While Kyrgios registered a 6-4, 6-7 (9-11), 6-3 win over 19-year-old German Alexander Zverev in the last-eight clash, Federer struggled past 10th seed Berdych 6-2, 3-6, 7-6 (8-6) to book his place in the semi-finals.
"Every match is going to be tough from now on", said second-seeded Kei Nishikori, who also survived a three-setter to reach the quarters. "I'm happy to come have through today", said Federer to ESPN after the match.
"I definitely got very lucky at the end".
Finally playing like he should have for the last decade, Berdych started cranking flat groundstrokes to all corners and took advantage of a dip in Federer's form to force a third set. She won the title in 1998, 1999 and 2001 and considers the tournament her hometown event - she lives 90 minutes north in Palm Beach Gardens. Also, the Frenchman has not had a good start to his new season as he has suffered semi-final defeats in Doha and Rotterdam, which was followed by early exits in Dubai and Indian Wells.
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The last of the quarter-finals at the ATP World Tour Masters 1000 event pits Australian No.12 seed Nick Kyrgios against German No.16 seed Alexander Zverev, with the victor earning a semi-final showdown with Federer. Federer is even in his FedEx ATP Head2Head with Zverev at 1-1.
Zverev, who turns 20 next month, showed no ill effects by playing just 24 hours after winning a three-setter over John Isner that went entirely to tiebreakers.
On his match-up with Kyrgios Federer said in his on-court interview: "You all should tune in if you're not in the stadium". "That's my game style that I've had success with, so that's what I'm going to bring". Yet Berdych responded by rattling off the next two games for the loss of just one point. He held serve throughout and broke Berdych again at 4-2 to put the set beyond doubt.
Federer saved the second match point with a superb first serve and set up his own with an ace down the middle.
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Wawrinka took the first set 6-4 but Zverev converted four of his five break points as he won the next two 6-2 6-1.
But Federer was not afforded the same opportunities to break in the second and instead it was Berdych who was rewarded for finding his rhythm with his forehand.
"I was like, 'Wow, double fault".
Federer has won all seven of the tiebreaks he has faced during his current American campaign. "But the crowds were great", Federer said. "But they seem to be working now".
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Gonzaga broke through that with a hard-fought win over West Virginia in the Sweet 16 and a blowout over Xavier in the Elite Eight. When they finally reached the Final Four it was like Gonzaga had finally escaped the dark shadow constantly looming over them.