A detailed study of resonance-assisted evanescent interference lithography to create high aspect ratio, super-resolved structures

Application of the Metal Reflector for Redistributing the Focusing Intensity of SPPs

The near-field photolithography system has attracted increasing attention in the micro- and nano-manufacturing field, due to the high efficiency, high resolution, and the low cost of the scheme. Nevertheless, the low quality of the nano-patterns significantly limits the industrial application of this technology. Theoretical calculations showed that the reason for the poor nano-patterns is the sharp attenuation of the surface plasmon polaritons (SPPs) in the photoresist layer. The calculation results suggest that the waveguide mode, which is composed of the chromium-equivalent dielectric layer-aluminum, can facilitate the energy flux density distribution in the photoresist layer, resulting in the enhancement of the field intensity of SPPs in the photoresist layer. This reduces the linewidth of nano-patterns, while it enhances the pattern steepness. Eventually, the focusing energy of the photoresist layer can be improved. The finite-difference time-domain method was employed to simulate and verify the theoretical results. It is found that for the rotational near-field photolithography with 355 nm laser illumination, the linewidths of the nano-patterns with and without the aluminum reflector are 17.54 nm and 65.51 nm, respectively. The robustness of the experimental results implies that the application of the aluminum reflector enhances the focusing effect in the photoresist, which can broaden the application of the near-field photolithography.

Fabrication of nano/micro dual-periodic structures by multi-beam evanescent wave interference lithography using spatial beats

We propose an effective method for fabricating dual-periodic structures using the combination of multi-beam interference lithography and evanescent wave exposure. Four-beam evanescent wave interference lithography (EWIL) is used as a prototype to demonstrate the fabrication feasibility of one-dimensional (1D) micro-grating structures covered with nanodots and two-dimensional microdot structures filled with subwavelength fringes by designing reciprocal lattice vectors of interference fringes. We experimentally fabricated 1D nano-/micro-grating structures with periods of 140 nm and 12.5 µm and microdots filled with subwavelength gratings of 450 nm period by four-beam EWIL. These structures are applicable to superlattice photonic crystals and subwavelength structured surfaces.

Herpin effective media resonant underlayers and resonant overlayer designs for ultra-high NA interference lithography

Dielectric waveguide resonant underlayers are employed in ultra-high NA interference photolithography to effectively double the depth of field. Generally a single high refractive index waveguiding layer is employed. Here multilayer Herpin effective medium methods are explored to develop equivalent multilayer waveguiding layers. Herpin equivalent resonant underlayers are shown to be suitable replacements provided at least one layer within the Herpin trilayer supports propagating fields. In addition, a method of increasing the intensity incident upon the photoresist using resonant overlayers is also developed. This method is shown to greatly enhance the intensity within the photoresist making the use of thicker, safer, non-absorbing, low refractive index matching liquids potentially suitable for large-scale applications.

Deep subwavelength interference lithography with tunable pattern period based on bulk plasmon polaritons

Interference lithography based on surface plasmon polaritons has been proven to break the diffraction limit and deliver the high imaging resolution. However, most previously reported studies suffer from the inflexible pattern pitch for a certain structure ascribed to fixed excitation mode, which limits the applications in micro-/nano- fabrications. In this work, the large area deep subwavelength interference lithography with tunable pattern period based on bulk plasmon polaritons (BPPs) is proposed. By simply tuning the incident angle, the spatial frequencies of the selected BPPs modes squeezed through hyperbolic metamaterial changes correspondingly. As a result, the pitch of the interference pattern is continuously altered. The results demonstrate that one-dimensional and two-dimensional periodic patterns with pitch resolution ranging from 45 nm (~λ/10) to 115 nm (~λ/4) can be generated under 436 nm illumination. Additionally, the general method of designing such an interference lithography system is also discussed, which can be used for nanoscale fabrication in this fashion.

Plasmonic Structures, Materials and Lenses for Optical Lithography beyond the Diffraction Limit: A Review

The rapid development of nanotechnologies and sciences has led to the great demand for novel lithography methods allowing large area, low cost and high resolution nano fabrications. Characterized by unique sub-diffraction optical features like propagation with an ultra-short wavelength and great field enhancement in subwavelength regions, surface plasmon polaritons (SPPs), including surface plasmon waves, bulk plasmon polaritons (BPPs) and localized surface plasmons (LSPs), have become potentially promising candidates for nano lithography. In this paper, investigations into plasmonic lithography in the manner of point-to-point writing, interference and imaging were reviewed in detail. Theoretical simulations and experiments have demonstrated plasmonic lithography resolution far beyond the conventional diffraction limit, even with ultraviolet light sources and single exposure performances. Half-pitch resolution as high as 22 nm (~1/17 light wavelength) was observed in plasmonic lens imaging lithography. Moreover, not only the overview of state-of-the-art results, but also the physics behind them and future research suggestions are discussed as well.