Thomas Sapiano
Senior Member
As much as I am an advocate of moving to a larger sensor, it is a considerable expense to do so. One has to remember that a FF sensor is more than twice as large as the current DX format (2.25x). Naturally, this means that you are eating up 2.25x more area on wafers that are basically of a fixed size, so for the same production costs you are getting much fewer sensors. Additionally, since wafers are circular you end up with more waste around the edges when you try to divide it up into larger rectangular dies.I dont see why they didnt make the dslr ff at the start. a ff
sensor would just mean larger actual pixels right? I couldnt see it
being a lot more to make a sensor slightly bigger, in fact i would
think making it smaller would cost more. But then again, im not an
engineer so i might be talking out of my butt.
Compounding this problem is that semiconductor fabrication is very sensitive to tiny imperfections in each sensor. A significant number of critical defects will exist on every wafer, and the larger each contigous element the more you have to throw away for each of them. The defect issue is very significant in modern semiconductor production and yields are one of the most important variables in the cost of the final product - this is especially the case for die sizes of this magnitude (even the APS sensor size is massive compared to conventional ICs).
For example, if you have a wafer with ten well distrubted defects if you fit 50 HF sensors you loose 10 sensors and keep 40 (80% yield). If you fit 20 FF sensors onto that same wafer you'd loose 10 and keep 10 (50% yield). Since that wafer costs the same either way, you can either split that cost across 10 sensors or 40 - as such, you'd end up paying 4X more for the larger sensors