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LU Meixuan, XU Haobo, WANG Ying, WANG Mengdi, HAN Yinhe. Co-design of Architecture and Packaging in Chiplet[J]. Journal of Electronics & Information Technology. doi: 10.11999/JEIT250626
Citation: LU Meixuan, XU Haobo, WANG Ying, WANG Mengdi, HAN Yinhe. Co-design of Architecture and Packaging in Chiplet[J]. Journal of Electronics & Information Technology. doi: 10.11999/JEIT250626

Co-design of Architecture and Packaging in Chiplet

doi: 10.11999/JEIT250626 cstr: 32379.14.JEIT250626
Funds:  The National Natural Science Foundation of China (62025404, 62495104)
  • Received Date: 2025-07-03
  • Rev Recd Date: 2025-09-14
  • Available Online: 2025-09-16
  •   Significance   Chiplet technology, enabled by advanced packaging techniques, integrates multiple chiplets into a single package to form a larger-scale chip system. This approach breaks through the “Area Wall” faced by traditional processes and has become a critical path for improving computing performance in the post-Moore era. The design flexibility afforded by packaging-level integration has created a new design paradigm that drives iterative advances in computing and integration architectures. In traditional monolithic chip design, architecture and packaging are relatively independent stages. By contrast, the ability to integrate chiplets fabricated in different processes and the scalability of chiplet technology greatly expand the design space but also increase design complexity. At the same time, the higher transistor density per unit volume intensifies multi-physics coupling effects, including thermal, mechanical, and electrical interactions. Therefore, traditional methods that rely solely on packaging design to address performance degradation and reliability issues are no longer sufficient for chiplet-based systems. Instead, architecture and packaging in chiplet design must be co-designed in a coordinated manner.  Progress   This work addresses the critical issues of architecture–packaging co-design in the context of chiplet systems. It reviews architectural design and co-optimization efforts, demonstrates the necessity of co-design, and proposes co-design optimization methodologies. First, it summarizes architectural characteristics and development trends driven by advanced packaging technologies. These technologies are categorized into 2D, 2.5D, 3D, and 3.5D integration according to chiplet arrangement and interconnection technologies, each leading to substantial architectural differences. A detailed comparison of packaging technologies is provided, outlining the architectural features and co-design considerations associated with each. The necessity of co-design is then clarified from the perspective of the profound effect of packaging technologies on performance and reliability. The increased integration density per unit volume in chiplet-based circuits introduces serious reliability challenges, including complex multi-physics coupling effects such as thermal, mechanical, and electrical interactions. Multiple research studies on chiplet reliability are cited, highlighting the severity of thermal, mechanical, and electrical problems arising from these couplings. Unlike traditional monolithic chip designs, reliability issues in chiplet-integrated circuits cannot be resolved through standalone packaging-level design. Separate design of architecture and packaging introduces performance risks and leads to unpredictable design and manufacturing timelines and costs. Therefore, co-design of architecture and packaging is a necessary trend for the advancement of chiplet-based circuits. Finally, by reviewing existing cross-layer co-optimization efforts, an architecture–packaging co-optimization methodology is proposed to provide guidance for design optimization. Key design factors and evaluation metrics at both the architectural and packaging levels are summarized, and the interfaces for cross-layer co-design are clarified. The co-design interface consists of two components: design factors and evaluation metrics. Adjustments to any design factor within the design space affect multiple evaluation metrics, which in turn drive the convergence of the design space. Two key components are summarized for each design layer: (1) the definition of the design parameter space and exploration methods, and (2) the selection of evaluation metrics together with evaluation models and methodologies. The co-design process is outlined in eight key steps, illustrated by prior works. Existing architecture–packaging co-design methods are reviewed, and design workflows are categorized and characterized.  Conclusions  Driven by the evolution of chiplet technology and objectives such as performance and cost, chiplet-integrated circuit architectures have developed characteristics that differentiate them from traditional monolithic designs. The strong coupling between architecture and packaging layers has substantially increased design complexity, while higher integration density has introduced intricate multi-physics interactions, elevating reliability risks. The traditional design paradigm, in which architecture and packaging are developed independently, now faces challenges including performance degradation, unpredictable verification timelines, and uncontrollable costs. Co-design has therefore emerged as a critical solution. Establishing cross-layer collaborative methods and making trade-offs among multidimensional objectives are essential. By defining the design spaces for both architecture and packaging, formulating efficient exploration strategies, and applying system- and packaging-level evaluation methods, it becomes possible to rapidly and accurately identify optimal design solutions. Architecture–packaging co-design enables performance, reliability, and other objectives to be optimized synergistically at the early stages of chiplet-integrated circuit design with minimal cost. This approach maximizes the benefits of high integration density while mitigating risks in chip design and manufacturing.  Prospects   Architecture–packaging co-design represents the future paradigm for chiplet design. Current co-design approaches remain limited in applicability: methods that rely on detailed models such as RTL and netlists, together with EDA tools, are unsuitable for early-stage chip development, whereas abstract modeling techniques may neglect critical design issues and introduce substantial inaccuracies. Future co-design methodologies must adapt to different stages of the design process and support the iterative advancement of both computing architectures and integration architectures.
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