To reduce charging and shrinkage, CD-SEMs utilize low electron energies and multiframe imaging. This results in every next frame being altered due to stage and beam instability, as well as due to charging. Regular averaging of the frames blurs the edges; this directly effects the extracted values of critical dimensions. A technique was developed to overlay multiframe images without the loss of quality. This method takes into account drift, rotation, and magnification corrections, as well as nonlinear distortions due to wafer charging. A significant improvement in the signal to noise ratio and overall image quality without degradation of the feature’s edge quality was achieved. The developed software is capable of working with regular and large size images up to 32K pixels in each direction.
CD-SEMs are an indispensable part of semiconductor manufacturing. Extending their functionality beyond routine work on CD metrology of a layer is highly desirable. The etch process greatly depends on CDs and the pitch of a pattern. Through pitch patterns consisting of two layers, each with different CDs and side wall angles, are widely used to develop and characterize etch processes. TEMs are widely used to measure these values for each layer. This is a time consuming and expensive process, and the feedback time to process development is long. It would be highly desirable to develop metrology for two layers, including their side wall angles, using top down SEM images in order to reduce cost and provide a fast feedback to process development and characterization.
A technique was developed to measure top and bottom CDs of each layer, as well as side wall angles of the layers using SEM images. The model based myCD software was used as the basis for this development. Hundreds of SEM images were taken at multiple test pattern areas with variable pitch and dimensions. The extracted values included top and bottom CDs of the top layer, top and bottom CDs of the bottom layer, as well as side wall angles of both layers. The pitch was also extracted for verification. The results of CDs and SWA were very consistent.
The verification was done in two ways: a) by comparing myCD results to results from corresponding TEM images; and b) by analyzing the noise of the measured data. It is believed that the variation of CDs and SWAs on the through pitch pattern was consistent with the designed pattern layout and their variation from the design due to process variation should be smooth. Both verifications confirmed excellent results of metrology. In particular, the repeatability of SWA measurements from top down images was found to be 0.4 degrees, a 3-sigma variation. There is no other method to our knowledge to measure SWA from top down images.
In contrast to semiconductor manufacturing where features are mostly lines or contact holes, the disk drive reader has a complex, nonlinear 3D geometry. Metrology of such geometries is challenging; especially with regard to repeatability of measurements. New methods were needed to keep up with production requirements for metrology regarding uncertainty of critical dimensions (CD). We report a new method developed for CD metrology of the disk drive writer pole. The method demonstrated improved uncertainties compared to the regularly used CD-SEM algorithms and also has capability for side wall angle (SWA) metrology for process control.
The method utilizes multiple steps: a) extract contours from SEM images, b) identify exact locations on a curvilinear feature where CD should be measured, and c) provide CD measurements at these locations. SEM images from a variety of production wafers were used for evaluation of the developed method. Multiple series of SEM images were processed using a software utilizing advanced algorithms without using regular brightness threshold CD-SEM methodologies. It was found that CD repeatability was improved by a factor of three compared to the results of the regular threshold based CD-SEM method.
TEM imaging is used to measure side wall angle; it takes a lot of efforts for sample preparation and the feedback is slow. If extraction of SWA is possible from top down SEM images it would provide instant feedback to manufacturing and reduce cost. Monte Carlo simulations were used to understand the sensitivity of SWA to the trench CD and depth. Height of features was measured using AFM. A method to extract SWA from top down images was developed. Numerous SEM images were processed; results were compared to experiment and analyzed. It was shown that the 3-sigma repeatability of SWA measurement was 0.15 degree. It was also found that the left and the right SWA were different on multiple wafers, the results were very consistent from one image series to another one, at the same time the SWA difference between the left and right walls was considerably larger than the uncertainty of SWA measurement.
High power (HP) laser diodes with apertures around 100um pump solid state and fiber lasers, used for material
processing. The necessity for the second stage lasers originates from the well-known limitation of brightness of laser
diodes with the aperture increase due to appearance of multiple lateral modes. For the first time we report suppression of
lateral modes of 100um wide laser diodes by digital planar holograms. Digital planar hologram narrows spectrum of
laser diodes, similar to simple gratings, used in DFB and DBR lasers.
Since the last decade many efforts in optical lithography are devoted to the improvement of various system components both in order to enhance the optical resolution and to decrease the printing error. Last year we presented a general (i.e. nonparametric) method of the optimization of the pattern-independent components of partially coherent imaging system, such as both the illuminator and the final lens pupil distributions. Here we present further development of the method for the case when printing at only certain orientations is required. We demonstrate the improvements of both CD linearity and the resolution for two important examples. The first one is an optimized stepper, where printing at one orientation is mainly required. The second case is an SLM-based mask writer with four main rotations, such as 0, 45, 90 and 135 degrees. The first experimental results for the second case are demonstrated to be in agreement with the simulation.
SLM-based mask writers have high speed, good CD uniformity, good resolution [1], but they are limited by the
resolution of the optics. Moreover the optical image is not perfectly neutral; it has certain artifacts due to the partially
coherent nature of the light. It is possible to remove those if the mask data file is OPC processed for the mask writer
optics before the data is sent to the mask writing tool, but not without an impact on cycle time and cost.
In this work we have combined several elements to create a system for real-time OPC, i.e. the OPC processing of the
mask data is embedded in the data path of the mask writer. In this way it adds neither time, nor cost to the mask
production. First, the scheme uses the analog tilting mirrors of the Sigma mask writers which are pure amplitude (not
phase) modulators which make the rasterisation simple and makes interpolation and summation of the mirror amplitudes
possible. Secondly, the optics is optimized to minimize the optical interaction length, thereby reducing the number of
operations needed. Third, an explicit perturbation formula is used to correct the intensity on every edge. The fourth
element, is a reduction of the optical kernel based on the symmetries of the image. We show that the described OPC
processing is suited to be implemented in state-of-the-art FPGA devices.
The ability of optical imaging system to print in a particular node is determined by both CD linearity and resolution characteristics of the system. We present a general (i.e. nonparametric) method of optimization of partially coherent optical system (i.e. both polarizing/nonpolarizing pupil and illuminator) for the printing of any particular set of objects in the best possible printing node. The method turns out to be equivalent to an iterative quadratic-linear programming problem with inequality constraints. Additional requirements, such as, for instance, the focus sensitivity, are introduced naturally as the additional constraints. We present also the results of a hypothetical SLM-based mask writer optimization.
The CD linearity error rather than other light beam characteristics, such as optical resolution, is only important for microlithography. Optimization of CD linearity can be achieved by proper design of optical system. The method of variations is used here for direct solution of the problem to get the optimal design, the best possible pupil function of final lens in particular. The resulting optimal design depends from the allowed CD linearity error threshold only. In particular, this theory shows that an i-line mask writer should be capable of writing sub-0.25 micron lines and spaces with less than 20 nm CD linearity error (for λ=413nm and NA=0.86). The optimization method can be used in different models of light propagation, vectorial Debye model is used here in particular. The method is computationally simple since it turns out to be an eigenvalue problem for linear system of equation. Various light polarizations can be utilized. The method is also applicable for partially coherent imaging systems.
Digital Planar Holography (DPH) has arrived due to progress in microlithography, planar waveguide fabrication, and theoretical physics. A computer-generated hologram can be written by microlithography means on the surface of a planar waveguide. DPH combines flexibility of digital holograms, superposition property of volume (thick) holograms, and convenience of microlithographic mass production. DPH is a powerful passive light processor, and could be used to connect multiple optical devices in planar lightwave circuits (PLCs), and if combined with active elements on the same chip, may perform not only analog operations but also logical ones. A DPH implementation of a multiplexer/demultiplexer with discrete dispersion is proposed and demonstrated, avoiding communication signal distortion inherent in multiplexers/demultiplexers with continuous dispersion. The concept of discrete dispersion leads to a device with a flat top transfer function without a loss penalty. The dispersion is created with custom-designed bandgaps for specific directions. A DPH hologram resembles a poly-crystal with long-range correlations, and it exhibits the properties of a quasi-crystal. Unlike photonic crystals, light in quasi-crystal may propagate in almost any direction. Single mode planar waveguides are specially designed to suppress parasitic reflections that appear due to mixture of TE-modes, TM-modes, and cladding modes. Demultiplexers with 2-32 channels were demonstrated on planar waveguides with binary single-layer lithography.
A novel concept of Photonic Bandgap Quasi-Crystal (PBQC) as a platform for planar integrated WDM optical devices is proposed. The PBQC can be lithographically fabricated in a planar waveguide as a computer-generated two-dimensional hologram. In this approach the spectral selectivity of Bragg gratings, focusing properties of elliptical mirrors, superposition properties of thick holograms, photonic bandgaps of periodic structures, and flexibility of lithography on planar waveguides are combined. In distinction to conventional combination of independent planar Bragg gratings, in PBQC we create multiple bandgaps by synthesizing a synergetic super-grating of a number of individual sub-gratings. The device spectral selectivity is determined by those of the sub-gratings. The super-grating comprises million(s) of dashes etched on an interface of a planar waveguide. Each dash is a binary feature placed by a computer program to serve simultaneously many channels. For realization of PBQC devices the software for generating super-gratings (GDS-II format) and 2-D simulation of its transfer function was developed. Direct e-beam writing and photolithography were used for manufacturing PBQC structures. For verification of the ideas behind the concept a number of multichannel MUX/DEMUX devices have been manufactured and experimentally tested. The results of detailed experimental study of 4- and 16-channel devices will be presented. Channel isolation ~30 dB was achieved in the 4-channel devices. The applications of PBQC platform for integrated light wave circuits are discussed.
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