Driven by ever-growing demands on 3D integration, various state-of-the-art electronics packaging techniques have been developed. This study presents a novel and cost-efficient 3D wafer level packaging technology based on co-planar Au–Si bonding structures, whose two remarkable features are (1) eliminating the height difference derived from multi-layer metal interconnection lines crossing bonding rings by building co-planar bonding structures and (2) accomplishing vertical interconnections of low-resistivity Si column structures by forming Au–Si bonding ohmic contacts. In this paper, the packaging structure is interpreted by designs, fabrications and tests, in which the efficiency verification on co-planar bonding structures and vertical interconnections is concretely addressed. The performances on co-planar bonding structures have been revealed by 3D profiles of bonding surfaces, cross-sectional SEM images (the gap-free bonding layer) and tensile tests for Au–Si bonding strength. Besides, tests on leak rates of packaged chips indicate good packaging hermeticity. In terms of vertical interconnection properties, an in situ extracting method on the specific contact resistance (ρc) is also introduced to quantitatively appraise the quality of Au–Si ohmic contacts. Therefrom, the measured resistance of a vertical interconnection (~1 Ω) could be qualified for most devices’ interconnection requirements. And further, the extracted ρc values of 1.83–3.48  ×  10−8 Ω · m2 also imply forming of good ohmic contacts in Au–Si bonding. More importantly, being analogously conducted by any available eutectic bonding techniques, this 3D packaging method has inherently extensive application prospects.

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KOH etching and Au/Si eutectic bonding are cost-efficient technologies for 3D device fabrication. Aimed at investigating the process compatibility of KOH etching and Au/Si bonding, KOH etching tests have been carried out for Au/bulk Si and Au/amorphous Si (a-Si) bonding wafers in this paper. For the Au/bulk Si bonding wafer, a serious underetch phenomenon occurring on the damage layer in KOH etching definitely results in packaging failure. In the microstructure analysis, it is found that the formation of the damage layer between the bonded layer and bulk Si is attributed to the destruction of crystal Si lattices in Au/bulk Si eutectic reaction. Considering the occurrence of underetch for Au/Si bonding must meet two requirements: the superfluous Si and the defective layer near the bonded layer, the Au/a-Si bonding by regulating the a-Si/Au thickness ratio is presented in this study. Only when the a-Si/Au thickness ratio is relatively low are there not underetch phenomena, of which the reason is the full reaction of the a-Si layer avoiding the formation of the damage layer for easy underetch. Obviously, the Au/a-Si bonding via choosing a moderate a-Si/Au thickness ratio (⩽1.5:1 is suggested) could be reliably compatible with KOH etching, which provides an available and low-cost approach for 3D device fabrication. More importantly, the theory of the damage layer proposed in this study can be naturally applied to relevant analyses on the eutectic reaction of other metals and single crystal materials.

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KOH etching and Au/Si bonding are primarily cost-efficient technologies for the miniaturization and integration of 3D device fabrications. In view of the incompatibility between conventional Au/bulk Si bonding and KOH etching, a modified Au/bulk Si eutectic bonding structure is proposed and verified in this study. Inspired by the local oxidation of silicon processes, the Au/Si eutectic reaction interfaces, which are vulnerable in KOH etching, can be protected with the oxide layers by the two-step thermal oxidation processes. Based on IR, SEM and EDS analyses, different etching performances have been dissected at different process parameters, in which choosing the two-step oxidation thicknesses plays a critical role. Specifically, the first-step oxidation thickness should be 1.273 times larger than the second-step oxidation while considering the KOH etching ratio of Si to silica. Further, acquired from tensile tests, the average floor levels of bonding strengths (∼23 MPa) indicate considerable application potential of the modified Au/bulk Si bonding structure in packaging, structure supporting, etc. This study provides an analogical strategy for another Si-based eutectic bonding technique suitable for wet etching processes.