Current status of EUV lithography

It is undeniable that extreme ultra-violet lithography has progressed in an extraordinary way in the last 12 months.

Until recently, it was not commonly agreed upon in the lithography industry whether EUV litho would have made it to full production or HVM (high-volume manufacturing) at all.

Naysayers were pointing to the fact that the power of the light source was lagging much behind the level needed for HVM and that the issues in mask defectivity control and in resist development were far from being addressed properly.

Fortunately enough, in the last 12 months huge progress has been made in most if not all areas of EUV litho:

1. Light source development

Most of EUV pundits believe that light source power is the single most important issue for successful EUV lithography development and most resource investment related to EUCV has been focused in achieving a light source powerful enough to sustain high-volume manufacturing requirements.

Only one year ago, TSMC was having problems in breaking the 10W barrier while now the same company made public their results and claimed they were able to achieve an impressive 1000 wafers processed in a single day with a 80W source.

The two major companies behind EUV light source development, Cymer and Gigaphoton, are both claiming to be on track to achieve a 125W power source by the end of this year with a 250W light source on the horizon for next year.

Cymer claims to have a 100W power source running in their labs with 3.5% conversion efficiency and based on a 15KW laser which they hope to be able to upgrade to 5.5% conversion efficiency using a 27KW laser by next year at latest, which would mean 250W of light source power, well enough for high volume manufacturing

Gigaphoton, on the other hand, recently issued a press release announcing to have a light-source running at 142W with 50% duty cycle (=71W at 100% duty cycle), a significant improvement from last December when they claimed to have a 120W working at 50% duty cycle. Gigaphoton made clear that they are now looking for achieving 250W in “burst mode” before being able to expand the source availability.

While neither Gigaphoton nor Cymer have any plans for light sources beyond the 500W mark, Free Electron Lasers are now being considered by other players as a viable route to step into the 500W~10000W range which is what will be needed for high-NA scanner machines.

2. High-NA scanners

Carl Zeiss is currently working on improving the optics quality and based on this, ASML is now hoping to be able to achieve numerical aperture (NA) of 0.5 up from the current mark of 0.33 which would allow to reach a couple of nodes beyond 10nm without the need of multiple patterning using EUV.

3. Resists

Resist development has been an issue mostly disregarded by EUV pundits until recently as all the attention went to what was considered as the major hurdle for full development of EUV litho, that is, the availability of a light source powerful enough for HVM.

Since now the problems with light source development seem to be on track to be solved, attention is back to other aspects of EUV litho development such as resist.

Due to strict requirements it takes quite some time, even 1~3 years at least, to have a resist validated for full production so it has now become imperative to address this issue as well.

Much of the recent work is now behind negative-tone CAR resists, while Intel is working with resist makers on HfO2-based resists trying to improve their shelf-life from the current range of few weeks to a few months or more.

The advantage of metal oxide-based resists is that they have high absorption properties and therefore they can allow the use of light sources with lower power.

Other areas of development where control in EUV mask defectivity, with Hoya showing promising results in reducing the mask blank defects, and mask defect inspection, with Carl Zeiss announcing their upcoming tool specifically targeted at EUV mask inspection by the end of this year .

IBM’s EUV System Exceeds Target Output at 637 Wafers / Day

IBM has recently reported that their latest ASML extreme ultraviolet (EUV) lithography scanner system, NXE3300B, has produced 637 wafers in its first 24 hours of operation using a 44 watt light source at a rate of 34 wafers per hour, exceeding their target throughput of 500 wafers per day.

EUV is considered as the next generation technology for lithography scanners that will make the continuation of Moore’s law possible. As predicted by Moore’s law, the amount of transistors that can fit in a chip at a reasonable cost will double every two years. And the industry is now looking at EUV as the primary printing solution for finer patterns of smaller and denser chips.

However, even at the rate of IBM’s EUV scanner, it will still be difficult for the industry to continually shrink the transistors in a chip.  This technology will still be under research due to a couple of challenges. One of which is the weak light source, limiting the system from reaching the throughput requirement of at least 100 wafers per hour for mass volume production. Such throughput needs about 250 watts of light. Dan Corliss, IBM program manager for EUV development, said that they [IBM] are hoping to get an 80 watts of light source from ASML in about six months.

Comparing with the previous EUV systems of IBM and ASML which produced 7 and 14 wafers per day, respectively, this latest result of 637 wafers in a day is definitely a pleasant surprise for both IBM and ASML. Corliss’ team has been working on the EUV technology for 12 years. They had been calibrating the NXE3300B scanner for two months, which was initially delivered with only 25 watts of light source.

During the first tests, the system experienced interruptions along the way and the scanner was only up for about 77% of the time delivering 20 milliJoules across 83 pattern fields per wafer. Corliss estimated that without those interruptions, they would have produced more than 800 wafers in a day. The team is looking at the intermittent availability of the light source, and other issues with the system like mask defects.

In parallel to the EUV research activity in IBM, ASML is also working on pellicle development.  Pellicle is the filter used in immersion scanners and the manufacturers of ICs have been wanting it on their EUV systems too. Once ASML successfully emerge pellicle in EUV systems, the industry will surely benefit from this.

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Gigaphoton’s EUV Light Source Advances to 92 Watts Output at 4.5 CE

Gigaphoton Inc. has recently announced that they were able to produce a light output for extreme ultraviolet (EUV) lithography scanners with more than twice of the amount they had three months ago. From the 43 watts at 2.4 conversion efficiency (CE) reported output last February, their prototype laser-produced plasma (LPP) is now emitting light at 92 watts with 4.5 CE.

As one of the main manufacturers in lithography light sources, Gigaphoton has committed to continuously explore the EUV light sources until its output is ample for mass-production. Because of the low output power of the light sources used in EUV systems, wafer exposure takes longer time to complete, which results to throughput insufficiency for high-volume manufacturing (HVM). To demonstrate it with an actual manufacturing data,  a 70 watts light output can only produce 52 wafers per hour. With 92 watts, on the other hand,  Gigaphoton estimated that the throughput will increase to 60 wafers per hour. By the end of 2014, Gigaphoton aims to produce as much as 150 watts and eventually push it further until it reaches the minimum considered output for HVM, which is  250 watts.

Hitoshi Tomaru, Gigaphoton’s president and CEO, said that their achievement of 92 watt output with their light sources is a fruit of the steady, yet unique, R&D efforts to achieve development of higher output, stable, and lower cost of ownership [on] LPP light sources. He also believes that their expertise and efforts to develop LPP light source that accelerates the development of EUV scanners for HVM will encourage the industry to introduce the EUV scanners as the next-generation lithography tools.

The big leap in the energy output of Gigaphoton’s LPP prototype can be attirbuted to the optimized lasers, which radites small tin droplets of diameter less than 20 micrometer with solid state, pre-pulser laser (Yag laser) and high power CO2 laser.  The Yag  laser breaks up the tin droplets into smaller fragments, which when once spread at a sufficient diameter is theexposed on the CO2 laser. The electrons of the plasma radiate with the tin ions, emitting photons of a desired wavelength of 13.5 nanometers. To optimize the performance of the collector mirror, the unwanted tin debris of the radiation are removed by a high output, super conducting magnet and tin etching.

Gigaphoton is a wholly owned subsidiary of Komatsu Ltd. Their EUV light source reasearch and development is a program subsidized by New Energy and Industrial Technology Development Organization (NEDO). Gigaphoton’s innovative efforts on LPP EUV technology and other laser technologies has paved the way to cost effective and productive lithography light sources.  They have been working aggressively on EUV lithography with the obejctive of surpassing the era of ArF lithography.

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The role of Applied Materials in the upcoming 3D stacking revolution (part 2)

3D stacking

So where Applied Materials see their strength in this process?

One of the areas where Applied Materials can work well with is the creation of the structure itself as the requirement for high precision manufacturing of the staircase structure leaves, as said, very little room for error. While an inferior process may lower the yield of a planar structure of just one or two percentage points, the same inferior process may lower the overall yield of a 16 or 32-layered structure considerably.

Another advantage for Applied Materials with 3D stacking is that the lithography part of the equation, while still important, is somehow less crucial to the final result as a 3D stacked structure built with 45nm lithography technology may have similar performance than a planar structure built with 22nm lithography. This would be good news for Applied Materials, who has more control on the etching and stacking side of the process and less control on the lithography and patterning side.

However, a loosening on tolerances on the lithography part comes with stricter tolerances on the etching part due to the precision needed to align and etch each layer: but here is where Applied Materials believes to have a competitive edge over other companies

One of the areas where Applied Materials claims to be able to offer improvements to the current process is with high aspect ratio etching. With 3D stacked ICs it is necessary to etch vias with aspect ratio up to 70:1 or higher, but problems of charged particles need to be carefully controlled on this regard.

New technological improvements such as the ability to control source and bias of the etching machine are aimed to solve the problem of charge particles which could make the creation of straight vias impossible. In addition to this, another improvement is the ability to etch separate layers without having to load and upload the wafers in between, are claimed to be real breakthroughs aimed at bring forward 3D stacking to IC manufacturing.

But etching vias with high aspect ratio is not the only issue: being able to etch them fast enough is also a must. This means that it is necessary to apply top layers with high selectivity and thick enough so that the underlying layers will be etched fast and deep enough. Moreover, a highly anisotropic process is needed.

Lack of high selectivity would mean that the mask layer would have to be very thick to be able to etch deep enough and this may result in impractically thick mask layers. Lack of a highly anisotropic process would mean side walls not vertical enough to be able to reach the required depth for the vias.

Another potential show stopper is the requirement of strict tolerances with thin film thickness and therefore ability to be able to deposit layers with less than one percent variation in thickness along the whole surface of the wafer and among different layers of the same structure is critical.

In conclusion, creation of 3D structures involves many more steps than simply exposure, develop, etch and resist removal. In addition to this, focus in the process moves away from the sole lithography as other steps of the process, namely deposition and etching, become critical. It remains to be seen if Applied Materials and the other big guys involved in the industry will be able to deliver the new solutions that are needed to move from planar to 3D ICs, still going 3D may be the only way for the whole semiconductory industry to keep pace with the continuous trend of increase in performance for ICs due to the numerous delays that have affected EUV and other litho technologies that were supposed to extend Moore` s Law life until the 2020s at earliest.

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The role of Applied Materials in the upcoming 3D stacking revolution (part 1)

3D stacking

Recently in the internet there is much buzz about 3D stacking and in particular 3D NAND stacking with the upcoming revolution in the flash memory market with the mass adoption of this technology by all the major players.

One of the major companies involved is Applied Materials, a giant company based in the Santa Clara, California, US, founded in 1967 and with a long history of innovations in materials and processes for the semiconductor industry.

While there is much optimism in the industry for 3D stacking, still few major obstacles remain to solve before the technology is cleared for volume production.

3D stacking technology is very different from another technology that also includes the letters 3D in its name, that is, 3D FinFet technology, but with FinFets we are talking about a different shape of the transistor while with 3D stacking we are instead talking about materially stacking layers one over the other

Many different ways of stacking has been explored so far, some of them involving patterning an entire wafer and then folding it once or many times so that one side is over the other, other techniques involve patterning two or more wafers and then bonding them together to create a single structure.

While 3D stacking can be done in many ways, the main issues at the core of the technology are the same: how to align multiple layers of transistor or cells with the adjacent ones, how to create vias so that each layer can communicate and delivery information electrically to the others.

Since complex structures may require to stack up to 32 layers one over the other, it is quite clear that the issues involved can become very complex as soon as more and more layers are added to the structure.

So far, viable solutions to 3D stacking for ICs have been found for NAND flash cells, with several companies such as SanDisk, Samsung and others already offering 3D NAND products to consumers, while 3D stacking for logic is still few years away, according to analysts.

Still, several solutions have been proposed to overcome problems with stacked 3D NANDs and ICs as well. One of the major problems seems to be how to get signals on and off the structure, since it is not possible to use the classic solution of just putting a contact on top of each cell as you would do with planar flash.

A proposed solution is about creating a staircase-like structure where the area of the layers at the bottom of each structure is slightly and by a few microns in diameter larger than the area of the layer immediately above, therefore leaving some areas at the edge of each layer unexposed and free to be connected by a contact.

However, creating such a structure is very challenging as it requires to etch every layer in a different way, with high precision and with very little room for error and then create the necessary contact structure with different contact points for every layer. This amounts to a series of challenges mostly new for the whole industry. [To be continued]

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Nikon announces scanner for sub-10nm lithography

Direct self assembly

Japanese maker Nikon Corporation has introduced the new NSR-S630D ArF immersion scanner for patterning of IC chips at 10nm and below.

This news could be very important in an industry which is now moving from 14nm patterning to 10nm patterning and below in the next few years. Intel is already working on 10nm for its next generation of chips and beginning of production of 10nm IC components is scheduled for 2015.

Due to the increasing process complexities needed to transfer patterns of few tens of nanometers from the mask to the wafer, the industry has been exploring various options in the last two decades as it was widely believed until a few years ago that traditional stepper lithography would run out of gas around 90nm. The most prominent of such technologies is without doubt EUV, and most of the top-tier IC makers have invested billions in this technology. EUV technology is not employing a 193nm wavelength, but instead uses a much thinner 13.5-nm extreme ultra-violet light-source therefore allowing the patterning of much finer lines.

But while EUV has been plagued by numerous delays and it is now expected to reach maturity for high-volume production in a couple of years at the earliest, the life of traditional UV lithography has been extended thanks to numerous tweaks and fixes like multiple patterning and immersion which have helped the industry move from 90nm to the current generation of IC devices patterning at 14nm.

The new S630D stepper is part of the advanced Streamlign platform and delivers revolutionary solutions in order to extend the life of 193 nm immersion lithography until the 7nm node or possibly even up to the 5nm node, which is widely believed to be the end of traditional transistor scaling and the beginning of quantum-related nanotechnology.

Differently from EUV technology, where engineers are struggling to reach an output of 100 wafers/hours, Nikon has qualified their new scanner for HVM (high volume manufacturing) production at a whopping 250 wafer-per-hour efficiency. The new scanner is now able to achieve a resolution with is more than an order of magnitude finer than the wavelength of the laser used thanks to the improvements in reticle positioning accuracy and in thermal stress management. The new S630D is now able to reach a previously-unheard-of mix-and-match overlay (MMO) lower than 2.5nm and this means that the scanner is now able to meet most stringent requirements needed for multiple patterning with immersion.

The reason why such overlay requirements are so stringent is due to the fact that patterning such fine lines with a 193nm is like drawing a fine sketch using a broad brush. In order to achieve this, it is necessary to split all the patterning process into two, three or more masks and dedicate each single mask to a part of the whole patterning process. However, splitting the patterning process into multiple parts requires a strict overlay in order to avoid positioning errors between two subsequent exposures.

Hamid Zarringhalam, Nikon Precision Executive Vice President stated that his company is working hard to satisfy the device makers increasingly high demands for high-throughput production of IC devices at increasingly finer dimensions. Mr. Zharringalam believes that the key aspect of the new scanner offered by Nikon is the extremely accurate overlay control which reaches below 2.5nm and allows to bring multiple patterning to sub 10-nm patterning.

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MIT is working on direct self assembly

Direct self assembly

MIT (the Massachusetts Institute of Technology) has publicly announced some of the results obtained working on DSA (direct self assembly) patterning technology in an article published on Nature magazine.

DSA is one of the promising technologies that may enable the electronics and chip industry to keep pace with the requirements dictated by Moore` s Law.

Current lithography technologies like immersion and multi-patterning lithography, EUV among others, are becoming increasing expensive and the industry is exploring alternative solutions.

Electron beam, nanoimprint are among the alternatives, but electron beam technology is simply too slow to pattern large areas with sub-20nm features. Nanoimprint has several issues with alignment of planes for patterns on different layers.

Among the candidates we have direct self-assembly, a technology by which a block copolymer self-assemblies itself in order to produce small patterns in the order of few tens of nanometers. The technology, until recently considered very far from practical applications in volume production for IC manufacturing, is however heavily studied and worked upon. Direct self-assembly is now on the ITRS roadmap as next-generation lithography candidate

While DSA has already been proved on 300mm-wafers, the patterns produced so far had not enough resolution and very limited control on geometry. One of the main issues with direct self-assembly is that pattern size is not strictly determined and instead tends to variate between a lower value and a higher value.

Differently from traditional lithography, where the pattern is carefully produced on a mask and then copied in a step-and-repeat fashion on several wafers and in an exact manner, direct self-assembly relies on a statistical approach to patterns. Whether this new way to produce patterns can be applied in an industrial scale for IC manufacturing remains to be seen.

MIT has developed a simple but effective method to create a pre-defined pattern over a large area using direct self-assembly with the help of electron-beam lithography to work as a trigger for the self-assembly process.

We think that our current work will enable Moore’s Law to continue to be able to scale up transistors density and to help shrink feature size. Other patterning methods and technologies are available but the issue of the investments involved may prove prohibitive. Our research represents a possible future solution for this problem said Caroline Ross, MIT professor of Materials Science and Engineering.

Bob Havemann, Director of Nanomanufacturing Sciences at Semiconductor Research Corporation, a consortium of companies funding university research in energy-related areas such as photovoltaics, power electronics, energy storage and smart grid is also bullish on direct self-assembly as a potential enabler of Moore`s Law in the medium-long term. The request for more computer power due to increasing bandwidth and more power-crunching applications will simply keep increase in the next years. While traditional lithography has so far been able to cope with such increase in demand, the cost of keeping this growth going has also increased exponentially and this trend will not be sustainable in the long term. Therefore, the industry has to look for alternatives. I believe the work done by MIT represents a step in this direction.

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The long (and unfinished) story of EUV technology

EUV lithography

There are times in life when you understand that you are not so young anymore.

To me, it happens when I think about EUV technology.

I still remember very well when EUV was started to be heralded like the next generation breakthrough technology for lithography steppers.

I was an avid technology reader at the time and I first heard about EUV around 1995 or 1996, if I remember well.

Few years later, I remember the first discussions about when EUV would have been ready for production, I remember few analysts claiming EUV would have been ready for the 65nm node.

Well, this would have meant to have a production-ready tool by 2005.

Needless, to say, EUV never made it for an insertion at the 65nm node, then skipped the 45nm node as well, the 32nm node, the 22nm, the 16nm and now ASML is talking about alate insertion at the 10nm node, but most analysts are skeptical that the technology will be ready on time

I remember that few years after I started to hear talks about EUV, another technology was coming out as the most promising NGL (next generation lithography) candidate: 157nm.
157nm lithography was in some ways less revolutionary than EUV, it was the logical step in the traditional evolution of lithography, from using 248nm wavelengths lasers, to 193nm finally to 157nm

157nm lithography actually never made it into production as alternatives like immersion and multi-patterning lithography became mainstream.

So what about EUV?

EUB is still in the game, so much in the game that recently Intel has invested some $2.1billion in ASML and in return ASML has bought Cymer, a light-source maker specialized in light-sources for EUV.

At a party at the Belgian Embassy here in Tokyo, after the annual conference of IMEC at the New Otani Hotel, I approached a senior researcher from IMEC and asked why, despite the numerous delays of EUV, still the major players in the industry were pouring billions in this yet to be completely proven technology.

His answer was plain and honest: There are no other options

And his comment proved to be true: all the technologies that were hoped to become a potential replacement in case of EUV failure become players in other markets or simply disappeared.

Multiple beam E-beam technology, proposed by Mapper who got funded by TSMC, was assumed to become a player at the end of last decade but the hopes failed to materialize.
Nanoimprint technology is alive, kicking and growing, but not for IC manufacturing (despite Molecular Imprints` s claims to have a soon-to-be-ready IC-patterning capable tool). The technology has found a vast interest in the bio, film-replica and other markets.

Multiple patterning and immersion lithography have been heavily used to extend the life of conventional 193nm lithography so far, but costs are increasing exponentially at every node, and multiple patterning, once a synonymous of double-patterning, is now meaning triple, quadruple or even quintuple-patterning.

Direct self-assembly is promising, but still very much at the R&D level.
So what is left?
Not much, I would say.
Despite the claims of Peter Wennink, the new CEO of ASML, that EUV will, finally, be production-ready soon, we come to know that the technology will reach improved standards only by 2017, this is, definitely late for the 10n node and possibly late for the 7nm node.

While I do believe that EUV may be ready for mass-production before the end of the decade, the main issue would be if EUV will be ever seen as the savior of Moore` s Law or if, instead, will be relegated as a complementary technology with the mainstream production ecosystem moving to alternative solutions like 3-D stacking, for example.

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