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ENSC E - 130 Teaches you microfabrication Techniques, Familiarize you with micro-Electro-MechanicalSystems (MEMS) Present applications in several domains: Biological and medical, Electrical, Magnetic, Structural, Fluids, Thermal. This course is part of 4 courses that may earn you a Citation in "Nanotechnologies and applications in bioscience"
ENSC E - 130 Teaches you microfabrication Techniques, Familiarize you with micro-Electro-MechanicalSystems (MEMS) Present applications in several domains: Biological and medical, Electrical, Magnetic, Structural, Fluids, Thermal. This course is part of 4 courses that may earn you a Citation in "Nanotechnologies and applications in bioscience"
ENSC E - 130 Teaches you microfabrication Techniques, Familiarize you with micro-Electro-MechanicalSystems (MEMS) Present applications in several domains: Biological and medical, Electrical, Magnetic, Structural, Fluids, Thermal. This course is part of 4 courses that may earn you a Citation in "Nanotechnologies and applications in bioscience"
Applications to BioMEMS ENSC E 130 2 Fundamentals of Microfabrication with Applications to BioMEMS Fawwaz Habbal Senior lecturer on Applied Physics and Harvard School of Engineering and Applied Sciences Executive Dean Ofce: Pierce Hall 216 ENSC E 130 Mondays at 5:30 PM 3 Fundamentals of Microfabrication with Applications to BioMEMS Teaching Assistant: Alexis Vitti Email address: lexvitti@seas.harvard.edu ENSC E 130 Mondays at 5:30 PM 4 Fundamentals of Microfabrication with Applications to BioMEMS Course website http://courses.fas.harvard.edu/ext/13210 Course e-mail (homework - Communications - Questions) mems130@fas.harvad.edu Ofce Hours By Appointment only -- Write to: Habbalf@SEAS.Harvard.edu 5 Course Objective This course Teaches you microfabrication Techniques, Familiarize you with Micro-Electro-Mechanical- Systems (MEMS). Present applications in several domains: Biological and medical, Electrical, Magnetic, Structural, Fluids, Thermal .. You will not become an expert - but you will be able to take more advanced courses and complement your working knowledge - if any. Discussion is important - Ask questions 6 Lectures Lectures will contain support materials and needed background Only general and introductory physical sciences background is necessary Some mathematics (not at a high level) will be encountered Lectured can be viewed on the internet Questions are welcomed during class and by e-mail We will devote a lecture or more to visit CNS labs at Harvard 7 Citation This course is part of 4 courses that may earn you a Citation * in Nanotechnologies and applications in Bioscience The courses are: ENSC E-130 (BioMEMS) - offered this semester ENSC E-140 (Nanotechnology) - offered next Fall ENSC E-150 (Bio-Nano) - offered this semester ENSC E-155 (Microuidics) - offered next semester (*) Minimum grade B is required 8 Homework and Exams Homework: Series of questions to expand on. Articles to read and discuss during the lectures. 40 % of your nal grade Final is a combination of: Questions (take home exam): 30% of your nal grade Term paper: 30% of your nal grade 60% of nal grade 9 Lecture 3 Fabrication Technologies 10 Fabrications Technologies Outline ! Hard Fabrication ! Lithography ! Etching Methods ! Deposition of Materials ! Soft Fabrication ! Micomolding ! Three Dimensional Photopolymerization ! Thick Film Technologies 11 Hard Microfabrication Will discuss mainly Silicon materials 12 Device Fabrication A material to create the device -- Silicon A process to follow -- Micromachining Process Characteristics Reproducible Reliable Scalable Inexpensive Environmentally friendly Tools to create the device - Lithography Tools to examine and verify - Microscopy Packaging Integration methods and tools 13 Micromachined Materials Device Material -- Substrates Silicon GaAs Other elemental or compound semiconductors Metals (bulk and foils) Glasses Quartz Sapphire Ceramics Plastics, polymers and other organics 14 Additive Materials Silicon (amorphous, polycrystalline, epitaxial) Silicon compounds (oxides, nitrides, carbides, ) Metals and metal compounds Glass Ceramics Polymers and other organics Biomaterials Micromachined Materials 15 Fabrication Processes Reference materials: Chapter 1 in Madous Book In Particular pages 1-31 16 Process needs to be one in a Cleanroom Small Features require cleanroom environment No particles or dust ! Different Classes for different applications 17 Methods - Top down Write the required pattern with: 1) Optical Lithography 2) Ion and Electron Beam Lithography 3) X-ray Lithography 18 Bottom Up Approach Chemical and statistical forces can create systems with natural scale in the sub-100 nm. Self-assembly Energetic and statistical forces cause crystalline order in solids, can spontaneously form of arrays of highly ordered nanostructures. Examples: Quantum dots Langmuir-Blodgett lms 19 Process to Create Patterns Pattern Generation Design Wafer WRITE the Pattern 20 Direct Write 21 Direct Write Mask Light Light Ions Ions X-ray Electrons Electrons Wafer Process to Create Patterns Pattern Generation Design 22 Direct Write Hardware No mask is needed Higher end systems use Direct Write on Wafer (DWW) exposure systems Excimer lasers: geometries down to 1 - 2 m Electron beams: geometries down to 0.1 - 0.2 m Focused ion beams: geometries down to 0.05 - 0.1 m But, this is a serial process wafer cycle time is proportional to the beam writing time, the smaller the spot, the longer it takes 23 Reactive Ion Etching (RIE and DRIE) RIE : chemical etching is accompanied by ionic bombardment Bombardment opens areas for reactions Ionic bombardment: No undercutting since side-walls are not exposed Greatly increased etch rate Structural degradation Lower selectivity 24 Reactive Ion Etching (RIE and DRIE) Deep Reactive Ion Etching (DRIE) Uses electron cyclotron resonance (ECR) source to supplement RIE Microwave power at 245 GHz is coupled into ECR Magnetic eld is used to enhance transfer of microwave energy to resonating electrons DRIE uses lower energy ions --> less damage and higher selectivity 25 DRIE AMMI Locus Nova BOSCH Patent 26 Lithography 27 Process to Create Patterns Pattern Generation Design Direct Write Mask Light Light Ions Ions X-ray Electrons Electrons Wafer 28 Photolithography A process to transfer a pattern that is created on a photomask onto a photoresist thin lm Photo masks are generated by an optical system or an electron system 29 Overview: Device Fabrication Surface Preparation Coating (Spin Casting) Pre-Bake (Soft Bake) Mask Alignment Exposure Development Post-Bake (Hard Bake) Processing Using the Photoresist as a Masking Film Stripping Post Processing Cleaning (Ashing) 30 Si Wafer Fabrication and Characteristics 31 Material Structure Atoms are arranged with a certain periodicity Each side has a length (a) There are also Hexagonal structures 32 Material Structure Miller indices for a simple Cubic Crystal [010] [001] [100] 33 Material Structure Miller indices for a simple Cubic Crystal [010] [001] [100] (100) (110) 34 Silicon Structure 35 Wafer Preparation 36 Wafer Fabrication http://www.egg.or.jp/MSIL/english/msilhist0-e.html Czochralski Crystal Growth Float Zone Process Gradual pull - from a rotating silicon seed SEED 37 Wafer Fabrication YEAR 38 Silicon Oxides 39 Silicon Oxides: SiO 2 Uses Diffusion masks Surface passivation Gate insulator (MOSFET) Isolation, insulation Formation: Grown / native Thermal: highest quality Anodization Deposited: CVD, evaporate, sputter 40 Thermal Oxidation of Silicon Thermal Oxidation is at high temperatures (900 - 1200 C) Two main processes : Dry Oxidation Si + O 2 --> SiO 2 @1 atm , 1000 C Wet Oxidation Si + 2H 2 O --->SiO 2 + 2H 2 Dry oxidation produces a better (more dense) oxide as compared to wet oxidation 41 Silicon Oxide 42 Other Silicon Compounds 43 Doping Doping n-type (e.g., Sb, As, P, Bi) electron donors (5 electrons in outer shell) p-type (e.g., B, Ga, In) acceptors (3 electrons in outer shell)
44 Polysilicon Silicon Carbide Polycrystalline Diamond Refractory Metals 2WF 6 + 3SiH 4 --> 2W + 3SiF 4 +6H 2 45 Silicon Nitride Si 3 N 4 uses Diffusivity of O 2 , H 2 O is very low in nitride Mask against oxidation, protect against water/corrosion Diffusivity of Na is also very low Protect against mobile ion contamination 46 Silicide Films Silicides are metal-silicon compounds. They are used for contacts. Typical thickness 0.1 to 0.2 m 47 Silicide Films 48 Silicide Films Ion Implant for mixing 49 Method for Creating Features 50 Si Etching and Characteristics 51 Etchant Properties Selectivity to masking layer(s) Selectivity to metals (e.g., Al) Etch rate Anisotropy (crystal plane selectivity) Surface roughness Control of etch parameters 52 Etching Plans 53 Etching Silicon etching: different rates Anisotropic Isotropic 54 KOH Etching Etching Rate: Varies with Temperature and Concentration (110) > (100) > (111) (100) > (110) > (111) 55 Anisotropic Etching (100 Surface) (110 Surface) Petersen Anisotropic = direction dependent 56 Anisotropic Etching 57 Creating Patterns with Lithography 58 An Overview 59 Major Pieces of Equipment Stepper position Accuracy can be as good as 50 nm 60 Masking with Photoresist 61 Creating a Mask The mask is the stencil of the required pattern CAD systems are used to create the patterns Pattern is created by photo projection exposure 62 Masks Create master patterns are transferred to wafers Both glass and quartz are used Photographic emulsion on soda-lime glass (cheap) Fe 2 O 3 on soda-lime glass Cr on soda-lime glass Cr on quartz glass (expensive, used with deep UV) Polarity light-eld: mostly clear, drawn feature are opaque dark-eld: mostly opaque, drawn feature are clear 63 Masking Shadow masking 15nm diameter had been prepared Exposure 1:1 to 10:1 Lateral resolution (b) is b = k (! / NA) NA is the numerical aperture; k = 0.5 theoretically b is affected by depth of focus 64 Mask Alignment 65 Mask Alignment Create marks on wafer to consecutively align several masks 66 Alignment 3 degrees of freedom between mask and wafer Modern process lines use automatic pattern recognition and alignment systems Usually takes 1-5 seconds to align and expose on a modern stepper Human operators usually take 30-45 seconds with well-designed alignment marks Normally requires at least two alignment mark sets on opposite sides of wafer or stepped region Use a split-eld microscope to make alignment easier 67 Alignment - Exposure 68 Alignment and Exposure Hardware Projection systems give the ability to change the reproduction ratio 10:1 reduction allows larger size patterns on the mask - more robust to mask defects Most wafers contain an array of the same pattern, so one cell of the array is needed on the mask These machines are also called Steppers Example: GCA-4800 Disadvantage of steppers: absolutely no defects, since it will be reproduced all over the wafer 69 An Alignment Machine (Karl-Suss) 70 Photoresist Materials and Application 71 Photoresist PR: Radiation-sensitive compound Requirements Etch resistance Thermal stability Ease of development Good adhesion Difcult to achieve in the UV region 72 Photoresist -Types Positive resists Exposed region becomes more soluble Patterns are the same as those on the mask Negative resists Exposed regions become less soluble Patterns are the reverse of the mask patterns 73 Components of Photoresist Conventional optical photoresist has three components 1) Matrix material 2) Sensitizer 3) Solvent Sensitizer (also called inhibitor) Photoactive compound (PAC) - Insoluble without radiation - preventing resist to be dissolved Take photochemical reaction upon exposing to light, transferring from dissolution inhibitor to dissolution enhancer 74 Photoresist - Matrix and Solvent Solvent Keep photoresist in liquid state Allows spin coating of the resist Solvent content determines resists viscosity and hence the its thickness Matrix Material (resin) Serves a binder Inert to radiation Dissolves fast in developer (~ 150 A/s) Provides resistant to etchers Provides adhesion to the substrate Contributes to the mechanical properties of the resist 75 Photoresist - Photo active Compound Function of PAC Dissolution Enhancer 1000 2000 /s Matrix + Sensitizer with Radiation Dissolution Inhibitor 10 20 /s Matrix + Sensitizer without Radiation NA 150 /s Matrix Differential solubility before and after exposure 100 : 1 76 Photoresist - Types Positive photoresist Three constituents: a photosensitive compound, a base resin, and an organic solvent. After irradiation, the photosensitive compound changes its chemical structure, and transforms into a more soluble species. Upon developing, the exposed areas are expunged. Negative photoresist Polymers combined with a photosensitive compound. Photosensitive compound absorbs the radiation energy - initiate a chain reaction that causes crosslinking of the polymer molecules. The cross-linked polymer has a higher molecular weight and becomes insoluble in the developer solution. After development, the unexposed portions are removed. 77 Positive and Negative Photoresist Positive Resist The solubility of exposed regions is much higher than the unexposed region in a solvent (developer) produces a positive image of the mask Negative Resist The solubility of exposed regions is much lower than the unexposed region in developer produces a negative image of the mask
78 Commercial Photoresist 79 Absorption of x-rays in some materials 80 Applying the Photoresist Spin Coating 81 Photoresist Spin Coating Wafer is held on a spinner chuck by vacuum Resist is coated to uniform thickness by spin coating Typically 3000-6000 rpm for 15-30 seconds Resist thickness is set by Resist viscosity Spinner rotational speed Resist thickness is given by t = kp 2 / " w k = spinner constant, typically 80-100 p = resist solids content in percent w = spinner rotational speed in rpm/1000 82 Spin Coating Use a centrally rotating substrate. Fast rotation creates centrifugal force with solvent evaporation create a constant thickness. Thickness can be 100nm Organic polymers and biopolymers can be deposited Stretching and orienting of molecules 83 Spin Coating 84 Spin Coating Machine PR applicator Wafer 85 Stages of Coating 86 Spin Coating - Defects Striations 30 nm variations in resist thickness due to nonuniform drying of solvent during spin coating 80-100 mm periodicity, radially out from center of wafer Edge Bead residual ridge in resist at edge of wafer; 20-30 times the nominal thickness of the resist radius on wafer edge greatly reduces the edge bead height Solvents are spun on after resist coating - partially dissolve away the edge bead Streaks radial patterns caused by hard particles of diameter greater than the resist thickness 87 Wafer Baking 88 Pre-Bake Pre-bake evaporate coating solvent Increase the density of the resist after spin coating. Typical thermal cycles 90-100C for 20 min. in a convection oven 75-85C for 45 seconds on a hot plate Microwave heating and IR lamps are also used in production lines 89 Pre-Bake A narrow time-temperature window is needed to achieve best linewidth control. The thickness of the resist is usually decreased by 25 % during prebake for both positive and negative resists. 90 Pre-Bake Convection ovens Solvent at surface of resist is evaporated rst can develop impermeable skin, trapping the remaining solvent inside Heating must go slow to avoid solvent burst effects Conduction (hot plate) Need an extremely smooth surface for good thermal contact and heating uniformity Temperature rise starts at bottom of wafer -- more thorough evaporation Faster and more suitable for automation 91 Hard Bake Removes all traces of the coating solvent or developer. Harden the developed photoresist prior to the processing steps - e.g. metal deposition, acid etching Main parameter is the plastic ow or glass transition temperature Some shrinkage of the photoresist may occur; introduces some stress into the photoresist 92 Photoresist Removal 93 Photoresist Removal Simple solvents are generally sufcient for none hard baked photoresists Positive photoresist acetone trichloroethylene (TCE) phenol-based strippers (Indus-Ri-Chem J-100) Negative photoresist: methyl ethyl ketone (MEK), CH 3 COC 2 H 5 methyl isobutyl ketone (MIBK), CH 3 COC 4 H 9 Plasma etching with O 2 is effective for removing organic polymer debris Shipley 1165 stripper (contains n-methyl-2-pyrrolidone) - effective on hard baked resist 94 Creating Patterns Using Masks and Photoresist 95 Pattern Transfer Now we have a substrate coated with a resist stencil. The stencil can be used to protect parts of the substrate during an additive step like a metal deposition. Or the stencil can allow some etching procedure to reach the substrate in well-dened locations in a subtractive step. Deposition is usually through evaporation or sputtering. 96 Photomask and Pattern Creation Mask Silicon wafer covered with Photoresist Expose Remove the exposed (or the unexposed) areas Z 97 Another Patterning Method mask Subtractive Additive Function layer mask Remove mask 98 Exposure 99 Exposure Methods 100 Projection Wafer Dioptric Reticle 101 Projection Lithography 102 Characteristics of a Microlithography System Resolution The resolution of an optical system is its capability to distinguish closely spaced objects. For a microlithography system, resolution denes the minimum linewidth or space that the system can print.
103 Characteristics of a Microlithography System Registration Capability A measure of degree to which the pattern being printed can be t (aligned) to previously printed patterns. Dimensional Control Ability to produce the same feature size with the same tolerance and position accuracy across an entire wafer and wafer-to-wafer Throughput The time to complete a print
104 Resolution Airy Disk: the smallest distance, L min , an optical system can resolve Rayleigh Criterion: The central maximum of each point sources lie at the rst minimum of the Airy disk L min = 0.61 ! / NA Numerical Aperture: NA = sin " For small ", sin " = " Numerical Aperture NA = ", L min
105 Depth of Focus (DoF) Requirement Why do we need to meet DoF Requirement? Substrate is not at - can varies as much as 10 m across a wafer There are previously fabricated patterns on the wafer DOF - The range over which there are clear optical images Depth of focus, DoF, can be expressed as: DoF = n
l / [2(NA) 2 ] DOF decreases fast when NA increase! 106 Homework Due next week. Send by e-mail to lexvitti@Seas.harvard.edu Also copy to: mems130@fas.harvard.edu Homework What is the depth of focus for a situation with ! = 435 nm, NA = 0.6, n =1.47 (DI water) 107 Depth of Focus
108 Photoresist - Contrast Contrast is determined by the Gamma (slope) of the response curve Gamma Represents the ability of resist to distinguish between light and dark regions Resist UV DUV + ive 2 - 3 1 - 2 - ive 5 - 10 3 - 6 Sensitivity (mJ/Cm 2 ) Resist UV DUV 100 20 - 40 109
Photoresist - Fabrication Issues Surface Reection Standing Wave Anti-reection coating Add unbleachable dyes to resist Post baking after exposure (before development) Multi-wavelength exposure
110 Light Transmission Near the Edges Z D = the thickness of the photoresist 2b = the minimum pitch of line spacing Z = the spacing For Contact Imaging: 2 b = 3 " (0.5 d ! ) For Proximity Imaging: 2 b = 3 " ! (Z + 0.5 d) 111 Homework Due next week. Send by e-mail to lexvitti@Seas.harvard.edu Also copy to: mems130@fas.harvard.edu Homework For the case of != 400 nm, d = 1m , Z = 10 m What is the minimum resolution for contact and proximity imaging? 112 Edges and Proles Feature edge prole is affected by The distance between the mask and the photoresist (Reduce the diffraction) The thickness of the photoresist The Exposure time The development 113 Modulation Transfer Function 114 How to Create Contact Problems: Optically at photoresist Dust Stiff masks 115 Smallest Features In the far eld approximation (like in microscopy), resolution limit is determined by diffraction L min =
!/ (2 #$) In contact printing, the exposure takes place via near eld. So, diffraction is not a limiting factor 116 Near Field Diffraction Z 117 Proximity Exposure 118 Phase Shifting Masks 119 Conformable Contact Lithography Wave Length = 220 nm Pattern Resolution = 100 nm L min = 50 nm 120 200 nm Grating Scanning electron micrograph of a 200-nm-pitch grating embedded in a deep-ultraviolet transparent SiO2 substrate depicts the structure of the embedded-amplitude mask 121 SEM image of a pattern replicated by Deep UV (100nm) 500 nm 100 nm 122 45 nm 123 Other Exposing Beams Electron and X-rays Beams Other Methods 124 E-Beams and X-ray Lithography DoF and resolution are improved with short wave illumination Throughput is an issue. So, these are used to create the masks Early 80s, deep UV (248 nm and 193 nm) was used with ArF and KrF excimer lasers X-ray required using synchrotron generators 125 Advanced Lithography Technology
E-Beam Lithography X-Ray Lithography Focused Ion Beam Lithography Imprinting Lithography 126 Electron-beam lithography The most common method to create very small features Electron beam exposure alters the chemistry of the resist instead of light exposure. 127 Electron Beam Lithography Electron beam lithography is one of the most promising of nanolithography. Similar to a Scanning Electron Microscope and often a scanning electron microscope is used. An electron beam is formed and scanned at a controlled rate over the surface of a photoresist. Scan rate is adjusted to deliver a "critical" dose of electrons to a selected area of the resist. The resist is either developed in a chemical bath similar to photolithography, or the electron beam interacts with the material to remove the resist material. 128 Electron-Beam Lithography (EBL) Diffraction is not a limitation on resolution Resolution depends on beam size, can reach ~ 5 nm Two applications: Direct Writing Projection (step and repeat) Issues: Throughput of direct writing is very low research tool or low pattern density production Projection stepper is in development stage. Mask making is the biggest challenge. Back-scattering and second electron reduce resolution with dense patterns 129 Schematic of E-Beam System
130 E-Beam Issues Electron Scattering in Resist and Substrate The scattered electrons also expose the resist!
131 E-Beam Issues - Proximity Effect MTF is greatly reduced at high pattern density - requires Use thin resist and thin substrate Adjust acceleration voltage Split pattern into several writings using different doses Adjust pattern size and shapes Adjust dose level to compensate scattering
132 Raith-150 EBL System at CNS Direct Writing and SEM system - Thermal assisted eld emission Resolution: 2 nm @ 1.0 KeV Column voltage range: 200 30V Resolution of laser interferometer register: 2 nm Maximum wafer size: 6 Writing speed: 10MHz
133 X-ray Lithography 134 X-ray Lithography X-ray lithography is one of the most promising technologies for nanolithography. Mask is made of an X-ray transparent material with a pattern of high Z material either etched or deposited on it. The mask is the limiting factor in X-ray lithography. Resolution of the pattern is dependant on the variations in the mask. Scalability to manufacturing would be relatively easy compared to some other techniques such as SPM lithography. 135 X-Ray Lithography (XRL) Very short wavelength (1.0 0.01 nm), Very high resolution Area exposure: higher throughput than e-beam system X-ray is transparent: Low level of dust/contamination impact Issues: Optics is extremely difcult no lens available for focused of defocused Point source and shadow exposure Geometric error Expensive and complicated X-ray sources Very complicated mask (Boron nitride) and fabrication Heavy metal (Au) as opaque material Low mass membrane (1 ~ 2 micrometer Si 3 N 4 ) as substrate 136 Minimum Feature Size in a Proximity Exposure with soft x-rays S nm Resist Mask 137 Focus Ion Beam Lithography 138 Focused Ion-Beam (FIB) Lithography Like EBL, FIB is used as direct writing exposure Potential: Less backscattering (larger mass than electron) Resist for FIB lithography is more sensitive Energy higher than electrons Better resolution and faster exposure speed than E-beam Issues: Lack of reliable ion sources Harder to be focused Shorter penetrate (absorption) depth in resist (~ 30 500 nm) - multilayer resist process Unexpected ion implantation on substrate beneath resist 139 Focused Ion-Beam (FIB) Lithography Conventional Photoresist Resist Implantation 140 Focused Ion-Beam (FIB) Lithography Inorganic Resist Ion Induced etching and Development 141 Focused Ion-Beam (FIB) Lithography Ion Beam Etching and Ion Implantation 142 Scanned Probe Lithography 143 Scanned probe lithography (SPL) Plowing: use an AFM tip to literally plow a groove through either a very thin resist layer or a self-assembled monolayer (SAM) on the substrate. Can produce lines in these layers as narrow as 20-30 nm Local oxidation: use either a conductive AFM tip or an STM tip to do local electrochemistry on the substrate Dip-pen lithography: use the tip of a AFM to transfer SAMs from reservoirs down the tip to the substrate STM lithography: position individual atoms one at a time to build up structures 144 Scanning Probe Microscope Lithography Performed by oxidizing a material with the electric eld created at the tip of a scanning probe microscope. Oxidized material can be removed by preferential etching. Resist materials can include Si and Ti (easily oxidized). 25 nm and 35 nm lines were formed by oxidizing Si with the AFM and then dry etched to a depth of 30 nm. 145 References 146 References B. J. Lin Contact and proximity Printing in Fine Line Lithography, Elsevier J. Goodberlet Applied Physics Letters Volume 76, 2000 Introduction to Microelectronic Fabrication Richard C. Jaeger, Addison-Wesley, 1993 S.K. Ghandi, VLSI Fabrication Principles John Wiley and Sons, New York, 1983 - Chapter 4