28nm vs 40nm vs 65nm — The Real Cost, Risk, and Power Trade-Off for ASICs

Choosing between 28nm, 40nm, and 65nm is one of the most common — and most underestimated — decisions in ASIC development.

These nodes dominate industrial, automotive, consumer, and IoT ASICs, yet teams often choose based on habit or outdated assumptions. In reality, the differences between 28nm, 40nm, and 65nm go far beyond geometry. They affect cost structure, power efficiency, design risk, IP availability, and long-term scalability.

This guide provides a practical, engineering-focused comparison to help you decide which node best fits your project — before committing to a foundry or locking specifications.

Quick Comparison: 28nm vs 40nm vs 65nm

Key insight:

Newer is not always safer — and cheaper nodes often reduce schedule and execution risk more than they increase unit cost.

What Really Changes When You Move Between Nodes

65nm — The “Safe Default” Node

65nm remains one of the most widely used nodes for ASICs that prioritize reliability, cost control, and fast execution.

Strengths

• Lowest NRE and mask costs
• Extremely mature IP ecosystem
• Predictable yields and timelines
• Ideal for mixed-signal and high-voltage integration

Trade-offs

• Larger die sizes
• Higher active power compared to newer nodes

Best suited for

• Industrial control
• Automotive subsystems
• Power management and analog-heavy designs
• First-time ASIC teams

40nm — The Transitional Node

40nm sits between mature and advanced nodes, offering moderate power improvement without the full complexity of 28nm.

Strengths

• Better power efficiency than 65nm
• Lower leakage than 28nm
• Balanced NRE vs performance

Trade-offs

• Shrinking MPW availability
• Fewer new IP developments compared to 28nm

Best suited for

• Consumer electronics
• Cost-sensitive digital designs
• Teams migrating from 65nm cautiously

28nm — The Most Misjudged Node

28nm is often selected as a “modern but safe” node — but this assumption can be dangerous.

Strengths

• Significant power and density improvements
• Massive IP availability
• Long-term roadmap compatibility

Trade-offs

• Higher leakage and power density
• Increased design and verification complexity
• Higher NRE and mask costs

Best suited for

• Performance-sensitive designs
• High-integration SoCs
• Products with clear volume justification

Power, Cost, and Risk — Side-by-Side Reality Check

Reality check:

Many teams underestimate how much verification effort and power management increase at 28nm — especially when migrating from 65nm.

Ecosystem and Foundry Support Considerations

All three nodes are supported by major foundries such as:

• TSMC
• UMC
• GlobalFoundries

However, access conditions differ:

• 65nm is widely available and startup-friendly
• 40nm access varies by region and volume
• 28nm engagement often requires stronger business justification

MPW availability, support responsiveness, and qualification requirements vary significantly by foundry and program timing.

Which Node Should You Choose?

Choose 65nm if:

• You want the lowest risk and fastest execution
• Cost predictability matters more than die size
• You are building an industrial or automotive ASIC

Choose 40nm if:

• You need moderate power reduction
• You want a step down from 65nm without jumping to 28nm
• You are cost-sensitive but performance-aware

Choose 28nm if:

• Power or integration density is critical
• You expect meaningful production volumes
• You can absorb higher NRE and verification cost

Common Mistakes Teams Make

• Choosing 28nm “to be safe for the future”
• Underestimating leakage and power density challenges
• Ignoring MPW and prototyping constraints
• Locking node selection before architecture is validated

These mistakes often lead to re-spins, schedule delays, or cost overruns.

How AnySilicon Helps with Node Selection

AnySilicon supports teams by:

• Evaluating node suitability based on real constraints
• Shortlisting foundries for 28nm, 40nm, or 65nm
• Connecting you with qualified ASIC design partners
• Providing visibility into MPW and prototyping options

Ready to Validate Your Node Choice?

Get a confidential ASIC node recommendation

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Recommended Calculator (Place Directly Below This Section)

Use our ASIC MPW vs Full Mask estimator to understand what your node choice means for cost, risk, and feasibility — before engaging foundries.