As technology continues to scale aggressively, Sub-Resolution Assist Features (SRAF) are becoming an increasingly key resolution enhancement technique (RET) to maximize the process window enhancement. For the past few technology generations, lithographers have chosen to use a rules-based (RB-SRAF) or a model-based (MB-SRAF) approach to place assist features on the design. The inverse lithography solution, which provides the maximum process window entitlement, has always been out of reach for full-chip applications due to its very high computational cost. ASML has developed and demonstrated a deep learning SRAF placement methodology, Newron™ SRAF, which can provide the performance benefit of an inverse lithography solution while meeting the cycle time requirements for full-chip applications [1]. One of the biggest challenges for a deep learning approach is pattern selection for neural network training. To ensure pattern coverage for maximum accuracy while maintaining turn-around time (TAT,) a deep-learning-based Auto Pattern Selection (APS) tool is evaluated. APS works in conjunction with Newron SRAF to provide the optimal lithography solution. In this paper, Newron SRAF is used on a DRAM layer. A Deep Convolutional Neural Network (DCNN) is trained using the target images and Continuous Transmission Mask (CTM) images. CTM images are gray tone images that are fully optimized by the Tachyon inverse mask optimization engine. Representative patterns selected by APS are used to train the neural network. The trained neural network generates SRAFs on the full-chip and then Tachyon OPC+ is performed to correct main and SRAF simultaneously. The neural network trained by APS patterns is compared with those trained by patterns from manual selection and multiple random selections to demonstrate its robustness on pattern coverage. Tachyon Hierarchical OPC+ (HScan+) is used to apply Newron SRAF at full-chip level in order to keep consistency and increase speed. Full-chip simulation results from Newron SRAF are compared with the baseline OPC flow using RBSRAF and MB-SRAF. The Newron SRAF flow shows significant improvements in NILS and PV band over the baseline flows. This whole flow including APS, Newron SRAF and full-chip HScan+ OPC enables the inverse mask optimization on full-chip level to achieve superior mask performance with production-affordable TAT.
In advanced DRAM fabrication, wafer alignment is a key enabler to meet on-product overlay performance requirement. Due to the extreme complexity of patterning and integration process involved, it’s becoming a challenge to design alignment marks that can be patterned robustly through process window, meet process integration constraints, withstand large process variation or changes, and provide accurate alignment measurement, during early development. The unique tilted pattern in DRAM fabrication technology poses special challenges during both design and process phase. In this paper, we present a holistic computational approach to design robust alignment marks with ASML’s integrated Design for Control (D4C) and OPC solutions. With this integrated solution, we design a complex set of alignment marks for the entire full flow process from FEOL through BEOL, tailored by each stack of different lithography layers. In mark design stage, marks’ signal and robustness are optimized by D4C simulation, taking into account the design rule and process constraints, while patterning fidelity and process window of these marks is ensured by OPC, subject to the design rule constraints. We demonstrate that the process window (PW) of the resulting alignment marks, especially for the challenging layers with extreme off-axis illuminations and tight design constraints, are significantly improved, while simultaneously accurate and robust alignment measurements are obtained on full loop wafers.
Inverse lithography is increasingly being used as a viable OPC solution to maximize process window (PW), improve CD uniformity (CDU) and minimize the mask error factor (MEF), especially for memory devices. The device yield is typically limited by the process window of a few critical layers, and the Via layer is identified as one of the process window limiters for advanced 3D-NAND devices. To maximize the on-chip yield, ASML has developed advanced image based Mask-3D (M3D) inverse technology that can optimize freeform mask shapes and enhance design printability throughout the mask optimization flow. Mask rule checks (MRC) and side-lobe printing are optimized simultaneously to deliver the maximum process window.
The advanced image based M3D inverse lithography technology (ILT) is used to perform full chip mask correction on the Via layer of a 3D-NAND device. 3D NAND devices contain highly repetitive cell and page buffer patterns. To ensure the full chip device performance, the consistency of the mask correction is important. Our strategy is to use the computationally intensive mask optimization solution from the new advanced image based M3D inverse technology to generate a freeform mask which gives the best lithography performance. We then use Tachyon’s Pattern Recognition and Optimization (PRO) engine to propagate the freeform mask solution of the repetitive patterns to the full chip. The periphery of the chip is optimized using conventional OPC methods. The simulation results from the advanced image based M3D inverse technology are compared against the baseline flow, which uses a standard inverse solution. The simulation results from both the flows are further validated on wafer. Significant improvement in overlapping process window (OPW) and CD uniformity is observed using the new advanced inverse technology. The simulation data shows a 32% improvement in depth of focus (DOF), a 5% improvement in the image log slope (ILS) and a 25% reduction in best focus shift (BFS) range. The improvement has also been verified at the wafer-level.
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