The
directed self-assembly (DSA) of a 20 nm full-pitch silicon-containing
block copolymer (BCP), poly(4-methoxystyrene-b-4-trimethylsilylstyrene),
was performed using a process that produces shallow topography for
hybrid chemo-/grapho-epitaxy. This hybrid process produced DSA with
fewer defects than the analogous conventional chemo-epitaxial process,
and the resulting DSA was also more tolerant of variations in process
parameters. Cross-sectional scanning transmission electron microscopy
(STEM) with electron energy loss spectroscopy (EELS) confirmed that
BCP features spanned the entire film thickness on hybrid process wafers.
Both processes were implemented on 300 mm wafers initially prepatterned
by 193 nm immersion lithography, which is necessary for economic viability
in high-volume manufacturing. Computational analysis of DSA extracted
from top-down SEM images demonstrates the influence of process parameters
on DSA, facilitating the optimization of guide stripe width, guide
stripe pitch, and prepattern surface energy. This work demonstrates
the ability of a hybrid process to improve the DSA quality over a
conventional chemo-epitaxial process and the potential for high-volume
manufacturing with high-χ, silicon-containing BCPs.