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Concept
Etching (microfabrication)
Summary
Etching is used in microfabrication to chemically remove layers from the surface of a wafer during manufacturing. Etching is a critically important process module, and every wafer undergoes many etching steps before it is complete.
For many etch steps, part of the wafer is protected from the etchant by a "masking" material which resists etching. In some cases, the masking material is a photoresist which has been patterned using photolithography. Other situations require a more durable mask, such as silicon nitride.
The two fundamental types of etchants are liquid-phase ("wet") and plasma-phase ("dry"). Each of these exists in several varieties.
The first etching processes used liquid-phase ("wet") etchants. This process is now largely outdated but was used up until the late 1980s when it was superseded by dry plasma etching. The wafer can be immersed in a bath of etchant, which must be agitated to achieve good process control. For instance, buffered hydrofluoric acid (BHF) is used commonly to etch silicon dioxide over a silicon substrate.
Different specialized etchants can be used to characterize the surface etched.
Wet etchants are usually isotropic, which leads to a large bias when etching thick films. They also require the disposal of large amounts of toxic waste. For these reasons, they are seldom used in state-of-the-art processes. However, the photographic developer used for photoresist resembles wet etching.
As an alternative to immersion, single wafer machines use the Bernoulli principle to employ a gas (usually, pure nitrogen) to cushion and protect one side of the wafer while etchant is applied to the other side. It can be done to either the front side or back side. The etch chemistry is dispensed on the top side when in the machine and the bottom side is not affected. This etching method is particularly effective just before "backend" processing (BEOL), where wafers are normally very much thinner after wafer backgrinding, and very sensitive to thermal or mechanical stress.
Official source
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