Cascade2D: A design-aware partitioning approach to monolithic 3D IC with 2D commercial tools

Monolithic 3D IC (M3D) can continue to improve power, performance, area and cost beyond traditional Moore's law scaling limitations by leveraging the third-dimension and fine-grained monolithic inter-tier vias (MIVs). Several recent studies present methodologies to implement M3D designs, but most, if not all of these studies implement top and bottom tier separately after partitioning, which results in inaccurate buffer insertion. In this paper, we present a new methodology called ‘Cascade2D’ that utilizes design and micro-architecture insight to partition and implement an M3D design using 2D commercial tools. By modeling MIVs with sets of anchor cells and dummy wires, we implement and optimize both top and bottom tier simultaneously in a single 2D design. M3D designs of a commercial, in-order, 32-bit application processor at the foundry 28nm, 14/16nm and predictive 7nm technology nodes are implemented using this new methodology and we investigate the power, performance and area improvements over 2D designs. Our new methodology consistently outperforms the state-of-the-art M3D design flow with up to 4× better power savings. In the best case scenario, M3D designs from the Cascade2D flow show 25% better performance at iso-power and 20% lower power at isoperformance.