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It's been a while since I've been out of that industry, but back around the 45nm days, one of the biggest concerns was yield. If you've got 100x the surface area, the probability of there being a manufacturing defect that wrecks the chip goes up. Now, you could probably get away with selectively disabling defective cores, but the chiplet idea seems, to me, like it would give you a lot more flexibility. As an example, let's say a chiplet i9 requires 8x flawless chips, and a chiplet Celeron requires 4 chips, but they're allowed to have defects in the cache because the Celeron is sold with a smaller cache anyway.

In the "huge chip" case, you need the whole 8x area to be flawless, otherwise the chip gets binned as a Celeron. If the chiplet case, any single chip with a flaw can go into the Celeron bin, and 8 flawless ones can be assembled into a flawless CPU, and any defect ones go into the re-use bin. And if you end up with a flawed chip that can't be used at the smallest bin size, you're only tossing 1/4 or 1/8 of a CPU in the trash.




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