400 Gbit Ethernet Full Profile PCIe x16 Card

The Terabit Ethernet card is designed and suitable for filtering TCP packets on optical fiber.

Malicious packets can be dropped, and packets carrying selected protocols or data can be picked and forwarded for further processing.

Target customers include ISP data centers, cloud services, and stock trading companies.

400 Gbit Ethernet Full Profile PCIe x16 Card

Our Task and Challenge

Terabit Ethernet PCIe Card

Consilia was requested to create a layout for this 400 Gbps PCIe card. The component density was reaching the physical limits of the manufacturing process.

Thermal management posed a significant challenge due to the excessive power dissipation of the packet processing FPGA.

Solution

Hardware Design from PCB Concept to Production

Consilia was responsible for the PCB design from scratch.

The first challenge was the selection of the proper stack-up and the PCB manufacturer. There are only a few manufacturers in the world that have and can process materials designed for this kind of card. 

After weeks of comparing various materials and stack-ups, the PCB layout started.

The placement of the components was an input for the thermal management system team that started thermal simulations.From then on, the thermal management system team and the layout team cooperated closely. The Development teams discussed the change of placement of each component from the point of view of signal integrity and thermal management.

The result is a board with 18 Layers with a component coverage exceeding 77 % of the board area.

When the board was finished, a DFM (Design for Manufacturing) analysis was conducted at the selected assembly house to ensure that the cards could be manufactured and assembled at the target line.

Business Value

Fast and Flexible Packet Filtering

The card can be programmed in P4 – a high-level programming language optimized for packet forwarding. The packets can be inspected in real time at a full speed of 400 Gbps and thrown away immediately if detected as malicious. 

Consilia provides turnkey solutions for PCB layout of any complexity ranging from 2-layer automotive PCBs up to xx-layer high-speed telecom cards and backplanes touching manufacturing limits.

How It Is Made

High Class PCB

The critical parameters of the board are PCB with 18-layer stack-up, high-speed differential pairs, blind/buried and stacked vias/µvias, back-drilling, FPGA chip with 3000 pins, and over 1800 components on PCB.

For cooling, a highly efficient copper profile cooler is specially designed for externally provided airflow, with efficient cooling of up to 100A power consumption.

Client

Innovative Producer in the Infrastructure Field

Our client operates and develops the national e-infrastructure for science, research, and education which encompasses a computer network, computational grids, data storage, and a collaborative environment. The client offers a rich set of services to connected organizations.

Implementation period: 2021—NOW

We designed the PCB in the year 2021. Currently, we are working on a new innovative variant.

Links

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Next Solutions

Since the foundation of Consilia in 2004, we have finished and supported over 42 projects.

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Used Services

FPGA Design

Our team has been making advanced FPGA designs for more than 20 years. We implement designs for the chips produced by the top FPGA manufacturer brands, like Intel, AMD, and Lattice.

PCB Design

This is a crucial activity we do in the complete product creation or as an on-demand service. We can support you with our considerable experience and technical background, including circuit design know-how, manufacturing services, and a professional PCB layout team.

Hardware Design

We are active in all hardware design activities and all development stages.

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Application Areas

Automation

We can offer you our competence in designing automation systems based on our long-term expertise. Our know-how is deepened by developing new generation PLCs or developing industrial test cards.

Military

We can assist our customers from the military segment in developing modern and customized solutions, following all the security standards.

Industry 4.0

We have always focused intensely on making our products interconnected and finding the best balance between autonomous and centralized approaches for the systems.

IT Infrastructure

Our modules achieve a data throughput of 400 Gbps.

30

30

developers

ready to assist you

Consilia has a workforce of 30 developers in the competence fields of software development, software testing, hardware design, RF design, FPGA design, DSP design, and PCB design.

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