Reshore semiconductor manufacturing to UK and US to meet sustainability goals, study says

Making semiconductors in the UK and the US would be the most sustainable way to manufacture the materials that power every electronic device on the planet, according to new research from the University of Sheffield.

The study, "Geo-spatial prospective life cycle sustainability of InGaN and InGaP compound semiconductors," published in Scientific Reports, is the most detailed to date on the sustainability of the semiconductor supply chain.

Led by Professor Lenny Koh, an expert in supply chains at the University of Sheffield's Management School in collaboration with Cardiff University, the researchers analyzed 80 different global supply chain scenarios, spanning 11 countries and looking ahead to the years 2030, 2040, and 2050. Their aim was to understand how the environmental impact of semiconductor production could change over time and place.

Professor Lenny Koh, Chair in Operations Management at the University of Sheffield, said, "Semiconductors are at the heart of modern life—powering everything from phones to electric cars to the systems that power our energy and health care infrastructures—but their production is energy-intensive and growing rapidly as demand rises in parallel with the growth of AI technology."

The team examined two key materials used in next-generation electronics, known as InGaN and InGaP. These materials are particularly vital for advancing artificial intelligence, as well as underpinning consumer electronics at the heart of many people's lives, such as smartphones and LED televisions.

Results from the analysis show that manufacturing in countries with cleaner energy systems, such as the UK and the United States, consistently led to the lowest environmental impacts. By contrast, production centered in regions still heavily reliant on coal power, such as China, produced the highest levels of pollution—even in future projections.

At the moment, the majority of semiconductors are made in Taiwan, South Korea, and China, but the study is calling for manufacturing to be reshored to countries with lower energy intensity—the amount of energy required to produce one unit of economic output (GDP)—to be more sustainable.

The study also assessed the impact that the supply chain has on global warming, marine ecotoxicity, terrestrial acidification, and water depletion.

According to the analysis, shifting the manufacturing of InGaN and InGaP to the UK will have the greatest environmental impact reduction— approximately 70% and 66% impact reduction from 2040 to 2050.

Scenarios involving manufacturing microchips in the UK, U.S. and Taiwan consistently achieve the highest sustainability scores across global warming, toxicity, and resource depletion categories, particularly in 2050.

While cleaner electricity will reduce many emissions, the study found that some parts of chip manufacturing will remain major environmental challenges and therefore require research and innovation to tackle them.

Processes such as crystal growth and material preparation—known as "epitaxy" and substrate production—are expected to become the biggest sources of sustainability challenges in the future. These steps rely on complex chemicals and large amounts of energy and water, meaning further innovation will be needed to make them greener.

InGaN epitaxy is predicted to require approximately 80% more energy as compared to InGaP, as well as generate more toxic waste.

Professor Lenny Koh added, "Our study offers one of the most detailed pictures yet of how the global semiconductor industry could evolve in a low-carbon future. It shows that while technology itself is important, the biggest sustainability gains may come from smarter choices about where and how products are made.

"If acted upon, the insights from our study could help the electronics industry and policy makers cut emissions, reduce pollution and build a more sustainable and resilient future as technology advances.

"Our findings send a clear message to industry and policymakers: strategic reshoring, cleaner fabrication, and targeted innovation in high-impact processes like epitaxy and substrate preparation are essential if next-generation semiconductor technologies are to deliver on both performance and sustainability."

Dr. Moein Shamoushaki, Post Doctoral Research Associate at the University of Sheffield's Management School, said, "While decarbonized electricity reduces environmental impacts in energy-intensive phases, future reductions must focus on cleaner materials and safer chemical handling in fabrication workflows."

Professor Peter Smowton, Director of Compound Semiconductor Manufacturing Hub, from Cardiff University said, "Our research shows that the future sustainability of advanced semiconductors is not fixed—it is shaped by where and how we build them.

"By modeling global supply chain scenarios through to 2050, we find that cleaner electricity alone can drive major reductions in environmental impact, but it is not enough. The biggest gains will come from rethinking supply chains—prioritizing low-carbon regions, investing in safer materials and processes, and accelerating recycling and circular economy practices."

Provided by University of Sheffield