- Article
Test time per chip plays an essential role in manufacturing tests. Keeping a low number of test patterns becomes one of the prime objectives in concurrence with achieving the desired fault coverage. Unfortunately, finding an optimum set is an NP-hard problem. Today’s commercial ATPG tools have significantly reduced the number of test patterns to achieve a high fault coverage. However, there is still a huge gap for reducing the total pattern count, equivalent to minimizing test costs in the production phase. In this paper, we propose two novel methods to lower the test pattern count to detect all stuck-at faults in a circuit with the same or higher fault coverage as in the commercial ATPG tool, e.g., TetraMAX II. The first approach begins by applying a small set of random patterns to solve easy-to-detect faults. The remaining faults are detected by the SAT-based attack on logic locking with converting all the remaining faults into one locked circuit. Each stuck-at fault is modeled with its equivalent key gate. The second approach selects the first few patterns generated by the ATPG tool and applies the SAT attack of logic locking to determine the test patterns for detecting the undetected faults. By exploiting the overall linear iteration complexity and the exponential removal of incorrect key combinations per each SAT attack iteration, it is feasible to significantly reduce the total pattern count while maintaining the same or higher fault coverage as the ATPG counterpart. We demonstrate the effectiveness of both approaches and show that we are able to achieve a more compact test pattern set compared to a commercial ATPG tool.
6 December 2025


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