A new Robust Process Window Qualification (PWQ) Technique to perform
systematic defect characterization to enlarge the Lithographic process window is
described, using a Die-to-Database Verification Tool (NGR2100).
As the design technology node becomes smaller, k1 factor is decreasing below 0.3 and optical proximity correction
(OPC) divergence is increasing. The gate critical dimension (CD) control and systematic defect inspection is becoming
critical to improving circuit yield. For more accurate OPC verification and systematic defect inspection, design based
metrology become increasingly important, because accuracy of simulation based OPC model verification has its
limitation. In this paper, we used NGR-2100 as a design based metrology tool to confirm the accuracy of OPC modeling
and process window qualification. NGR-2100 uses high energy wide-beam for high speed secondary electron sampling
and large field of view. It can measure full chip CD distribution and more accurate process window compared to optical
inspection tool. Because of using high energy beam, conducting layer like carbon film should be coated on photo resist
patterned sample wafer to prevent local electron charging. However, coated carbon may increase CD variation. By using
atomic layer deposition-type TiN layer instead of carbon, CD variation could be reduced.
With the shrinking of device sizes, the issue of controlling gate critical dimension (CD) is becoming increasingly
important. In particular, the ability to find systematic defects and use that information in the design, optical proximity
correction (OPC), and mask creation phases is becoming critical to improving circuit yield. Current critical dimension
electron scanning microscopes (CD-SEMs) and macro inspection systems, however, fail to address this area in a
practically usable manner - with CD-SEMs limited by their low throughput, and macro inspection systems limited by
their low resolution. The NGR2100 die-to-database verification system introduces high-throughput, wide field of view
(FOV) electron beam scanning technology to allow for mass gate measurement and analysis. Using the collected data
combined with layout data and statistical analysis, the NGR2100 system categorizes and outputs the systematic CD
errors existing on a wafer, which can be fed back to the design, OPC, and mask creation phases for true design-for-manufacturing
(DFM) realization. This paper provides an overview of the NGR2100, the process involved for gate
CD error detection, and presents an actual case in which the NGR2100 was used to collect and analyze data for a
memory device.
The NGR4000 enables high precision verification of mask features, by matching Scanning Electron Microscope (SEM)
images of the mask features to their intended mask design data. The system detects defects in Critical Dimensions
(CDs) and feature placement relative to the large Field of View (FOV). This tool is optimized to determine pattern
fidelity and perform CD measurements with repeatability well ahead of ITRS roadmap requirements. This paper will
show examples and describe the advantages of mass CD measurements, and relative feature placement accuracy as new
technique to define pattern fidelity.
Imprint lithography has been included on the ITRS Lithography Roadmap at the 32 and 22 nm nodes. Step and Flash Imprint Lithography (S-FILTM) is a unique method for printing sub-100nm geometries. Relative to other imprinting processes S-FIL has the advantage that the template is transparent, thereby facilitating conventional overlay techniques. Further, S-FIL provides sub-100nm feature resolution without the significant expense of multielement, high quality projection optics or advanced illumination sources. However, since the technology is 1X, it is critical to address the infrastructure associated with the fabrication of templates. With respect to inspection, although defects as small as 70nm have been detected using optical techniques, it is clear that it will be necessary to take advantage of the resolution capabilities of electron beam inspection techniques. This paper reports the first systematic study of die-to-database electron beam inspection of patterns that were imprinted using an Imprio 250 system. The die-to-database inspection of the wafers was performed on an NGR2100 inspection system. Ultimately, the most desirable solution is to directly inspect the fused silica template. This paper also reports the results on the first initial experiments of direct inspection fused silica substrates at data rates of 200 MHz. Three different experiments were performed. In the first study, large (350-400nm) Metal 1 and contact features were imprinted and inspected as described above. Using a 12 nm pixel address grid, 24 nm defects were readily detected. The second experiment examined imprinted Metal 1 and Logic patterns with dimensions as small as 70nm. Using a pixel address of 3nm, and a defect threshold of 20 nm, a systematic study of the patterned arrays identified problem areas in the design of the pattern layout. Finally, initial inspection of 200mm fused silica patterned substrates has established proof of concept for direct inspection of imprint templates.
The Geometry Verification System NGR2100 enables verification of the entire die, on a resist or an after-etch wafer, by comparing images of a die with corresponding target CAD data. The system detects systematic defects by variable criteria setting for allowable deformation quantities and obtains a CD distribution diagram. The result of systematic defects can then be used to make root cause analysis. The CD distribution diagram can achieve stepper aberration analysis, process windows extraction, macro-loading effect analysis, FEM measurement, and trend analysis more efficiently. Consequently, the Geometry Verification System NGR2100 will contribute to quicker TAT for DFM in Design, Lithography and Mask production.
The Geometry Verification System NGR2100 enables verification of the entire die, on a resist or an after-etch wafer, by comparing images of a die with corresponding target CAD data. The system detects systematic defects by variable criteria setting for allowable deformation quantities and obtains a CD distribution diagram. The result of systematic defects can then be used to make root cause analysis. The CD distribution diagram can achieve stepper aberration analysis, process windows extraction, macro-loading effect analysis, FEM measurement, and trend analysis more efficiently. Consequently, the Geometry Verification System NGR2100 will contribute to quicker TAT for DFM in Design, Lithography and Mask production.
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