With the introduction of the NXE:3400 scanner, EUV has progressed to High-Volume Manufacturing (HVM) for sub-10nm lithography. In this context, manufacturers are pursuing a dual-path approach towards near-zero reticle defectivity: EUV-compatible pellicle or zero particles towards reticle by advanced particle contamination control. However, given the high cost of reticles, it is equally important to establish tooling and processes for cleaning the reticle should a particle land on it.
To this end, we investigated an extension of the existing MeRiT mask repair product line to also address particle defects. The resulting tool for particle removal leverages the MeRiT know-how on defect repair using e-beam based repair schemes with a novel in-situ manipulator to remove particles, including real-time observation by SEM (scanning electrode microscopy).
This paper will focus primarily on a feasibility study, successfully demonstrating proof of principle of defect removal, reviewing the area of interest by SEM and showing no collateral damage being observed by SEM-EDX (Energy Dispersive X-ray) analysis.
Mask repair is an essential step in the mask manufacturing process as the extension of 193nm technology and the insertion of EUV are drivers for mask complexity and cost. The ability to repair all types of defects on all mask blank materials is crucial for the economic success of a mask shop operation. In the future mask repair is facing several challenges. The mask minimum features sizes are shrinking and require a higher resolution repair tool. At the same time mask blanks with different new mask materials are introduced to optimize optical performance and long term durability. For EUV masks new classes of defects like multilayer and phase defects are entering the stage. In order to achieve a high yield, mask repair has to cover etch and deposition capabilities and must not damage the mask. We will demonstrate in this paper that low energetic electron-beam (e-beam)-based mask repair is a commercially viable solution. Therefore we developed a new repair platform called MeRiT® neXT to address the technical challenges of this new technology. We will analyze the limits of the existing as well as lower energetic electron induced repair technologies theoretically and experimentally and show performance data on photomask reticles. Based on this data, we will give an outlook to future mask repair technology.
The introduction of extreme ultraviolet (EUV) lithography into manufacturing requires changes in all aspects of the infrastructure, including the photomask. EUV reflective masks consist of a sophisticated multilayer (ML) mirror, capping layer, absorber layer, and anti-reflective coating thereby dramatically increasing the complexity of the photomask. In addition to absorber type defects similar to those the industry was forced to contend with for deep ultraviolet lithography, the complexity of the mask leads to new classes of ML defects. Furthermore, these approaches are complicated not only by the mask itself but also by unique aspects associated with the exposure of the photomask by the EUV scanner. This paper focuses on the challenges for handling defects associated with inspection, review, and repair for EUV photomasks. Blank inspection and pattern shifting, two completely new steps within the mask manufacturing process that arise from these considerations, and their relationship to mask review and repair are discussed. The impact of shadowing effects on absorber defect repair height is taken into account. The effect of mask biasing and the chief ray angle rotation due to the scanner slit arc shape will be discussed along with the implications of obtaining die-to-die references for inspection and repair. The success criteria for compensational repair of ML defects will be reviewed.
Mask repair is an essential step in the mask manufacturing process as the extension of 193nm technology and the
insertion of EUV are drivers for mask complexity and cost. The ability to repair all types of defects on all mask blank
materials is crucial for the economic success of a mask shop operation. In the future mask repair is facing several
challenges. The mask minimum features sizes are shrinking and require a higher resolution repair tool. At the same time
mask blanks with different new mask materials are introduced to optimize optical performance and long term durability.
For EUV masks new classes of defects like multilayer and phase defects are entering the stage. In order to achieve a high
yield, mask repair has to cover etch and deposition capabilities and must not damage the mask. These challenges require
sophisticated technologies to bring mask repair to the next level. For high end masks ion-beam based and e-based repair
technologies are the obvious choice when it comes to the repair of small features. Both technologies have their pro and
cons. The scope of this paper is to review and compare the performance of ion-beam based mask repair to e-beam based
mask repair. We will analyze the limits of both technologies theoretically and experimentally and show mask repair
related performance data. Based on this data, we will give an outlook to future mask repair tools.
The EUV-photomask is used as mirror and no longer as transmissive device. In order to yield defect-free reticles, repair capability is required for defects in the absorber and for defects in the mirror. Defects can propagate between the EUV mask layers, which makes the detection and the repair complex or impossible if conventional methods are used. In this paper we give an overview of the different defect types. We discuss the EUV repair requirements including SEM-invisible multilayer defects and blank defects, and demonstrate e-beam repair performance. The repairs are qualified by SEM, AFM and wafer prints. Furthermore a new repair strategy involving in-situ AFM is introduced. This new strategy is applied on natural defects and the repair quality is verified using state of the art EUV wafer printing technology.
The EUV-photomask is used as mirror and no longer as transmissive device. In order to yield defect-free reticles, repair
capability is required for defects in the absorber and for defects in the mirror. Defects can propagate between the EUV
mask layers, which makes the detection and the repair complex or impossible if conventional methods are used. In this
paper we give an overview of the different defect types. We discuss the EUV repair requirements including SEMinvisible
multilayer defects and blank defects, and demonstrate e-beam repair performance. The repairs are qualified by
SEM, AFM and through-focus wafer prints. Furthermore a new repair strategy involving in-situ AFM is introduced. We
will apply this new strategy on real defects and verify the repair quality using state of the art EUV wafer printing
technology.
The EUV-photomask is used as mirror and no longer as transmissive device. In order to yield defect-free reticles, repair
capability is required for defects in the absorber and for defects in the mirror. Defects can propagate between the EUV
mask layers, which makes the detection and the repair complex or impossible if conventional methods are used. In this
paper we give an overview of the different defect types. We discuss the EUV repair requirements including SEMinvisible
multilayer defects, and demonstrate e-beam repair performance. The repairs are qualified by SEM, AFM and
through-focus wafer prints. Furthermore a new repair strategy involving in-situ AFM is introduced. Successful repair is
demonstrated on real defects.
Defects of the multi-layer (ML) mirror on a EUV reticle, so-called ML-defects, are a prime aspect why EUV mask
defectivity is considered a challenge before EUV lithography can be used for the production of future node integrated
circuits. The present paper addresses the possibility to mitigate the printability of these defects by repair. Repair of
natural EUV mask defects is performed using the electron beam based Carl Zeiss MeRiT® repair technology and is
evaluated by wafer printing on the ASML EUV Alpha Demo Tool (ADT) installed at IMEC. Both absorber defects and
ML-defects are included. The success of absorber defect repair (both opaque and clear type) is illustrated. For
compensation repair of ML-defects experimental proof of the technique is reported, with very encouraging results both
for natural pits and bumps. In addition, simulation is used to investigate the limitations of such compensation repair,
inspired by the residual printability found experimentally. As an example it was identified that alignment of the
compensation repair shape with the ML-defect position requires sub-20nm accuracy. The integration of an Atomic Force
Microscope (AFM) into the repair tool has been an important asset to cope with this.
EUVL requires the use of reflective optics including a reflective mask. The mask contains a reflecting
multilayer, tuned for 13.5 nm light, and an absorber which defines the dark areas. The EUV mask itself is a
complex optical element with many more parameters than just the mask CD uniformity of the patterned
features that impact the final wafer CDU. One of these parameters is absorber height. It has been shown
that the oblique incidence of light in combination with the small wavelength compared to the mask
topography causes a so-called shadowing effect manifesting itself particularly in an HV wafer CD offset. It
was also shown that this effect can be essentially decreased by reducing absorber height and, in addition, it
can be corrected by means of OPC.
However, reduction of absorber height has a side effect that is an increased reflectivity of a mask black
border resulting in field-to-field stray light due to parasitic reflections. One of the solutions to this problem
is optical process correction (OPC) at field edges. In this paper we will show experimental data obtained on
ASML EUV Alpha tool illustrating the black border effect and will demonstrate that this effect can be
accurately predicted by Brion Tachyon EUV model allowing for a significant cross field CD uniformity
improvement with mask layout correction technique.
Also we show by means of rigorous 3D simulations that it is possible to improve the imaging performance
significantly by performing global optimization of mask absorber height and mask bias in order to increase
exposure latitude, decrease CD sensitivity to mask making variations such as CD mask error and absorber
stack height variations. By sacrificing some exposure latitude throughput of exposure tool can be increased
essentially and HV mask biasing can be reduced. For four masks with different absorber thicknesses from
44 nm to 87 nm it is proven experimentally by means of the EUV Alpha tool exposures of 27 nm L/S that
the absorber thickness can be tuned to maximize exposure latitude. It was also proven that dose to size
grows with absorber height and optimal feature bias depends on mask absorber height.
EUVL requires the use of reflective optics including a reflective mask. The reticle blank contains a
reflecting multilayer, tuned for 13.5nm, and an absorber which defines the dark areas. The EUV mask is a
complex optical element with many more parameters than the CD uniformity of the patterned features that
impact the final wafer CDU. Peak reflectivity, centroid wavelength and absorber stack height variations
need to be tightly controlled for optimum performance. Furthermore the oblique incidence of light in
combination with the small wavelength compared to the mask topography causes a number of effects which
are unique to EUV, such as an H-V CD offset and an orientation dependent pattern placement error. These
so-called shadowing effects can be corrected by means of OPC, but also need to be considered in the mask
stack design.
In this paper we will show that it is possible to improve the imaging performance significantly by reducing
the sensitivity to mask making variations such as capping layer thickness and absorber stack height
variations. The impact of absorber stack height variations on CD and proximity effects will be determined
experimentally by changing the local absorber stack height using the novel e-beam based reticle repair tool
MeRiT® HR 32 from Carl Zeiss in combination with exposures on ASML's alpha demo tool. The impact of
absorber reflectivity will be shown experimentally and used to derive requirements for the reticle border
around the image field, as well as possible correction techniques.
Due to the updated ITRS roadmap EUV might enter the market as a productive solution for the 32 nm node1.
Since the EUV-photomask is used as mirror and no longer as transitive device the severity of different defect
types has changed significantly. Furthermore the EUV-photomask material stack is much more complex than
the conventional 193nm photomask materials which expand the field of critical defect types even further. In
this paper we will show, that "classical" 193 mask repair processes cannot be applied to EUV material. We
will show the performance of a new repair process based on the novel ebeam repair tool MeRiT® HR 32.
Furthermore this process will be applied on real EUV mask defects and the success of these repairs
confirmed by wafer prints.
UV nanoimprint lithography (UV-NIL) is a high-throughput and cost-effective patterning technique for complex nanoscale
features and is considered a candidate for CMOS manufacturing at the 22nm node and beyond. To achieve this
target a complete template fabrication infrastructure including inspection and repair is needed. Due to the 1X
magnification factor of imprint lithography the requirements for these steps are more challenging compared to those for
4X photomasks. E-beam repair is a very promising repair technology for high-resolution imprint templates. It combines
the advantages of precise beam placement using fine resolution images and damage free repair by electron beam induced
chemical reactions. In this work we performed template repair using a new test stand with improved beam and stage
stability. Repeatability of 3D pattern reconstruction with main focus on shrunk lateral repair dimensions and height
control was investigated. The evaluation was done on various features in a 40nm half pitch design. Additionally, the
resolution capability of the new hardware was examined on selected programmed defects in a 32nm half pitch design. A
first qualitative examination of the repaired template was done using top-view SEM images taken from the test stand
before and after repair. The repaired template was then imprinted on 300mm silicon wafers, and the imprinted repaired
defects were analyzed using a SEM Zeiss Ultra 60.
In today's economic climate it is critical to improve mask yield as materials, processes and tools are more time and cost
involved than ever. One way to directly improve mask yield is by reducing the number of masks scrapped due to defects
which is one of the major mask yield reducing factors. The MeRiTTM MG 45, with the ability to repair both clear and
opaque defects on a variety of masks, is the most comprehensive and versatile repair tool in production today. The cost
of owning multiple repair tools can be reduced and time is saved when fast turnaround is required, especially when more
than one defect type is present on a single mask. This paper demonstrates the ability to correct repair errors due to
human mistakes and presents techniques to repair challenging production line defects with the goal of maximizing mask
repair yield and cycle time reduction.
The cost and time associated with the production of photolithographic masks continues to grow, driven by the ever
decreasing feature size, advanced mask technologies and complex resolution enhancing techniques. Thus employment of
a high-resolution, comprehensive mask repair tool becomes a key element for a successful production line. The MeRiT®
utilizes electron beam induced chemistry to repair both clear and opaque defects on a variety of masks and materials with
the highest available resolution and edge placement precision. This paper describes the benefits of the electron beam
induced technique as employed by the MeRiT® system for a production environment.
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