7 Signs it's time to convert your FPGA to an ASIC

Field-Programmable Gate Arrays (FPGAs) are an excellent choice for rapid development, prototyping, and low-volume production. But as products mature and volumes increase, many organizations reach a tipping point were continuing with an FPGA is no longer the most efficient or cost-effective option.

So how do you know when it’s time to make the move?

Below are 7 clear signs that your design may be ready for FPGA-to-ASIC conversion and how making the transition can improve performance, reduce costs, and ensure long-term supply.

1. Your Production Volumes Are Increasing

FPGAs are ideal for low-to-medium volumes, but their per-unit cost remains relatively high compared to ASICs. If your production volumes are scaling into the thousands (or more), an ASIC can significantly reduce unit cost over time.  

ASICs have higher upfront development costs (NRE), but much lower per-unit pricing, making them more economical at scale.

2. Power Consumption Is Becoming a Problem

FPGAs typically consume more power than ASICs because of their programmable architecture.

ASICs are optimized for a specific function, resulting in lower power consumption and improved efficiency, critical for embedded, industrial, and defense systems.

3. Performance Limitations Are Holding You Back

As system demands increase, FPGA performance may become a bottleneck.

ASICs offer higher speed and optimized performance, enabling designs that FPGAs simply can’t match in demanding applications.

4. Your Design Has Stabilized

FPGAs are valuable during early development because they allow for flexibility and reprogramming. If your design is no longer changing significantly, that flexibility becomes less important. Once stable, converting to an ASIC allows you to optimize cost, power, and performance without sacrificing functionality.

5. Component Obsolescence Is a Growing Risk

FPGA devices, especially older families, can become obsolete, creating long-term supply challenges.

ASIC conversion gives you greater control over lifecycle and supply, reducing dependency on commercial FPGA product cycles.

6. You Need Long-Term Product Support (10–30+ Years)

Many industries, especially aerospace, defense, and industrial, require systems to remain operational for decades.

FPGAs are typically not designed for such long lifecycles.

ASICs can be supported with long-term manufacturing strategies, ensuring continuity and reducing the risk of forced redesigns.

7. Your Total Cost of Ownership Is Too High

The true cost of using an FPGA goes beyond the unit price.

Hidden costs include:

• Power consumption
• Cooling requirements
• Board space
• Long-term sourcing challenges

An ASIC can reduce overall system cost, not just component cost, especially in high-volume or long-life applications.

SUMMARY

FPGA vs. ASIC: Quick Comparison

Converting from FPGA to ASIC isn’t just a technical decision, it’s a strategic move that can:

• Reduce long-term costs
• Improve system performance
• Lower power consumption
• Mitigate obsolescence risks
• Ensure long-term supply continuity

Tekmos provides a unique advantage for organizations considering FPGA-to-ASIC conversion, especially in high-reliability and long-lifecycle applications.

Key Benefits of Working with Tekmos

• Turn-Key ASIC Solutions
  From design through production and test, Tekmos manages the full lifecycle.
• Lifecycle and Obsolescence Expertise
  Ideal for programs requiring long-term support and stability.
• High-Reliability Focus
  Supporting aerospace, defense, and industrial applications.

With Tekmos, companies can confidently transition from FPGA to ASIC while minimizing risk and maximizing long-term value.

Frequently Asked Questions

Is ASIC conversion expensive?
It requires upfront investment but often reduces total cost over the product lifecycle.

Can FPGA designs be directly converted to ASICs?
In many cases, yes, but optimization and validation are required.

How long does FPGA-to-ASIC conversion take?
Timelines vary depending on complexity, but it typically ranges from several months to over a year.

Considering FPGA-to-ASIC conversion? Tekmos offers turn-key solutions designed to optimize performance, reduce costs, and ensure long-term supply for mission-critical applications.