Defectivity of EUV reticles and their impact on wafer printing has continued to plague the future adoption of EUV lithography. This study presents a methodology for assessing the impact of defect detection of EUV reticles by e-beam inspection of both the reticle and the exposed photoresist on a wafer. The programmed defect test reticle is designed with both additive and subtractive features of varying size and shape, which are superimposed on a variety of features ( ex: line/space, holes, and brick patterns). To test defectivity of the EUV reticle, e-beam inspection images from an HMI eXplore® 5400 are compared to the post OPC mask shapes in a die-to-database mode. We show that the e-beam system can detect defects with sensitivity and capture rate comparable to a standard die-to-die measurement. An example of the capability of the e-beam system for detection of sub-20nm defect size feature on a variety of programmed defect design shapes and defect types using an automated defect classification is shown in Figure 1. The auto-detect defect capability on both the mask absorber and non-absorber is demonstrated in Figure 2.
The Albany Nanotech Alpha Demo EUV Tool was employed to expose wafers with the inspected test reticle (on HMI eXplore® 5400 mask inspection tool) having the same programmed defect structures. The printability of defects on the EUV reticle can be assessed by comparing e-beam inspection images from an HMI eScan® 320Xp (wafer inspection tool) to the print simulation in die-to-database mode using the HMI SuperNova™ system. We show that the e-beam defect inspection on EUV resist wafer for both die to die and die to database (print simulation) are at comparable sensitivities. Figure 3 shows an example of the capability of sub-10nm defect size detection on wafer for a variety of design shapes and defect types using automated defect classification.
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