Digital Scanner (DS) is an optical maskless exposure tool with a SLM (Spatial Light Modulator) and a DUV solid-state laser with wavelength of 193 or 248 nm. There are two configurations of SLM: a tilt SLM, in which each micro-mirror pixel tilts to change the amplitude of reflected light; and a piston SLM in which each micro-mirror pixel moves along optical path to change the phase of reflected light. Both types are applicable for DS, but piston SLM has a better image contrast due to strong phase shift effect. A DS proof-of-concept tool (DS-POC) with piston SLM and exposure wavelength of 193 nm was developed, which has a similar imaging resolution with the DS248, a tool planned as the first DS product for lithography of 180 nm node or below. Exposure results of 180 nm node logic patterns by DS-POC are presented. Process window analysis of the logic patterns by simulation shows better performance of piston SLM than tilt SLM on exposure latitude. CD accuracy of less than 10% was experimentally demonstrated for resolution chart of L/S with CD from 150 nm through 300 nm using piston SLM at DS-POC.
Nikon has been developing the Digital Scanner, an optical maskless exposure tool with a DUV light source. The Digital Scanner uses a spatial light modulator and rasterized pattern data, instead of glass photomasks, to project an optical image. The modulator is a micromirror array and each micromirror takes one of two possible states, so the pattern data are essentially equivalent to a one bit per pixel bitmap image. In spite of the one-bit depth input similar to a black-and-white bitmap, the Digital Scanner can control projected patterns in subpixel resolution because the pixel size is chosen to be smaller than the resolution of the projection optics. Besides the projection hardware, we have also developed special pattern data preparation system for the Digital Scanner in order to realize the subpixel controllability. Polygons from GDSII or OASIS files are rasterized by dedicated pixel-based algorithms so that the optical image of the resulting pixel data becomes equivalent to that of input polygons. Another pattern data converter with optical proximity correction (OPC) capability is also being developed and available for large area conversion. We explain the exposure system of the Digital Scanner and report the progress of the pixel-based data preparation system including recent demonstration printing results of exposure data generated by the new converter that has OPC capability.
Digital scanner (DS), a deep ultraviolet optical maskless exposure tool is being developed. DS uses a micromirror-type spatial light modulator to create the “mask” pattern combined with a solid-state laser with a wavelength of 193 or 248 nm. The exposure concept of DS and advantage of solid-state laser as an exposure light source is described. DS proof-of-concept tool with resolution of half-pitch 80 nm L/S was developed. The exposure results of maskless unique application, such as large area printing and chip ID printing for security purposes, are shown.
The first planned Digital Scanner product, DS248, will have the optical resolution of 110 nm and overlay accuracy of less than 10 nm, the same level as a KrF mask scanner. In addition, DS248 has more application areas, such as individual chip customization and large-area printing up to wafer size, with KrF resolution, which are not possible with the current mask scanner but will be beneficial for performance enhancement of semiconductor devices in future. The latest exposure results of DS-POC, which has the similar imaging performance with DS248, are introduced including chip ID exposure on entire 200 mm wafer and exposure of wafer scale integration substrate. Simulation data of high aspect ratio patterning with high resolution by means of integration of multiple heads of solid-state laser is described. Development progress of DS’s pixel mask conversion software that directly generates pixel mask from target pattern with OPC is reported.
Nikon has been developing the Digital Scanner (DS), an optical maskless exposure tool with a DUV light source and a micromirror-type spatial light modulator (SLM). Rasterized digital data, essentially huge bitmap files, are used to drive the SLM. The DS enables new applications such as large area printing and chip customization because its digital pattern data are easily modified. Flexible and fast data preparation software was developed for the new applications. As a standard operation of DS data preparation software, a CAD file (GDS or OASIS) is converted into bitmap files. In addition, bitmap file generation by a scripting language is available without a CAD file. This is useful when the CAD file includes a lot of polygons in which each polygon is similar but not identical, resulting in a huge file. As an example of application, a metasurface consists of sub-wavelength periodic patterns with various shapes, which are arranged to achieve the desired optical effect. The shape of each pattern at a grid point can be determined by a computer program, i.e., a pattern generator script. On the other hand, data preparation time can be shortened for periodic pattern which is often seen in semiconductor circuits. We report those data preparation methods for the DS, which have been used for our recent exposure experiments.
Maskless exposure makes possible of individual chip design customization and large area chip fabrication that are impossible with mask exposure.
We are developing DUV optical maskless exposure tool named as Digital Scanner (DS) that uses a spatial light modulator as a pattern generator and a DUV solid-state laser as a light source (193 or 248 nm).
We will report technology development progress of DS including the latest experimental data. Sub-pixel patterning capability by DS will be presented. Finally, we will discuss on the DS production tool with 248 nm exposure wavelength that are being prepared to release in mid-2020s.
The Digital Scanner (DS) being developed by Nikon is an optical maskless exposure tool with DUV light source and a micromirror-type spatial light modulator (SLM). The SLM forms a pixelated image; although each micromirror operates in a binary mode, the DS is capable to control pattern edges with subpixel resolution. This is because the pixel size on the wafer plane is smaller than the optical resolution, and therefore multiple pixels can contribute to each point in a projected image. We report simulation results of subpixel edge placement controllability of the DS. Actual exposure results on our experimental tool are also presented.
Digital Scanner (DS), a DUV optical maskless exposure tool is being developed. It uses a micromirror-type spatial light modulator (SLM) to create the “mask” pattern combined with a solid state laser with wavelength of 193 or 248 nm. The exposure concept of DS and advantage of solid state laser as an exposure light source is described. DS proof-of-concept tool with resolution of half-pitch 80 nm L/S was developed. The exposure results of maskless unique application such as large area printing and chip ID printing for security purposes are shown.
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