It really sounds like Nvidia would be much better off dumping Global Foundries / TSMC and going into manufacturing themselves. This isn't the first time they've been screwed by their supplier's incompetence.
It's been happening a lot lately it seems.
Although would they have the ability to get such a large fab up and running quickly? Would the investment pay off for them?
nvidia don't have the money, engineering staff, or capability to get into manufacturing. They also don't use Global Foundries in any way and never have, likely never will but they might.
They have never been screwed by their suppliers incompetence, ever. At every stage when Nvidia has blamed TSMC ALL of their competitors have been able to make working chips without problems. Nvidia pass the buck for blame, citing yield problems at TSMC when AMD had working chips out months before and multiple other customers. When all customers bar one has no problems with the process and that one customer who has had trouble for 3 generations in a row blames TSMC..... lol.
For the record, the touted price of upcoming(delayed but still coming) 450mm wafer fabs is in the 14 billion range, and one small customer can absolutely not come close to making that financially viable. That is JUST the production and equipment, R&D will be a minimum of another several billion. Nvidia have exactly zero experience in an industry in which extremely experienced people are selling off their manufacturing capabilities because of the exponentially increasing costs and complexity. IBM have more knowledge than most, bigger volume than Nvidia, but small enough volume that they want to sell off their fabs, AMD did so, again with larger volume than Nvidia and several other manufacturers have also.
If they started R&D for a future process and then planned a new fab and built it, you're talking about them not having the slightest chance of being up and running within 6 years. GloFo trying to get into the business have spent pushing 20billion now and it will take a LOT more investment two more fabs planned at probably 15billion + a piece for New York and a potentially a new fab in the mid east. With billions in investment to the fabs in Singapore and Germany. It's a business where the small producer(several times larger than Nvidia's volume) can't compete and can't turn anything but huge losses.
Intel is struggling has cancelled one fab, closing another and has low utilisation and they have many many times the volume that AMD/Nvidia do, they are struggling with the costs/production difficulties of having too few customers. Silicon production is already being dominated and will likely be completely dominated by those who can spread the cost of R&D and equipment amongst hundreds of thousands of customers over a period of 5-10 years per process.
nvidia, AMD, Intel, they need the latest and greatest process and have no business for old process/equipments. TSMC has a huge number of fabs. They'll spend 15billion on a 10nm 450mm fab but 10 years later that equipement will be churning out calculator chips by the millions at tiny costs, but effectively extending the life of a process by 4-5 times longer than someone like Nvidia/AMD/Intel would use that process. It's the only way to really succeed in the industry.