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Intel Faces Yield Problems in Key 18A Manufacturing Process for Next PC Chip

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Intel’s ambitious push to regain leadership in high-end chip manufacturing has hit a significant hurdle. According to sources familiar with the matter, its next-generation “18A” production process — critical for the upcoming “Panther Lake” laptop chips — is struggling with low yields, raising concerns about profitability and competitiveness against industry leader TSMC.

The 18A process is central to Intel’s strategy of expanding its in-house chipmaking and building a competitive foundry business. Billions have been invested in factories and technology, aiming to close the gap with TSMC. Panther Lake, expected in high volumes in 2025, features next-gen transistors and a more efficient power delivery system.

However, early tests have shown disappointing results. Only a small fraction of chips have met required standards, with yields reportedly around 5% late last year and about 10% by mid-2024. Intel disputes these figures but has not disclosed official numbers. Industry norms suggest profitability usually requires yields between 70% and 80%. Without major improvements by the planned Q4 launch, Intel may face selling chips at reduced margins or even at a loss.

Intel CFO David Zinsner acknowledged yields “start off low and improve over time” and stressed that the product remains “fully on track.” Still, sources describe the 18A rollout as risky, likening it to a “Hail Mary” due to the simultaneous introduction of multiple untested technologies.

Compounding the challenge, defect rates per chip area are reportedly about three times higher than acceptable for mass production. While Intel is working to improve yields monthly, margins are not yet favorable even at current levels. The company has warned that without securing external business for 14A — the successor to 18A — it could exit advanced manufacturing altogether.

For now, Intel still relies partly on TSMC for some in-house designs. Its follow-up to Panther Lake, “Nova Lake,” is also expected to be produced partly by TSMC.

Samsung Profit Plunges 56% Amid AI Chip Woes, U.S. Export Curbs to China

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Samsung Electronics reported a steep 56% year-on-year drop in Q2 operating profit, projecting earnings of 4.6 trillion won ($3.36 billion)—significantly below analyst expectations of 6.2 trillion won, according to LSEG SmartEstimate. This marks Samsung’s weakest quarterly performance in six quarters, as its semiconductor division continues to struggle with shifting global dynamics in the AI chip market.

The South Korean tech giant blamed its sharp decline on U.S. restrictions on AI chip exports to China, which have disrupted its sales pipeline. However, analysts pointed to delays in delivering high-bandwidth memory (HBM) chips to Nvidia as a major factor in its underperformance. Unlike rivals SK Hynix and Micron, which have seen strong AI-driven chip demand, Samsung has been slower to supply its latest HBM3E 12-layer chips, with customer evaluations still ongoing and no specific update on Nvidia shipments.

“Everything ultimately comes back to HBM,” said Ryu Young-ho, an analyst at NH Investment & Securities, noting that Samsung’s competitive edge hinges on reclaiming leadership in the HBM segment.

Revenue for the quarter is expected to come in nearly flat at 74 trillion won, down just 0.1% from a year ago. But the semiconductor division likely took the hardest hit, with analysts estimating its operating profit may have dropped over 90% to just 500 billion won, partly due to inventory value adjustments and unsold HBM stockpiles.

Adding to the challenges, potential U.S. tariffs and mounting competition in China—where Samsung still has a heavy market presence—are expected to weigh on both its chip and smartphone margins in the near term.

Samsung’s foundry business also saw falling earnings, attributed to low utilisation rates and inventory write-downs, stemming from the same U.S. AI chip export restrictions. However, the company expects foundry performance to gradually improve in the second half of 2025 as utilisation recovers with demand.

Despite the weak outlook, Samsung announced a 3.9 trillion won ($2.85 billion) share buyback, part of a broader 10 trillion won repurchase plan unveiled in late 2024. Investors remained cautious, with Samsung shares slipping 0.2%, while Korea’s benchmark KOSPI index rose 1.2% during morning trading.

Looking ahead, Samsung hopes to recover with upcoming phone launches and by expanding HBM sales beyond Nvidia to other customers. A full breakdown of business unit performance is expected on July 31, when the company releases its detailed Q2 earnings report.

Intel CEO Considers Major Shift in Foundry Strategy, Focuses on 14A Chipmaking to Compete with TSMC

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Intel’s new CEO Lip-Bu Tan is contemplating a significant change to the company’s contract chip manufacturing business, potentially abandoning the costly 18A process developed under his predecessor to focus on the newer 14A technology. This move aims to better compete with Taiwan Semiconductor Manufacturing Co (TSMC) and attract major clients like Apple and Nvidia, sources familiar with the matter told Reuters.

The 18A process, which Intel invested billions in, is seen as losing appeal among prospective customers. Shifting focus away from it could lead to a substantial financial write-off for Intel, possibly costing hundreds of millions or even billions of dollars. Intel confirmed it would continue producing chips using 18A for its own internal designs, including the “Panther Lake” laptop chips planned for 2025, as well as fulfilling existing contracts with Amazon and Microsoft.

Tan, who took over in March, has quickly moved to cut costs and reshape Intel’s direction amid years of falling behind in chip technology. The 18A process, which features new transistor designs and energy delivery methods, was intended to rival TSMC’s leading-edge technology but is now considered roughly comparable to TSMC’s earlier N3 node.

By emphasizing 14A, Intel hopes to offer a more competitive foundry service and win contracts from major chip designers currently reliant on TSMC’s manufacturing. The company is customizing 14A to client needs and planning a strategic discussion with its board as soon as this month, with a final decision expected in the fall.

Intel’s move reflects the high stakes involved in regaining its manufacturing edge after a difficult period culminating in an $18.8 billion net loss in 2024. Tan has also revamped Intel’s leadership and streamlined management to improve agility.

While the strategy is still forming, the potential pivot marks one of Tan’s boldest efforts to restore Intel’s chipmaking leadership and profitability.