.0104), 0.00004, "silicon.die-edge"), Xform(translation: V3(hx, hy + 0.00009, hz)), to: "dies")
+                for s in 0..<4 {
+                    let yy = hy + 0.00018 + Float(s) * 0.00014 + 0.00007
+                    rig.add(box(V3(0.0100, 0.00011, 0.0092), 0.00002, s % 2 == 0 ? "silicon.die-edge" : "metal.solder"), Xform(translation: V3(hx, yy, hz)), to: "dies")
+                }
+                rig.add(box(V3(0.0100, 0.00006, 0.0092), 0.00002, "silicon.die-edge"), Xform(translation: V3(hx, hy + hbmH - 0.00003, hz)), to: "dies")
+            }
+        }
+
+        // ---- lid: plate, perimeter wall, sealant bead, laser marking
+        _ = rig.part("lift", pivot: V3(0, lidTop, 0), joint: .slide(axis: V3(0, 1, 0), 0...0.07, duration: 1.0))
+        _ = rig.part("lid", parent: "lift", pivot: V3(0, subTop, -0.043), joint: .hinge(axis: V3(1, 0, 0), -120...0, duration: 1.2))
+        let lm = lidMaterial
+        rig.add(box(V3(lidOuter, lidT, lidOuter), 0.0004, lm), Xform(translation: V3(0, lidTop - lidT / 2, 0)), to: "lid")
+        let wallH = lidBot - subTop + 0.0002
+        let wallY = subTop - 0.0002 + wallH / 2
+        for s in [Float(-1), 1] {
+            rig.add(box(V3(lidOuter, wallH, lidWall), 0.0002, lm), Xform(translation: V3(0, wallY, s * (lidOuter / 2 - lidWall / 2))), to: "lid")
+            rig.add(box(V3(lidWall, wallH, lidOuter - 2 * lidWall + 0.0004), 0.0002, lm), Xform(translation: V3(s * (lidOuter / 2 - lidWall / 2), wallY, 0)), to: "lid")
+            // Sealant bead: rounded rail hugging the foot.
+            rig.add(box(V3(lidOuter + 0.0016, 0.00042, 0.0009), 0.00018, "plastic.underfill"), Xform(translation: V3(0, subTop + 0.0001, s * (lidOuter / 2 + 0.0004))), to: "lid")
+            rig.add(box(V3(0.0009, 0.00042, lidOuter + 0.0016), 0.00018, "plastic.underfill"), Xform(translation: V3(s * (lidOuter / 2 + 0.0004), subTop + 0.0001, 0)), to: "lid")
+        }
+        // Fill-port notch dot and laser marking in dark engraved-oxide grey, proud 20 um.
+        let mk: MaterialKey = "silicon.die"
+        let my = lidTop + 0.00002
+        // Logo: hexagonal ring with bar.
+        rig.add(Prim.lathe([V2(0.0056, 0), V2(0.0056, 0.00004), V2(0.0042, 0.00004), V2(0.0042, 0)], segments: 6, seamTile: 1, material: mk),
+                Xform(translation: V3(-0.026, my - 0.00002, -0.024)), to: "lid")
+        rig.add(box(V3(0.0044, 0.00004, 0.0010), 0.00001, mk), Xform(translation: V3(-0.026, my, -0.024)), to: "lid")
+        // Text-like lines: glyph runs.
+        var tr = rng.fork(7)
+        for line in 0..<4 {
+            var x: Float = -0.0125
+            let z = -0.0285 + Float(line) * 0.0042
+            let n = line == 0 ? 9 : 6 + line
+            for _ in 0..<n {
+                let w = tr.float(0.0010...0.0026)
+                rig.add(box(V3(w, 0.00004, line == 0 ? 0.0023 : 0.0015), 0.00001, mk), Xform(translation: V3(x + w / 2, my, z)), to: "lid")
+                x += w + 0.0010
+            }
+        }
+        // Data-matrix code, 8 x 8 cells.
+        var qr = rng.fork(11)
+        for a in 0..<8 { for b in 0..<8 where a == 0 || b == 7 || qr.chance(0.5) {
+            rig.add(box(V3(0.0012, 0.00004, 0.0012), 0.00001, mk),
+                    Xform(translation: V3(0.0185 + Float(a) * 0.0016, my, 0.0235 + Float(b) * 0.0016)), to: "lid")
+        } }
+        // Serial strip.
+        for k in 0..<14 {
+            let w = qr.float(0.0008...0.0018)
+            rig.add(box(V3(w, 0.00004, 0.0016), 0.00001, mk), Xform(translation: V3(-0.0330 + Float(k) * 0.0030, my, 0.0345)), to: "lid")
+        }
+        // Chamfer corner mark on the lid.
+        rig.add(Prim.extrude([V2(0, 0), V2(0.0045, 0), V2(0, 0.0045)], depth: 0.00004, bevel: 0.00001, bevelSegments: 1, material: mk),
+                Xform(translation: V3(-0.0385, my, 0.0385), rotation: simd_quatf(degrees: -90, axis: V3(1, 0, 0))), to: "lid")
+
+        rig.states = [
+            RigState("lid-off", ["lid": -105]),
+            RigState("assembled"),
+            RigState("exploded", ["lift": 0.07, "dies": 0.032, "interposer": 0.014, "balls": 0.012]),
+        ]
+        return rig
+    }
+}