A review of mask errors on a variety of pattern generators

The question of how mask dimensional errors impact yield is becoming increasingly critical to VLSI manufacturing. Both the magnitude and the spatial correlation of CD and registration errors are believed important to this issue. As part of a program to characterize these errors, we have had one identical test mask made on 6 different state-of-the-art mask pattern generators with widely different architectures. The test mask provides information on both registration and feature-size errors in both x- and y-directions, and does so over distances of several centimeters with spacing between measurements as small as 1 μm. More than 100000 data points have been collected from these test plates using a LMS2000 optical metrology system, and are analyzed in the spatial frequency domain where error contributors as small as 1 nm can be identified. All systems were found to have similar characteristics in that most error contributors occur at a number of machine-specific spatial frequencies correlated to the particular architecture and printing strategy of the machine. Comparison of raster to vector machines show that vector machines tend to have more periodic error contributors, especially in the high spatial frequency range, which is consistent with the more complex writing fields used to achieve higher throughput