Extreme ultraviolet lithography (EUVL) was thoroughly reviewed over a broad range of topics, including history, tools, source, metrology, condenser and projection optics, resists, and masks. Since 1988, many studies on EUVL have been conducted in North America, Europe, and Japan, through state sponsored programs and industrial consortiums. To date, no “show stopper” has been identified, but challenges are present in almost all aspects of EUVL technology. Commercial alpha lithography step-and-scan tools are installed with full-field capability; however, EUVL power at intermediate focus (IF) has not yet met volume manufacturing requirements. Compared with the target of 180W IF power, current tools can supply only approximately 55–62W. EUV IF power has been improved gradually from xenon- to tin-discharge-produced plasma or laser-produced plasma. EUVL resist has improved significantly in the last few years, with 25nm 1:1 line/space resolution being produced with approximately 2.7nm (3σ) line edge roughness. A...

Extreme ultraviolet lithography: A review

Localized defects in multilayer coatings

The control of line-edge roughness (LER) of features printed in photoresist poses significant challenges to next-generation lithography techniques such as extreme-ultraviolet (EUV) lithography. Achieving adequately low LER levels requires accurate resist characterization as well as the ability to separate resist effects from other potential contributors to LER. One potentially significant contributor to LER arises from roughness on the mask coupling to speckle in the aerial image and consequently to LER in the printed image. Here I numerically study mask surface roughness and phase roughness to resist LER coupling both as a function of illumination coherence and defocus. Moreover, the potential consequences of this mask effect for recent EUV lithography experiments is studied through direct comparison with experimental through-focus printing data collected at a variety of coherence settings. Finally, the effect that mask roughness will play in upcoming 0.3-numerical-aperture resist testing is considered.

Relevance of mask-roughness-induced printed line-edge roughness in recent and future extreme-ultraviolet lithography tests

As critical dimensions shrink, line-edge roughness (LER) and linewidth roughness become of increasing concern. Traditionally, LER is viewed as a resist-limited effect; however, as critical dimensions shrink and LER requirements become proportionally more stringent, system-level effects begin to play an important role. Recent advanced extreme-ultraviolet resist testing results have demonstrated lower bounds on achievable LER at the level of approximately 2–3nm. Here, the authors use modeling to demonstrate that a significant portion of this low bound may, in fact, be do to system-level effects and, in particular, the mask. Of concern are both LER on the mask as well as roughness of the multilayer reflector. Modeling also shows roughness (flare) in the projection optics not to be of concern.

/pdf/system-level-line-edge-roughness-limits-in-extreme-2u2mebkq6w.pdf

System-level line-edge roughness limits in extreme ultraviolet lithography

The production of defect-free mask blanks remains a key challenge for extreme ultraviolet (EUV) lithography. Integral to this effort is the development and characterization of mask inspection tools that are sensitive enough to detect critical defects with high confidence. Using a single programed-defect mask with a range of buried bump-type defects, the authors report a comparison of measurements made in four different mask inspection tools: one commercial tool using 488nm wavelength illumination, one prototype tool that uses 266nm illumination, and two noncommercial EUV “actinic” inspection tools. The EUV tools include a dark field imaging microscope and a scanning microscope. Their measurements show improving sensitivity with the shorter wavelength non-EUV tool, down to 33nm spherical-equivalent-volume diameter, for defects of this type. Measurements conditions were unique to each tool, with the EUV tools operating at a much slower inspection rate. Several defects observed with EUV inspection were below...

https://goldberg.lbl.gov/papers/Goldberg_JVSTB_24(6)_2006.pdf

Actinic inspection of extreme ultraviolet programed multilayer defects and cross-comparison measurements

An approximate method is proposed to calculate the extreme ultraviolet (EUV) scattering from a defect within a multilayer coating. In this single surface approximation (SSA) the defective multilayer structure is replaced by a single reflecting surface with the shape of the top surface of the multilayer. The range of validity of this approximation has been investigated for Gaussian line defects using two-dimensional finite-difference-time-domain simulations. The SSA is found to be valid for sufficiently low aspect ratio defects such as those expected for the critical defects nucleated by particles on the mask substrate. The critical EUVL defect size is calculated by combining the SSA with a multilayer growth model and aerial image simulations. Another approximate method for calculating the aerial image of an unresolved defect is also discussed. Although the critical substrate defects may be larger than the resolution of higher numerical aperture cameras, the point defect approximation provides a useful fra...

Practical approach for modeling extreme ultraviolet lithography mask defects

An approximate method is proposed to calculate the EUV scattering from a defect within a multilayer coating. In this single surface approximation (SSA) the defective multilayer structure is replaced by a single reflecting surface with the shape of the top surface of the multilayer. The range of validity of this approximation has been investigated for Gaussian line defects using 2D finite-difference-time-domain simulations. The SSA is found to be valid for sufficiently low aspect ratio defects such as those expected for the critical defects nucleated by particles on the mask substrate. The critical EUVL defect size is calculated by combining the SSA with a multilayer growth model and aerial image simulations. Another approximate method for calculating the aerial image of an unresolved defect is also discussed. Although the critical substrate defects may be larger than the resolution of higher NA cameras, the point defect approximation provides a useful framework for understanding the printability of a wide range of defects.

/pdf/a-practical-approach-for-modeling-euvl-mask-defects-v6prfjgra3.pdf

C. Cerjan

Papers

Practical approach for modeling extreme ultraviolet lithography mask defects

A practical approach for modeling EUVL mask defects