Mask distortion issues for next generation lithography
Roxann L. Engelstad
(

)
and Edward G. Lovell (

)
UW Computational Mechanics Center (UW-CMC),
1513 University Ave.,
University of Wisconsin,
Madison, WI 53706, USA
Advanced lithographic technologies face a difficult challenge in order to meet
the stringent requirements for the 70 nm node and below. Extending 157 nm
lithography to these lower nodes will indeed require innovative technical
approaches. Consequently, it may be necessary to accelerate research and
development on NGL alternatives in order to meet the expectations of the new
ITRS roadmap.
A key issue for both optical lithography and the NGL technologies is the
design and implementation of a low-distortion mask. Research at the
University of Wisconsin Computational Mechanics Center (UW-CMC) is addressing
the development of advanced lithographic masks for the sub-70 nm regime.
Modeling and simulation is being used to investigate materials, fabrication
processing and general system parameters in order to achieve the necessary
pattern placement accuracy. This presentation will detail our latest
predictions on the overlay performance of the EUV and EPL mask systems.
For the EUV mask, finite element (FE) models have been used to simulate the
complete fabrication process flow, illustrating the importance of employing
the same type of chucking within each tool. Thermomechanical models were
subsequently used to identify the thermal response of the mask during scanning
exposure. The flatness requirements for EUV reticle have been investigated in
conjunction with the SEMI EUV Reticle Standard. One source of image placement
error (during electrostatic chucking) is the distortions induced when a
particle becomes lodged between the mask and the chuck. Predictive modeling
has been used to assess the influence of particulates of various sizes, shapes
and materials on the micro- and macro-scale response of the EUV reticle.
The UW-CMC has also been participating in a study of continuous versus
stencil membrane formats for the fabrication of EPL masks. The effects of
pattern density gradients have been identified both numerically and
experimentally; correction methods to alleviate gradient effects have been
evaluated in detail and will be presented. Additional models to simulate the
exposure heating (and corresponding distortion) have been used to investigate
stitching issues associated with EPL-type masks. The results emphasize the
benefits of the modeling and simulation programs for design and optimization
before implementation.