Recently, metal-assisted chemical etching (MaCE) has been proposed as a promising method for micro-and nanostructures fabrication on silicon (Si) with high aspect ratio, high geometric uniformity and low cost. In MaCE, electron holes (h + ) are injected into Si through catalytic reduction of H 2 O 2 on metal catalyst thin film patterns. Si beneath the metal is etched through a redox reaction where h + are involved. This work investigated a fundamental electrochemical process during MaCE: the transport of h + , and revealed its unique correlation with the 3D profile of the etching results. It is discovered that under the uniform etching condition, etching occurs both in the Si beneath the catalysts as well as on the sidewall of the etched space. On N-type Si, the sidewall etching is intrinsically depressed, and highly vertical HAR structures are formed; on P-type Si and undoped Si, the sidewall tapering becomes significant as the pattern number and density increase. The variation of the 3D profile can be explained by the CT during etching using a Schottky junction model, which show dependence on the intrinsic properties of the Si. CT involved in the two etching process can further be correlated by diffusion or drift of h + , which explains the influence of catalysts geometry. Fabrication of micro-and nanostructures on silicon (Si) is a key step in manufacturing of modern electronic and optoelectronic devices. Especially, the high-aspect-ratio (HAR) structures, of which the vertical dimension is much larger than the lateral dimension, enable orders-of-magnitude higher integration density and superior system performance compared to that of traditional planar structures by utilizing the space inside Si. HAR structures, such as deep trenches and deep holes, have been widely used in advanced Si-based devices. For example, deep trenches are the core structures in the microelectromechanical systems; 1 deep holes serve as the interconnect routes in the emerging 3D integration technology in microelectronic packaging.
2Most of these HAR structures are fabricated by selective removal of certain volume of Si from the bulk Si substrate, which is generally referred to as the etching of Si. Until now, the major applicable Si etching method for HAR structures fabrication is the deep reactive ion etching (DRIE). 3,4 In DRIE, Si is put in a gas chamber and etched by plasma. Although DRIE is able to fabricate a wide range of HAR structures, it is suffered from high cost. On the other hand, metal-assisted chemical etching (MaCE), a novel low-cost wet chemical etching method, has attracted attention from both academia and industry.