The Challenges in Making NIL Master Templates
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1 The Challenges in Making NIL Master Templates Naoya Hayashi Dai Nippon Printing Co., Ltd. A Member of the ebeam Initiative 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved.
2 OUTLINE Recent Progress in Nanoimprint for CMOS Challenges in NIL master templates Patterning challenges Summary 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 11
3 NIL template strategy Multiple replica templates will be duplicated from high quality EB written master template. Master EB writing High quality master template Replica templates used as stamps for wafer lithography Imprint Replica Wafer imprint Multiple replica templates 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 22
4 Template fabrication process Master EB writing Develop Etching Repair Zero defect master Resolution IP control CDU Uniformity Inspection Fine repair Replica Master Replica Wafer imprint Imprint Defect IP control CDU Etching Uniformity Defect Inspection 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 33
5 Comparison between Optical masks and NIL templates Difficulties in NIL template fabrication Master template resolution and throughput are the most critical issues for X1 lithography Defect control becomes difficult due to near field (contact) lithography Duplication from master to replica template degrades master template performance NIL template Optical/EUV mask Lithography Near field lithography Far field lithography Magnification X1 X4 Field size 26mmx33mm 112mmx132mm Substrate 6025 Quartz 6025 Quartz Mask fabrication Master: EB / Replica: NIL EB lithography EB process High resolution / low sensitivity / Non-CAR High sensitivity / CAR 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 44
6 General performance status at hp3x nm generation 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 55
7 Replica Template CD uniformity CD map of the current template : - : + Error sources: Master uniformity, RLT uniformity, Etching uniformity, need to be optimized. Master RLT (Residual film thickness) CDU(3σ) = 1.5nm 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 66
8 IP : Master & Replica Image placement has been reached to less than 2.5nm. Master residual x=1.13nm, y=1.82nm Replica residual x=2.00nm, y=2.48nm Master 10nm Replica 10nm 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 77
9 Defect density (pics/sq.cm) History of replica template defect improvement Defect density (DD) has been reduced to 0.6 pcs./cm 2 by defect source analysis and process optimization Non-fills Plugs DD:0.6pcs/cm Master damages 10 Process defects 1 Q3 Q4 Q1 Q2 Q3 Q4 H1 H Dai Nippon Printing Co.,Ltd. All Rights Reserved. 88
10 Defect density of replica Defect density of replica template is now less than 5 pieces/cm 2 Defect density (pics/sq.cm) Number of replica 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 99
11 NIL Template Readiness Templates are ready for use! Target Status Defectivity (pcs/cm2) CD Uniformity (3σ, nm) Image Placement (3σ, nm) * Status of hp2x and 1x nm generation were updated at the morning sessions of today Dai Nippon Printing Co.,Ltd. All Rights Reserved. 1010
12 Patterning Challenges 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 111
13 1x nm template 1x nm replica fabrication is confirmed down to 18nm LS. Master resolution is a key to extend NIL. HP22nm HP20nm HP19nm HP18nm HP17nm Master Replica 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 1212
14 Multi-beam Mask Writer:10nm beam resolution HP22nm HP20nm HP19nm HP18nm HP17nm Master Replica EB with Non-CAR MBMW with Non-CAR 15nm L&S 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 1313
15 Multi-beam Mask Writer:10nm beam resolution Resist images Resolution with 100kV EB Writer hp16nm hp15nm hp14nm hp13nm 100KeV EB with Non-CAR MBMW with Non-CAR 15nm L&S 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 1414
16 Summary NIL template progresses in CMOS application CD uniformity of 1.5nm has been obtained. Image placement of within 2.5nm residual distortion has been obtained. Defect density on templates has been improved to zero defect on master template, and <1 defect/cm2 on replicated template at hp3x nm generation. We have been working on further improvement on hp2x/1x nm. Patterning challenges in master templates Resolution down to 1x nm and beyond Throughput Promising solution Multi e-beam mask writer will provide the solution! マスター 2011 Dai Nippon Printing Co.,Ltd. All Rights Reserved. 1515
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