Two new positive tone, chemically amplified, DUV resists from Shipley, XP-9525 and XP-9549Q (UV III) have been investigated for use as direct write e-beam resists. Both of these materials have shown extremely high resolution capabilities while maintaining excellent sensitivity to e-beam exposure. Sub-0.20 im line and space gratings were resolved in UV III, and 0.10 im gratings were resolved in XP-9525. A formal design of experiment was created and used as a framework to develop a process for UV III which would optimize several resultant responses including: exposure latitude, edge roughness, and sensitivity. This paper will discuss the process development of these resists, and detail their performance characteristics. Effects relating to post-exposure bake delay will also be considered due to the susceptibility of many chemically amplified resists to airborne contaminants. UV III exhibited much greater stability than XP-9525, and was able to maintain precise linewidth control after 4 hours of delay, making it acceptable for use in a normal process environment. In contrast, XP-9525 exhibited severe T-topping after post-exposure bake delays of only 15 minutes, a condition which can only be solved using additional processing steps and/or environmental controls.KEY WORDS: chemically amplified, deep UV lithography, direct-write, e-beam lithography, photoresist, UV 111, XP-9525, XP-9549
INTRODUCTIONModern e-beam lithography systems are capable of generating sub-0.25 im lines with a high level of pattern placement accuracy and linewidth control. To take advantage of their capabilities, an optimized photoresist process capable of high resolution must be used. In addition to resolution, direct write e-beam lithography ideally requires a resist which is etch resistant, and has enough sensitivity to allow for a high throughput.Typically, the highest resolution photoresists are extremely slow, requiring a high dose to attain full exposure. This greatly limits the throughput of e-beam systems, and relegates their usefulness mainly to single-device, R&D applications. PMMA is an example of a commonly used, low sensitivity, high resolution, E-beam resist routinely capable ofsub-0.25 pm lithography. (1) Other e-beam sensitive resists such as PBS (2) and EBR-9 (3) offer dramatically improved sensitivity. However, when compared to PMMA, PBS has lower resolution. Neither resist offers the level of plasma etch resistance which is critical for many wafer etch processes. As a result, they are more suitable for applications demanding high throughput such as 5xreticle generation.Presently, very little emphasis is being placed on the development of resists designed strictly for e-beam use because of its low volume relative to optical lithography. Resist manufacturers are currently working to develop resists for deep ultraviolet (DUV-248 and 193 nm) lithography, a technology expected to be the predominant lithography technique during the next decade. In addition, since these resists are designed for wafer processing applications, they are ...