Public Funding for Semefab Limited

ENERGY-3GBT will place the UK at the centre of next-generation power transistor production, ensuring UK industry is not impeded by global power semiconductor supply chain bottlenecks and can lead the world in improving energy-efficiency in the drive to net-zero. ENERGY-3GBT will develop, optimise and demonstrate low-cost UK-based pilot-scale manufacture of 99% efficient silicon-based third-generation bipolar transistors (3GBTs) that outperform 95%-efficient Insulated Gate Bipolar Transistors (IGBTs) and best-in-class 99% efficient Gallium Nitride (GaN) and Silicon Carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFETS) in applications requiring 10-100A, ≤1700V, ≤50 kHz switching speeds. ENERGY-3GBT initially targets replacement of IGBTs in industrial variable frequency drives (VFDs) through project partner Siemens UK. Secondary applications targeted include wind turbine power-converters, next-generation electric vehicles, rail electrification, 5G and more. Adoption of the 99% efficient 3GBT in industrial drives in the UK (accounting for about half of the manufacturing sector's delivered energy use) could save users £228.4m/year in reduced electricity costs and reduce greenhouse emissions by 440ktCO2e/year. Ultimately, replacement of IGBTs in industrial drives, renewable energy power converters, electric vehicles, rail, 5G and many more high-power products has potential to make a significant contribution to the UK's net zero ambitions.

Semefab,the indigenous, open access semiconductor and MEMs sensor design and manufacturing company with three wafer fabrication facilities in Glenrothes, Scotland, intends to become a mainstream, indigenous manufacturer of power semiconductors. The IGBT component is mainstream in PEMD switching semiconductor device applications. Semefab's application is based around establishing patented, performance leading 1700V Trench clustered IGBT (TCIGBT) manufacturing capability at Semefab in Fab 3 on 6 inch wafers. This will create a high current density, high performance component applicable to mainstream industrial drive, solar, wind farm and electric vehicle applications and create a platform for higher and lower voltage applications. Semefab's strategic development objective for power electronics follows our belief that there is a clear and present need for establishing this manufacturing capability within UK to enhance critical infrastructure, increase UK industrial supply chain resilience and deliver tangible benefits to existing and future UK users of such devices.

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"Exceptional electronic properties, surface sensitivity and selectivity, makes graphene an ideal candidate for a wide number of potential applications. However, in order to exploit these properties and enable such applications, substantial industrial research is necessary to overcome considerable material and process challenges that prevent graphene technology to move from the laboratory to large-scale manufacturing. Our Industrial Research project will explore novel graphene surface chemical modification processes, transfer methods and integration processes to be transferred and tested at the industrial level, enabling entirely new applications for in-line monitoring of allergens in food manufacturing, and Point-of-Care (POC) critical health diagnostics. The extraordinary surface sensitivity of graphene, coupled with the correct technology to modify its surface, makes it an ideal material for sensing applications. Performance evaluation of our optimised processes will be conducted through metrology on advanced sensing test structure, for the detection of i) milk allergens in food products and ii) Myocardial Infarction (heart attack) and the rapid detection of Cardiovascular Disease (CVD\*) biomarkers. The needs for tackling these two exemplary applications stems from: - the prevalence of food allergies (increasing globally and prompting food producers to pay increased attention to monitoring of the food processing plant): where there is a possibility of cross-contamination, food producers are obliged to label products and recall incorrectly-labelled products and ""faulty"" batches-- costing industry millions and producing negative publicity; - The incidence (and mortality) associated with heart attack and the global increase in the burden of National Health Services and global population caused by CVD\* - a rapid response in ruling out a potential heart attack and, if detected, understanding the disease progression in quasi real-time, will provide a powerful POC tool to clinicians, hospitals, and emergency units, help saving lives and lower costs. The development of our graphene-based technology will allow to ultimately enable fabrication of real-time sensing devices, developed for _in-situ_ monitoring of food & food processing units and POC critical health diagnostics, would enable instant and low-cost monitoring. The availability of quality control measures to be integrated with Aixtron's growth equipment will enable a pathway to rapid transition of graphene technology from research lab to factory. The availability of integrated graphene-based sensors for in-situ monitoring would offer end-user Unilever a real breakthrough in monitoring for milk allergen contaminants and explore new medical technology applications."

This project is based on a highly innovative, mass-producible, photonic miniaturised IR spectrophotometer, enabling low power, low cost,fit & forget deployment, multi-gas sensing. Currently no commercial sensor offers these in one product.

The project will develop an innovative Silicon Nanowire (SiNW) based point-of-care multiplex sensor platform for the early detection of multiple disease biomarkers simultaneously, for the monitoring of chronic conditions. The generic POC platform will enable more efficient & effective healthcare delivery and improved health outcomes for patients. SiNW sensors will be fabricated on full wafers and functionalised using a novel multi-electrode array. The first SiNW immunosensors will detect the hormone cortisol for the fertility market. Multiplex sensors will detect serotonin and noradrenelin in addition to cortisol. SiNW sensor devices will be integrated with printed electronics to form a self contained packaged, single-use sensor. The sensor platform can be adapted for the detection of other disease markers including, stroke, heart disease, cancer and dementia. A complete disposable strip and electronic reader system, akin to blood glucose monitoring kits, will be developed.

The SolarFAB project will develop a robust Concentrated Photovoltaic solar cell fabrication process on large 150mm substrates compatible with high efficiency multi junction solar cells operating at concentrations up to 1000 suns and current densities exceeding 10A/cm2. The project will develop robust top and bottom level metallisation processes and optimal current collection strategies with particular attention paid to minimise the cost and environmental impact of these stages. The metallisation for solar devices requires low contact resistance and solar shadowing, whilst optimising coupling of solar energy into the device with the aim of maximising the useful energy generated by the solar device. Different CPV cell producers use different lens concentrating arrangements e.g., creating a gaussian or uniform light distribution on the cell. The top level interconnects design strategies and Anti-Reflection Coatings will optimise conditions for the prevailing lens types. The key technical innovations are the development of such capabilities on triple junction 150mm substrates at a low cost, realising the competitive potential of CPV over other forms of photovoltaics. In recognising the growing importance of CPV in the renewable energy sector, the EU has recently announced the NER 300 project to develop a 20MWatts CPV system. A prime objective of the project is to place the project partners in an excellent position to supply CPV triple junction cell material/devices, putting the UK in a prime position to supply the solar renewable market, particularly regarding exports.

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