From ASIC to Fleet: Lessons from Building and Operating a Hyperscaler NIC
We describe the operational infrastructure built to deploy and operate fbnic, a custom multi-host NIC, across hundreds of thousands of production hosts at Meta. Vendor multi-host NICs, designed by retrofitting single-host architectures, suffered from shared firmware and buffers that created cascading isolation failures over seven years. fbnic eliminates these through physical isolation, but shifting to in-house hardware shifts the entire operational burden to the hyperscaler. We present a hardware-in-the-loop CI pipeline testing firmware, driver, and kernel cross-products; a unified observability pipeline co-locating NIC and switch counters for cross-layer fault attribution; a driver-first architecture with fewer than ten firmware message types; a targeted firmware upgrade orchestrator at sub-sled granularity; and scoped repair automation confining blast radius to individual host slices. Over ten months, fbnic achieved a 12X reduction in unplanned unavailability, 37% lower mean time to repair, and 2.3X fewer hardware swaps compared to vendor NICs on the same platform.