Semiconductor Tape-Out Contingency Budget Calculator
What this tape-out contingency calculator estimates
This tool helps you size the budget and schedule buffer needed to absorb likely semiconductor tape-out surprises: mask respins, schedule slips, and potential expedite fees at the foundry. It is aimed at tape-out leads, semiconductor program managers, and finance partners who need a directional view of how much contingency to hold around a mask set.
Rather than predicting the exact number of respins, the model focuses on expected values over your planning horizon. It combines your estimates of respin probability, mask set costs, schedule impact, and weekly burn rate to produce an indicative contingency amount and an implied schedule buffer.
Key inputs and how to choose values
The calculator uses a set of core program and cost parameters. Typical ranges are indicative only; adjust them to reflect your node, product type, and organizational risk tolerance.
- Base Mask Set Cost ($) – The planned cost of the initial mask set for the tape-out (sometimes called the first silicon mask). For advanced nodes, this can range from hundreds of thousands to several million dollars depending on layers and options.
- Probability of Needing a Respin (%) – Your estimated chance that you will need at least one additional mask set after first silicon. Early-generation or complex SoCs might see 30–60% respin probability, while mature derivatives or minor metal ECOs may be much lower.
- Cost per Respin Mask Set ($) – The incremental cost of each additional mask set, including foundry charges for the new set and any associated NRE. In many flows this is similar to, but not always identical with, the base mask cost.
- Schedule Slip per Respin (weeks) – The additional calendar time from finding a showstopper issue to having usable silicon again. Include debug, re-spin preparation, mask build, wafer processing, and re-qualification. Common values range from 4–12 weeks or more, depending on node and fab cycle times.
- Downstream Cost per Slip Week ($) – The economic impact of each week of delay. This can include lost gross margin from late revenue, penalties or lost design-in windows with key customers, and opportunity cost versus competitors.
- Probability of Needing Expedited Slot (%) – The chance that you will need to pay for a premium, expedited foundry slot to avoid missing a critical date (for example, a customer qualification window or a holiday build).
- Expedite Premium Cost ($) – The incremental fee charged by the foundry or by your OSAT/assembly test partners to pull in cycle time (for example, rush mask build, hot lots, or priority queueing).
- Design Team Burn Rate per Week ($) – The all-in weekly cost of the design and supporting teams that remain engaged while waiting for silicon: salaries, contractors, EDA tools, boards, lab equipment, and so on.
- Planning Horizon (months) – The time window your contingency plan should cover, often aligned with a product program phase or a fiscal planning cycle (for example, 12–24 months).
How the calculator works (formulas)
The model combines expected costs from three main sources:
- Additional mask sets driven by respins.
- Schedule slip from respins and its downstream financial impact.
- Potential expedite fees to pull in critical lots.
At a high level, the expected number of respins is approximated from your respin probability. The tool then multiplies this by the cost and time impact per respin to estimate contingency.
An example representation of the expected respin cost is:
Similarly, the schedule-driven financial impact is captured as:
The expected expedite premium is modeled as:
The calculator then adds the expected mask, slip, and expedite components to arrive at a total suggested contingency for the planning horizon.
Interpreting the results
When you run the calculation, you will typically see:
- An estimated contingency budget to reserve on top of the base mask set cost.
- An implied schedule buffer tied to the expected number of respins and slip weeks.
- A breakdown of how much of the contingency is driven by mask costs versus schedule-related effects (burn rate and downstream slip costs) and expedite fees.
Use these outputs as a starting point for internal discussion, not as a final answer. If the suggested contingency is small relative to your expected program revenue, you may accept the risk. If it is a large fraction of your projected profit, it can be a signal to invest more in verification, DFT, or silicon prototyping to drive respin probability down.
Remember that the financial impact of a slip is often dominated by lost opportunity, not just direct project expenses. For design-in driven businesses, even a few weeks of delay can mean missing a platform, socket, or OEM build window.
Worked example (advanced-node SoC)
Consider a new advanced-node SoC targeting a high-volume mobile platform. Suppose:
- Base mask set cost: $1,450,000
- Probability of needing a respin: 28%
- Cost per respin mask set: $975,000
- Schedule slip per respin: 6 weeks
- Downstream cost per slip week: $185,000
- Probability of needing expedited slot: 22%
- Expedite premium cost: $350,000
- Design team burn rate per week: $245,000
- Planning horizon: 18 months
The expected mask respin cost is roughly 0.28 × $975,000 ≈ $273,000. The expected delay-related financial impact is 0.28 × 6 × ($185,000 + $245,000) ≈ 0.28 × 6 × $430,000 ≈ $723,000. The expected expedite premium is 0.22 × $350,000 ≈ $77,000. Combined, this suggests reserving on the order of $1.0–1.1M in contingency on top of the base mask cost, plus planning for approximately 1–2 months of potential schedule slip in the roadmap.
In reviews, you can present both the base plan (one mask set, no respins) and the contingency-inclusive view to show executives the realistic budget envelope.
Scenario comparison: lean vs conservative planning
The table below illustrates how different assumptions change the recommended contingency. These are stylized examples, not prescriptions.
| Scenario | Respins Probability | Slip per Respin | Downstream Cost per Week | Expedite Probability | Indicative Contingency vs Base Mask |
|---|---|---|---|---|---|
| Lean (aggressive schedule) | 20% | 4 weeks | Moderate | 15% | Roughly 30–50% of base mask cost |
| Balanced (typical new SoC) | 30–40% | 6–8 weeks | High | 20–25% | Often similar to or larger than the base mask cost |
| Conservative (mission-critical, safety) | 40–60% | 8–12 weeks | Very high | 30%+ | Can reach 1.5–2.0× the base mask cost |
As you adjust your own inputs, think about which scenario best matches your program risk profile and customer expectations.
Using the outputs in planning discussions
Once you have a contingency estimate, you can:
- Size budget lines for mask respins, expedite fees, and schedule-related costs in your capital and operating expenditure plans.
- Challenge optimistic tape-out plans by comparing the "no respin" budget to a more realistic, probability-weighted plan.
- Support foundry negotiations by understanding how much value an expedited slot or improved cycle-time actually delivers in your financial model.
- Prioritize risk reduction activities (for example, additional verification, FPGA prototyping, or earlier metal ECO plans) when the expected contingency is uncomfortably high.
Assumptions and limitations
This calculator deliberately simplifies a complex reality. Keep these assumptions and limitations in mind:
- Single-stage expected values – The model uses probability-weighted averages, not a full distribution of potential outcomes. It does not simulate multiple respins or branching scenarios.
- Independent events – Respin and expedite probabilities are treated independently, even though in practice schedule slips can influence the urge to expedite later lots.
- Linear costs – Downstream delay costs and burn rates are assumed to be linear with time. Real programs often have step functions (for example, missing a customer qualification window may cause a discontinuous revenue impact).
- Mask granularity – The model does not distinguish between full mask sets and partial metal-only fixes, which can have very different costs and cycle times.
- Vendor-specific pricing – Foundry and OSAT pricing tiers, volume discounts, and node-specific options are not modeled. Always cross-check with actual quotes.
- Not a financial forecast – Outputs are directional planning aids, intended to inform conversations, not to replace detailed business cases or risk-adjusted financial models.
For high-stakes decisions, combine this calculator with detailed schedules, customer commitments, and vendor input.
Contingency Budget Summary
Expected respin count: 0.0
Recommended contingency reserve: $0
Expected schedule impact: 0 weeks
Carrying cost of delay: $0
Total financial exposure over horizon: $0
Why Tape-Out Contingency Planning Matters
Every advanced chip program wrestles with the risk that its first silicon will miss performance, power, or yield targets. Even with extensive verification, design-for-test methodologies, and emulation, late-stage bugs still surface. The Semiconductor Tape-Out Contingency Budget Calculator gives program managers a pragmatic framework for quantifying those risks. By entering mask costs, respin probabilities, schedule slip impacts, and burn rates, you can translate technical uncertainty into dollars and calendar time. The resulting outputs help you answer board questions about cash commitments, inform customer delivery dates, and align with foundry partners on slot reservations.
Tape-out is the transition from design to fabrication. Mask sets at cutting-edge nodes can exceed $1.5 million, and each respin requires weeks of layout fixes, sign-off reruns, and queueing for new foundry starts. Meanwhile, system integrators waiting on your chip may need to replan their launches. The calculator models both direct costs (additional mask sets and expedite fees) and indirect costs (lost revenue or penalties for late delivery). By adjusting the probability of respins and expedited slots, you can stress-test how changes in design maturity or foundry availability influence the contingency reserve.
It is tempting to assume that strong pre-silicon verification makes respins unlikely. However, advanced process nodes introduce variability in transistor behavior, and mixed-signal blocks often behave differently on silicon than in simulation. The calculator’s expected respin count captures that nuance by multiplying the probability of a respin by the number of potential attempts within your planning horizon. You can also reflect mitigations, such as formal verification coverage improvements or incremental ECO (engineering change order) mask sets, by lowering the probability input.
The indirect cost of delay is often underestimated. Design teams continue to burn payroll while waiting for silicon, and product management may authorize costly bridging strategies to keep customers engaged. The penalty per week input lets you quantify those ripple effects, whether they manifest as lost revenue, contractual liquidated damages, or the cost of supplying stopgap FPGAs. When you multiply that penalty by the expected schedule slip, you get a realistic picture of the business exposure beyond the engineering budget.
How the Calculator Works
The model first computes the expected number of respins over the planning horizon by multiplying the respin probability by the number of tape-out opportunities assumed to occur in that period. For simplicity, it treats each horizon year as containing two major tape-out opportunities, reflecting an initial launch and a backup respin slot. Expected respins are capped at three to prevent unrealistic scenarios. The contingency reserve combines the cost of those expected respins with the expected expedite fees. Schedule impact equals the expected respin count multiplied by the slip weeks. Carrying cost of delay adds the burn rate and downstream penalty per week to show the true financial exposure.
Formula Spotlight
The expected total contingency reserve can be expressed with MathML:
where
Worked Example
Imagine a startup pursuing a 5-nanometer networking ASIC. The base mask set costs $1.45 million. Engineering leaders estimate a 28% chance that the first silicon will require a respin, costing $975,000 and delaying the schedule by six weeks. The program also has a 22% chance of needing an expedited foundry slot for $350,000 to recover time. Entering those numbers reveals an expected respin count of 0.84 across the 18-month horizon. The recommended contingency reserve comes to roughly $1.1 million when combining respin and expedite exposure. The expected schedule slip is just over five weeks, translating to $925,000 in downstream penalties and team burn. Altogether, the total financial exposure exceeds $3.3 million, which management can now budget for instead of being surprised later.
Scenario Comparison
| Scenario | Respin probability | Expected reserve | Expected delay |
|---|---|---|---|
| Baseline assumptions | 28% | $1.1M | 5.0 weeks |
| Additional verification investment | 18% | $0.7M | 3.2 weeks |
| Foundry capacity crunch | 28% with 45% expedite probability | $1.6M | 7.4 weeks |
These scenarios show how strategic investments upstream (better verification) or external constraints (capacity crunches) change the contingency posture. Sharing the table with finance helps justify budget shifts, such as funding emulation infrastructure to reduce respin odds.
Limitations
The calculator assumes independent respin events and evenly spaced tape-out opportunities. It does not model partial mask revisions, metal-only ECOs, or software mitigation strategies that could soften schedule impacts. Downstream penalties are treated as linear per week, though real-world damages might escalate near contractual deadlines. Users should adjust the inputs if they negotiate foundry risk-sharing agreements or keep backup design teams on standby. Still, the tool offers a grounded starting point for aligning executive expectations with engineering realities.
Related Planning Resources
Chip programs balancing other capital decisions can reference the semiconductor wafer yield calculator and the foundry capacity reservation ROI calculator to triangulate total program exposure.
Hardware startups often share this calculator with venture investors to explain why seemingly large cash balances are not optional—they are shields against respin risk. By documenting the expected contingency reserve and delay costs, founders can make the case for milestone-based funding or convertible debt that closes before tape-out. Established companies can adapt the model to drive portfolio governance, allocating contingency dollars across multiple design teams competing for the same foundry slots. In both contexts, grounding the discussion in numbers improves trust between engineering, finance, and executives who must jointly manage risk.
The calculator can also inform supplier negotiations. Sharing a quantified view of expedite probability and cost enables more productive conversations about service-level agreements, shared-risk pricing, or volume commitments. Program managers can simulate how different foundry proposals alter their reserve needs and use the results to negotiate credits, flexible start windows, or dedicated engineering support. Combined with schedule visualizations, the data empowers cross-functional teams to decide when to trigger contingency plans versus accepting minor slips that do not jeopardize customer launches.
Semiconductor schedules are unforgiving. With this calculator you can build a contingency reserve grounded in probabilities rather than guesswork. Share the results with design leads, program management offices, and investors so everyone understands the financial runway needed to de-risk tape-out and ship working silicon.