Focused Ion Beam Lithography

Abstract

Optical lithography is the unrivalled mainstream patterning method that allows for costefficient, high-volume fabrication of microand nanoelectronic devices. Current optical photolithography allows for structures with a reproducible resolution below 32 nm. Nevertheless, alternative lithography methods coexist and excel in all cases where the requirement for a photomask is a disadvantage. Especially for low-volume fabrication of microdevices, the need for a photomask is inefficient and restricts a fast structuring, such as required for prototype device development and for the modification and repair of devices. The necessity of high-resolution masks with a price well above €10k is too cost intensive for the fabrication of single test devices. For this reason ‘direct-write’ approaches have emerged that are popular for several niche applications, such as mask repair and chip repair. Optical direct-write lithography and electron beam lithography are among the most prominent techniques of direct-write lithography. Less known, but highly versatile and powerful, is the ion beam lithography (IBL) method. Optical direct-write lithography uses laser beam writers with a programmable spatial light modulator (SLM). With 500 mm2/minute write speed and advanced 3D lithography capabilities, optical direct-write lithography is also suitable for commercial microchip fabrication. However, with a resolution of 0.6-μm minimum feature size of the photoresist pattern, optical direct-write lithography cannot be considered a nanopatterning method. Electron beam lithography uses a focused electron beam to expose an electron beam resist. Gaussian beam tools operate with electron beams with a diameter below 1 nm so that true nanofabrication of structures is feasible. A resolution of 10 nm minimum feature size of the e-beam resist pattern has been successfully demonstrated with this method. However, special resists are required for e-beam lithography, that are compatible with the high energy of forward scattered, back-scattered and secondary electrons. A common resist for sub-50nm resolution is polymethylmetacrylate (PMMA) requiring an exposure dose above 0.2 μC/μm2. For highest resolution (below 20 nm) inorganic resists such as hydrogen silsesquioxane (HSQ) or aluminium fluoride (AlF3) are used, which unfortunately require a high electron exposure dose. Hence, high-resolution electron beam lithography (EBL) is linked to long exposure times which, in combination with a single scanning beam, results in slow processing times. Therefore, this high-resolution method is only used for writing photomasks for optical projection lithography and for a limited number of high-end applications. A resolution to this dilemma may be the use of multi-beam electron tools, as are currently under development. Also electron projection lithography has been under