As the design rules and the actual sizes of the patterns being printed continue to shrink well below half the wavelength of light being utilized, the budgets associated with all variations in imaging likewise continue to squeeze to tighter required tolerances. In this environment, the control and adjustment of the imaging has continued to increase in importance. Building upon previous work in the field of lens adjustment and optimization, additional methods have been developed and implemented which enable more specialized adjustment towards the optimization of given priorities associated with a given patterning step. Specifically, it is fast becoming typical to leverage all available degrees of adjustment freedom uniquely for each critical layer identified in a given process. Various optimization goals are discussed, with procedures and results presented for each. Examples of these include: 1) optimization of a single machine towards the best possible ultimate CD uniformity performance while staying within a specified range of allowed residual distortion 2) optimization of ultimate distortion magnitude, while staying within a budgeted level of imaging/CD uniformity performance 3) optimization of specific aberrations while maintaining all others within budgeted levels of allowed magnitude The motivations driving each of these sorts of optimizations will be discussed, as well as limitations that may exist from various sources, including metrology, process variation and it effects, and the imaging tool. The impact such optimization capability can have on the defined CD budget will also be discussed, towards the goal of qualifying and, where possible, quantifying the overall improvement possible through application of these optimization techniques. These sorts of improvements and their documentation can allow for feedback into the device design process, leveraging the reduced level of variation resulting from such optimizations.
As introduced previously, all components now exist within the field of Microlithography to accurately measure the aberration content of a projection lens and to apply that information in a lens adjustment optimization procedure. The procedure previously detailed highlighted the use of available in-situ aberration measurement, and utilized the known aberration change response of a given projection lens as a function of lens element movement/adjustment. Various metrics were presented as candidates for inclusion in the optimization function. In any optimization routine, it is this definition of the specific optimization goals that drives the direction of the calculated optimum lens adjustment prescription. This concept has now been applied to several case studies, and tools have been developed to help automate the calculation and subsequent analysis of the optimum solution to a given optimization problem. This paper will discuss examples executed of lens adjustment optimization procedures, including the application of various target optimization functions toward the minimization of various aberration components. Included in the discussion will be the application of Zernike Sensitivity responses of specific patterns and imaging configurations to the optimization sequence. The Zernike Sensitivity treatments serve to bridge the gap between a pure Zernike Coefficient description of a lens and the “imaging performance” that the given lens is capable of. Further, the Zernike Sensitivity calculations can provide a quick overview and comparison of the aberration sensitivity of various patterns, delivering a simultaneously qualitative (e.g. “which aberration impacts the imaging most?”) and quantitative (i.e. “how much change in best focus can I expect from 10 milli-wave of Z9?”) description of the specific case. A summary will be provided of general knowledge gained and lessons learned as they relate to lens adjustment optimization, with an eye towards further progress in this field.
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