Beams of electrons and ions are now fairly routinely focused to dimensions in the nanometer range. Since the beams can be used to locally alter material at the point where they are incident on a surface, they represent direct nanofabrication tools. The authors will focus here on direct fabrication rather than lithography, which is indirect in that it uses the intermediary of resist. In the case of both ions and electrons, material addition or removal can be achieved using precursor gases. In addition ions can also alter material by sputtering (milling), by damage, or by implantation. Many material removal and deposition processes employing precursor gases have been developed for numerous practical applications, such as mask repair, circuit restructuring and repair, and sample sectioning. The authors will also discuss structures that are made for research purposes or for demonstration of the processing capabilities. In many cases the minimum dimensions at which these processes can be realized are considerably larger than the beam diameters. The atomic level mechanisms responsible for the precursor gas activation have not been studied in detail in many cases. The authors will review the state of the art and level of understanding of direct ion and electron beam fabrication and point out some of the unsolved problems.

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Gas-assisted focused electron beam and ion beam processing and fabrication

Nanoimprint lithography (NIL) is a high throughput, high-resolution parallel patterning method in which a surface pattern of a stamp is replicated into a material by mechanical contact and three dimensional material displacement. This can be done by shaping a liquid followed by a curing process for hardening, by variation of the thermomechanical properties of a film by heating and cooling, or by any other kind of shaping process using the difference in hardness of a mold and a moldable material. The local thickness contrast of the resulting thin molded film can be used as a means to pattern an underlying substrate on wafer level by standard pattern transfer methods, but also directly in applications where a bulk modified functional layer is needed. Therefore it is mainly aimed toward fields in which electron beam and high-end photolithography are costly and do not provide sufficient resolution at reasonable throughput. The aim of this review is to play between two poles: the need to establish standard processes and tools for research and industry, and the issues that make NIL a scientific endeavor. It is not the author’s intention to duplicate the content of the reviews already published, but to look on the NIL process as a whole. The author will also address some issues, which are not covered by the other reviews, e.g., the origin of NIL and the misconceptions, which sometimes dominate the debate about problems of NIL, and guide the reader to issues, which are often forgotten or overlooked.

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Nanoimprint lithography: An old story in modern times? A review

The fairly recent availability of commercial focused ion beam (FIB) microscopes has led to rapid development of their applications for materials science. FIB instruments have both imaging and micromachining capabilities at the nanometer–micrometer scale; thus, a broad range of fundamental studies and technological applications have been enhanced or made possible with FIB technology. This introductory article covers the basic FIB instrument and the fundamentals of ion–solid interactions that lead to the many unique FIB capabilities as well as some of the unwanted artifacts associated with FIB instruments. The four topical articles following this introduction give overviews of specific applications of the FIB in materials science, focusing on its particular strengths as a tool for characterization and transmission electron microscopy sample preparation, as well as its potential for ion beam fabrication and prototyping.

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Focused Ion Beam Microscopy and Micromachining

An extensive review is given of the results from literature on electron beam induced deposition. Electron beam induced deposition is a complex process, where many and often mutually dependent factors are involved. The process has been studied by many over many years in many different experimental setups, so it is not surprising that there is a great variety of experimental results. To come to a better understanding of the process, it is important to see to which extent the experimental results are consistent with each other and with the existing model. All results from literature were categorized by sorting the data according to the specific parameter that was varied (current density, acceleration voltage, scan patterns, etc.). Each of these parameters can have an effect on the final deposit properties, such as the physical dimensions, the composition, the morphology, or the conductivity. For each parameter-property combination, the available data are discussed and (as far as possible) interpreted. By combining models for electron scattering in a solid, two different growth regimes, and electron beam induced heating, the majority of the experimental results were explained qualitatively. This indicates that the physical processes are well understood, although quantitatively speaking the models can still be improved. The review makes clear that several major issues remain. One issue encountered when interpreting results from literature is the lack of data. Often, important parameters (such as the local precursor pressure) are not reported, which can complicate interpretation of the results. Another issue is the fact that the cross section for electron induced dissociation is unknown. In a number of cases, a correlation between the vertical growth rate and the secondary electron yield was found, which suggests that the secondary electrons dominate the dissociation rather than the primary electrons. Conclusive evidence for this hypothesis has not been found. Finally, there is a limited understanding of the mechanism of electron induced precursor dissociation. In many cases, the deposit composition is not directly dependent on the stoichiometric composition of the precursor and the electron induced decomposition paths can be very different from those expected from calculations or thermal decomposition. The dissociation mechanism is one of the key factors determining the purity of the deposits and a better understanding of this process will help develop electron beam induced deposition into a viable nanofabrication technique.

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A critical literature review of focused electron beam induced deposition

The application of focused ion beam (FIB) technology in microfabrication has become increasingly popular. Its use in microfabrication has advantages over contemporary photolithography or other micromachining technologies, such as small feature resolution, the ability to process without masks and being accommodating for a variety of materials and geometries. An overview of the recent development in FIB microfabrication technology is given. The emphasis will be on direct milling, or maskless techniques, and this can distinguish the FIB technology from the contemporary photolithography process and provide a vital alternative to it. After an introduction to the technology and its FIB principles, the recent developments in using milling techniques for making various high-quality devices and high-precision components at the micrometer scale are examined and discussed. Finally, conclusions are presented to summarize the reviewed work and to suggest the areas for improving the FIB milling technology and for future research.

https://iopscience.iop.org/article/10.1088/0960-1317/14/4/R01/pdf

Recent developments in micromilling using focused ion beam technology

In this article, some limitations of the processing of structures with dimensions in the nanometer range by focused ion beams will be discussed. In order to enable exact depth control of nanometer structures, the effective sputter yield of silicon was determined as function of the ion dose. At ion doses below 1016 cm−2, the effective sputter yield is not constant and the volume of the area processed increases due to the implantation of ions. Material removal can be measured for doses above 2×1016 cm−2 and it reaches equilibrium for doses of about 3×1017 cm−2. This dose dependence of the effective sputter yield becomes especially effective in beam tail regions with low ion intensity. The shape of nanostructures is further determined by combining the beam shape and the angle dependence of the sputter yield which was experimentally determined. Using this approach with a Gaussian beam shape, a comparison of simulated and measured sidewall angles has shown good agreement for trench structures. Only sidewall regions close to the surface and to the bottom of deep structures show slight deviations. At the surface, non-Gaussian beam tails lead to unintentional sputtering at the corners of the processed area. At the bottom, forward scattered ions lead to higher sputter erosion.

Limitations of focused ion beam nanomachining

UV nanoimprint lithography is attracting more and more interest, because it has the potential of becoming a high-resolution, low-cost patterning technique. The availability of suitable UV curing materials is mandatory for successful imprinting. Within this work, a systematic investigation of commercially available photocuring materials was conducted to provide an overview of the properties of these materials. Their wetting behavior with respect to different substrate surfaces was characterized and their surface tensions were determined from their contact angles against two specifically selected solid surfaces: This method is presented here for the first time. The adhesion properties of the UV curing materials to different substrate surfaces and to the mold were investigated and necessary curing times were estimated. Additionally, the dependence of the residual layer thickness on the viscosity and the initial dispensed volume of UV curing materials was analyzed. It was found that the resist formulation of ...

UV nanoimprint materials: Surface energies, residual layers, and imprint quality

For high precision micromachining of micro‐ and nanostructures by focused ion beams, the precision of the material removal process is of great importance. In this article, the topological properties of the ion beam generated structures like slope angles of trenches, surface roughness, and induced defects are investigated. The influence of the beam current and scanning strategy on the topological properties will be discussed. In addition, transmission electron microscopy analysis of thin lamellas generated by focused ion beams will be shown.

Investigations on the topology of structures milled and etched by focused ion beams

Focused ion beams are intensively used for device modification by local material removal and ion beam induced metal deposition. With shrinking dimensions on modern multilayer devices, the need for ion beam induced insulator deposition is increasing. In this article, tetramethoxysilane as a precursor for ion beam induced deposition has been investigated. The influence of beam parameters dwell time and loop time on the material deposition rate will be discussed and compared to model calculations. For optimized scanning conditions, a maximum deposition rate of 0.33 μm3/nC was found. Insulating films were also deposited using an electron beam. The chemical composition and electrical properties of these films were compared with the films deposited by the ion beam. For electron beam deposition, the resistivity of the deposited films was 1×106 Ω cm which is two orders of magnitude higher than for ion beam deposited film.

Tetramethoxysilane as a precursor for focused ion beam and electron beam assisted insulator (SiOx) deposition

The invention relates to a target device for a beam source for emitting high-frequency, especially X-ray-frequency, radiation (R) from the target device (21,...,26) which can be irradiated by a particle beam (e) in order to emit the high-frequency radiation (R) from an impact spot (12,11) of the target device. A source of the high-frequency radiation (R) is located in the region of the impact spot of the particle beam on the target device. A target material (A) which brakes the particles of the particle beam, and thus causes the high-frequency radiation, is associated with a carrier material (B) in the region of the impact spot (12,11,15,40) in such a way that the spatial definition of the target material, in a lateral and vertical direction (a1,a2,r), comprises essentially only the region which acts as a significant source of the high-frequency radiation (R), and the lateral resolution or dimension of one of the focal spots formed by the particle beam (e) is determined and is essentially limited to the target material (A).

C. Lehrer

Papers

Limitations of focused ion beam nanomachining

UV nanoimprint materials: Surface energies, residual layers, and imprint quality

Investigations on the topology of structures milled and etched by focused ion beams

Tetramethoxysilane as a precursor for focused ion beam and electron beam assisted insulator (SiOx) deposition

X-ray source having a small focal spot