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ABF Substrate Roadmap: Why AI Data Centers Face a Capacity Bottleneck

ABF is an insulating film inside some advanced package substrates. AI is increasing demand as packages grow more complex, while public capacity plans and reported bottlenecks point to a long-lead supply challenge.
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ABF is a specialized insulating film used to build fine wiring inside some advanced semiconductor package substrates—not the substrate itself, and not a material confirmed in every AI accelerator. Its importance is growing because high-performance packages are getting larger and more complex as well as more numerous. Ajinomoto has announced a new production site planned to begin operating in 2032, while a September 2026 trade report describes tight supply and larger substrate roadmaps. The public evidence supports a long-term capacity challenge, but it does not establish the size of a current industry-wide shortfall.

What is an ABF substrate?

“ABF substrate” is common shorthand for a package substrate built using Ajinomoto Build-up Film (ABF). ABF is the insulating film between layers of fine circuitry; it is not the whole substrate. The substrate connects the very small terminals on a semiconductor die to the larger connections used by the package and the printed circuit board.

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In a build-up process, manufacturers form successive wiring layers over a substrate core, with insulating material separating those layers. Ajinomoto says ABF’s surface can be laser processed and directly copper plated, allowing fine circuits to be formed. The company says a major semiconductor maker first adopted ABF in 1999 and describes the film as a standard material for high-performance CPU substrates.

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That evidence supports ABF’s importance in high-performance computing and advanced packaging, not a claim that all AI accelerators use it. Ajinomoto’s 2025 ASV Report calls ABF essential for high-performance semiconductors and describes its global market position as an “overwhelming share.” That is the company’s characterization; the report does not provide a quantified market-share figure in the cited material.

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Why does AI increase demand for ABF?

AI demand affects ABF through both chip volume and package design. Ajinomoto identifies high-performance computing, AI applications, multi-chip packages and 3D-IC packages as growth areas. It also says larger, more complex IC packages require more ABF per IC. Consequently, even if accelerator shipments were the only change, package growth could still increase the amount of film needed per device.

More ABF demand does not automatically translate into an equal number of finished substrates. The film is one input in a longer manufacturing chain. Substrate makers also need suitable materials such as glass cloth, equipment and factory capacity, then must achieve acceptable yields and produce output qualified for particular customers. A constraint at any of those stages can limit usable supply.

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Why are ABF substrates in short supply?

A September 10, 2026 Tom’s Hardware feature reports that ABF film capacity was fully loaded in the second quarter of 2026 and describes bottlenecks involving ABF, glass cloth and other materials, substrate equipment, large-format factories, yield and customer-qualified output. These are secondary-source reports; the available Ajinomoto announcements confirm plans to expand capacity and anticipated demand, but do not confirm utilization or quantify a current shortfall.

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The distinction between nominal capacity and supply a customer can use matters. A factory’s theoretical output does not show how much material meets specifications, how quickly production can ramp, or how much finished substrate has cleared a customer’s qualification process. The cited reporting identifies these as parts of the constraint, but it does not provide a complete, comparable capacity-and-yield dataset across suppliers.

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The same Tom’s Hardware feature reports projections for substrate-area growth and estimates of a supply-demand gap. Because their originating sources and methods were not independently established in the available material, those projections should not be treated as confirmed industry totals.

How does the substrate roadmap change package requirements?

Tom’s Hardware reports the following Ibiden roadmap for substrate dimensions and build-up structures. The figures are the roadmap as reported by that publication, not independently corroborated here against an original Ibiden presentation.

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Target year Substrate size reported Build-up structure reported
2026 90 × 90 mm 10-X-10
2028 110 × 110 mm 12-X-12
From 2030 130 × 130 mm or larger 14-X-14

Larger footprints and more complex structures illustrate why demand cannot be assessed by chip count alone: a more demanding package can require more substrate area and additional build-up layers. The reported roadmap does not state how many substrates Ibiden will produce at each size, what yields it will achieve, or how much qualified output will reach customers.

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What is the Ajinomoto ABF factory roadmap?

Ajinomoto Co., Inc. announced on May 7, 2026 that it had acquired a site in Kani City, Gifu Prefecture, for a third ABF production base. Its plan is to start construction in 2028 and begin operation in 2032. The company framed the site as a way to expand production capacity and business continuity in anticipation of demand after 2030; it is separated from the existing Kawasaki and Gunma plants for continuity purposes.

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The announcement does not give the new site’s output capacity, production ramp, or a site-level target. Its 2032 operating date is therefore a planned milestone, not a published measure of how much additional film will be available or when customers will receive it. The announcement also does not quantify today’s supply gap.

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What do Ajinomoto’s shipment figures show?

Ajinomoto’s May 2024 investor presentation provides a company shipment-volume indicator, not a measure of total industry output. It sets FY2017 at an index of 100, shows FY2021 at 190, and marks FY2025 at a planned index of 345. The presentation describes growth from FY2020 through FY2025 as approximately 18% CAGR. Because FY2025 is explicitly a plan in that chart, 345 should not be presented as a realized 2025 result.

The figures indicate the scale of growth Ajinomoto was planning for its own ABF shipments. They do not specify the share of demand met, the contribution from individual factories, or the volume available to any particular substrate maker.

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What the roadmap establishes—and what it does not

  • Established by company material: ABF is an insulating film for fine circuitry in build-up substrates; Ajinomoto identifies AI and advanced multi-chip packaging among demand drivers; and the company has announced a third production site with operation planned for 2032.
  • Reported by trade coverage: Q2 2026 full-load film capacity and the Ibiden size and layer-count roadmap. These claims remain attributed to the September 2026 Tom’s Hardware feature here.
  • Not established by the cited figures: an industry-wide shortage quantity, the new factory’s eventual output, actual FY2025 shipment volume from the 2024 plan, or a complete comparison of suppliers’ capacity, yields and qualified deliveries.

For data-center planners, the practical implication is that substrate availability is a supply-chain risk worth tracking alongside accelerator demand. But the public figures cited here describe a planned company expansion and a reported supplier roadmap—not a quantified forecast of how many AI systems will be delayed.

Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.

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