In the Connect Labs by Wexford in Downtown Phoenix, a passionate group of scientists, engineers and semiconductor materials industry experts are building the next generation of semiconductor manufacturing technology — using sound waves. This Arizona hard-tech startup, Crystal Sonic, is focused on reducing cost and waste. As the Arizona semiconductor industry continues to grow and chip manufacturers continue to drive technology advancements, public and private investments in startups like Crystal Sonic provide the resources needed to commercialize innovations quickly and further secure Arizona’s position as a leading semiconductor hub.
Using Sound Waves to Cut Costs and Waste
Chip manufacturing is a capital- and material-intensive process. Legacy manufacturing techniques for wafering and device thinning often waste 90% or more of the substrate material. Furthermore, the substrate itself can often consume 50% or more of the total device manufacturing cost for advanced semiconductors, such as those used in power electronics or radio frequency communications applications. Technological advancements across multiple industries are held back because of these manufacturing costs and waste issues.
On top of that, the next generation of semiconductor devices will be increasingly based on substrate materials, such as silicon carbide, gallium nitride, gallium arsenide and others. These materials unlock new benefits, like being able to create smaller devices that are more energy-efficient and perform better. They also give us new applications for power electronics, sensing and communications. To optimize the use of these materials, chip manufacturers will need a way to better utilize precious substrate materials in the manufacturing process, to reduce waste and costs.
That’s where sound wave technology comes in. Crystal Sonic’s patented Sonic Lift-Off technology harnesses the power of sound to separate thin devices from semiconductor substrate materials. After a device has been lifted from the substrates, the remaining substrate can be reused in the manufacturing process.
Partnering with Universities to Develop Arizona’s Semiconductor Workforce
Crystal Sonic’s product development is based out of the DEfECT Lab, focused on engineering for energy conversion technologies, directed by the company’s chief technology officer and ASU professor Mariana Bertoni. Partnering with ASU researchers gives Crystal Sonic the ability to further develop its technology. It also benefits students studying advanced manufacturing and training future innovators. Students support Crystal Sonic’s activities in the process development tasks and in the characterization of wafer surfaces post lift-off.
Through the Partnership for Economic Innovation’s Applied Research Centers, Crystal Sonic is able to collaborate with ASU researchers on a deeper level. The partnership enables researchers to leverage funding through the Arizona Commerce Authority to conduct process tests and feasibility studies on product prototypes. Thanks to this partnership, Crystal Sonic has hired an ASU intern for the remainder of the year to assist in the development of the technology.
Crystal Sonic is also able to leverage other partnerships including the Plug and Play accelerateAZ Advanced Manufacturing program. Along with 12 other Arizona-based startups, Crystal Sonic was able to collaborate with other experts to drive innovation in the semiconductor space. Through the program, the startups are able to gain valuable technical requirements and feedback from some of the largest established semiconductor industry participants. Research collaborations with other startups have also commenced, for example, where the Sonic Lift-off technology could assist in improving and commercializing their products.
Collaborating with the Semiconductor Ecosystem
Another key to Crystal Sonic’s success is being able to collaborate directly with other industry partners. Through programs like PEI’s Applied Research Center and ACA’s Plug and Play, startups like Crystal Sonic are connected to semiconductor companies that may use the Sonic Lift-Off technology in the future. This collaboration provides a direct line of communication for feedback between Crystal Sonic and industry material suppliers, equipment manufacturers and device manufacturers. Partners are able to test and validate the acoustic technology, confirm that it does reduce waste and costs, and apply the technology to an emerging class of chips, the kind that power electric vehicles, solar panels, sensors and a vast array of other technologies.
Investing in Startups to Drive Innovation
Startups play a critical role in the semiconductor industry. Their nimbleness and agility give them the advantage of solving complex industry problems at an accelerated pace. Public and private investments have kept Crystal Sonic’s momentum going, opening new opportunities to innovate around industry problems while also providing students with an avenue to build their skills and knowledge.
The investment in Sonic Lift-Off technology itself also ensures future technologies are manufactured in a way that is more sustainable and cost-effective.
Arno Merkle, co-founder and CEO of Crystal Sonic, is an accomplished leader in the capital equipment and deep tech industries. With a robust background in leading product teams and driving business development at renowned companies that include Carl Zeiss, Tescan, Xradia and XRE, Merkle has been instrumental in shaping the landscape of advanced electron- and X-ray microscopy instrumentation across various sectors. His strategic contributions led to successful exits at startups Xradia and XRE in 2013 and 2018, respectively. Merkle holds a Ph.D. in Materials Science and Engineering from Northwestern University and currently resides in Phoenix.
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