BLADE: Bi-Level Bayesian Optimization for Metal-Density-Constrained Multi-Layer Package Power/Ground Plane Synthesis

In advanced packages, large power/ground (P/G) planes are essential for power integrity but prone to warpage due to CTE mismatch. While uniform metal-density constraints combat warpage, mandatory degassing holes complicate adherence to these constraints and degrade IR-drop.

We propose BLADE, the first P/G plane synthesis methodology that enforces uniform metal-density constraints while optimizing power integrity. BLADE expands P/G planes from skeletons under metal density control to ensure connectivity, naturally leaving holes for degassing. Guided by a fast IR-drop evaluator, our bi-level Bayesian optimization framework efficiently navigates the complex design space.

Experiments on six SiP cases demonstrate that BLADE simultaneously satisfies the metal-density constraint and achieves superior IR-drop performance compared to existing methods, addressing the critical co-design challenge spanning power integrity, manufacturing yield, and long-term reliability in next-generation advanced packaging.