In this paper, we present four examples of highly integrated 60 GHz single-chip CMOS 90 nm digital radios and phased array solutions. These solutions include for the first time digital-to-analog/analog-to-digital conversion and embedded multi-gigabit mixed signal modem requiring no external processing. This convergence of 60 GHz CMOS digital radio, low power multi-gigabit mixed-signal processing and digital signal processing on a single chip offers the lowest energy per bit transmitted wirelessly at multi-gigabit rate to meet the very stringent low-power specifications for battery operated consumer electronic portable devices. Layout and temperature dependent 60 GHz CMOS 90 nm model development and critical high performance analog and mixed building blocks are presented as fundamental enablers for single chip integration. The designs have been optimized for robustness against process variation and temperature, and verified by measurement results.