A new paradigm for in-line detection and control of patterning defects

With continuously shrinking design rules and corresponding low-k1 lithography, defectivity and yield are increasingly dominated by systematic patterning defects. The size of these yield-limiting defects is shrinking along with feature size, making their detection and verification more difficult. We discuss a novel, holistic approach to pattern defect detection and control, which integrates full chip layout analysis and hybrid wafer metrology data to predict wafer locations with highest probability for defect occurrence. We assess the various components of this flow by an experimental study on a 10 nm BEOL process at IMEC, using state-of-the-art negative tone development (NTD) and triple Litho-Etch patterning process.