State of the Gas Delivery Industry
The semiconductor industry is experiencing significant growth in the US. In 2022, the US Congress announced the $52B CHIPS Act, providing the impetus for companies to return chip manufacturing back to the US. Tier I semiconductor companies then announced they would build large scale FAB’s throughout the US, particularly Arizona, Ohio, New York, and Texas.
The Gas delivery industry is expected to grow 13.7% annually (CAGR (Compound Annual Growth Rate) 2023-2030) due to increasing demand for high-quality devices and changing geopolitical factors, regulations, and code requirements. Process tool manufacturers including Applied Materials, LAM, VEECO, TEL, ASML and ASM are forecasting significant growth worldwide as well. Market sector growth in healthcare, automotive, and aerospace technologies have generated exponential demand for silicon, gallium, and graphene thin film chips - SiN, GaN, GaAs, SiC with new recipes and high wafer equipment demand.
Gas delivery systems safely deliver gases or liquids and prevent contaminants from entering the process tool to maintain semiconductor production integrity. Since the inception of the semiconductor industry in the early 1980’s, gas delivery systems have evolved from simple three and five valve panel designs with purge capabilities and microprocessor controls to more efficient panel designs with PLC and SCADA based systems.
Gas delivery systems can be divided into two segments:
Fully auto systems - Systems with pneumatic valves, auto purge sequencing and shutdown with minimal human intervention. Gas classifications include flammable, corrosive, pyrophoric, toxic, and/or highly toxic gases.
Semi auto systems - Systems with one pneumatic valve and manual purge with some human intervention. Gas classifications include inert and some flammable gases.
In the US, a handful of companies manufacture gas delivery systems. They range from gas manufacturers to systems integrators. Gas manufacturers offer gas delivery systems by leveraging their electronic and bulk gases with a focus on large-scale strategic accounts. System integrators typically focus on university, R&D labs, and smaller scale semiconductor facilities in their business model approach. However, with these new FAB announcements, system integrators are offering competitive bid package solutions to compete with the larger gas manufacturers.
Gas delivery system suppliers must continue to provide technological advancements in data analytics and communication to address process tool needs for cleanroom and equipment engineers. Facility engineers continue to express the need for site and analytical services of their facility's gas delivery systems. Their main concerns center on maintenance, cylinder changeouts and employee liability, should an event occur. Design engineers seek more efficient custom valve manifold box layouts that minimize piping design.
Critical Systems Inc. (CSI) provides comprehensive gas delivery solutions from source gas to the process tool that few can match. Since the 1990’s, CSI has evolved from supplying and reselling refurbished systems into a total solution systems manufacturer of panels and gas control systems for supporting the entire sub-FAB.
The portfolio of CSI’s product and services includes:
Delivery systems (liquid or gas)
Purification technology, purifiers, or systems
Cleanroom filtration
Abatement systems
Toxic gas monitoring
Facility monitoring
Orbital services
Site services
Supply chain constraints and component prices continue to be CSI’s biggest challenge. Tier I FAB’s continue to procure massive quantities of components from key suppliers which have contributed to extended lead times. Additionally, component prices remain volatile as costs continue to rise due to limited supply. Short term, CSI has overcome these challenges by qualifying alternate component suppliers that conform to CSI’s standard of quality and by using a just-in-time (JIT) approach to its manufacturing process. CSI continues to overcome challenges, poised for explosive industry growth.