Intel's first dual-core chip was a hastily concocted design that was rushed out the door in hopes of beating AMD to the punch, an Intel engineer told attendees at the Hot Chips conference yesterday.

With the realisation that its single-core processors had hit a wall, Intel engineers plunged headlong into designing the Smithfield dual-core chip in 2004 but faced numerous challenges in getting that chip to market, said Jonathan Douglas, a principal engineer in Intel's Digital Enterprise Group, which makes chips for office desktops and servers.

"We faced many challenges from taking a design team focused on making the highest performing processors possible to one focused on multi-core designs," Douglas said in a presentation on Intel's Pentium D 800 series desktop chips and the forthcoming Paxville server chip, both of which are based on the Smithfield core.

Intel was unable to design a new memory bus in time for the dual-core chip, so it kept the same bus structure used by older Pentium 4 chips, Douglas said. This bus was capable of supporting two separate single-core processors, but it was not as nearly as efficient as the dual-independent buses that will appear on the Paxville processors or the integrated memory controller used on AMD's chips. The memory bus or front-side bus on Intel's chips is used to connect the processor to memory.

All of Intel's testing tools and processes had been designed for single-core chips, Douglas said. This meant that the company had to quickly come up with a new testing methodology for dual-core chips that could measure the connections between both cores.

Also, a new package had to be designed for the Pentium D chips that could accommodate both cores. "We're putting two cores in one package, it's like trying to fit into the pair of pants you saved from college," Douglas said.

Intel would have preferred to design a package that would put two pieces of silicon in a single package, like the design that will be used for a future desktop chip called Presler, but its packaging team simply didn't have time to get that in place for Smithfield, Douglas said.

The company's Pentium D processors consist of two Pentium 4 cores placed closely together on a single silicon die. That design creates some problems in that dual-core processors must have some logic that coordinates the actions of both cores, and those transistors have to go somewhere in an already small package, Douglas said. This caused signaling problems that needed to be overcome, he said.

Intel also had to design special thermal diodes into the chip that would closely monitor the heat given off by the combination of two fast processor cores, Douglas said.

In total, Intel completed the Smithfield processor core in nine months. By Intel's standards, that is an extremely aggressive goal for a major processor design, said Kevin Krewell, editor in chief of The Microprocessor Report. "Most designs take years," Krewell said. "But it was very important for them to get back in the game and have a road map."

Intel began to put together the Smithfield project around the time it publicly announced plans in May 2004 to cancel two future single-core designs and concentrate on multi-core chips. The company realised that wringing more clock speed out of its single-core designs would require a significant engineering effort to deal with the excessive heat given off by those chips.