Compact-2D: A Physical Design Methodology to Build Commercial-Quality Face-to-Face-Bonded 3D ICs

The recent advancement of wafer bonding technology offers fine-grained and silicon-space overhead-free 3D interconnections in face-to-face (F2F) bonded 3D ICs. In this paper, we propose a full-chip RTL-to-GDSII physical design solution to build high-density and commercial-quality two-tier F2F-bonded 3D ICs. The state-of-the-art flow named Shrunk-2D (S2D) requires shrinking of standard cells and interconnects by a factor of 50% to fit into the target 3D footprint of a two-tier design. This, unfortunately, necessitates commercial place/route engines that handle one node smaller geometries, which can be challenging and costly. Our flow named Compact-2D (C2D) does not require any geometry shrinking. Instead, C2D implements a 2D IC with scaled interconnect RC parasitics, and contracts the layout to the F2F design footprint. In addition, C2D offers post-tier-partitioning optimization that is shown to be effective in fixing timing violations caused by inter-tier 3D routing, which is completely missing in S2D. Lastly, we present a methodology to recycle the routing result of post-tier-partitioning optimization for final GDSII generation. Our experimental results show that at iso-performance, C2D offers up to 26.8% power reduction and 15.6% silicon area savings over commercial 2D ICs without any routing resource overhead.