Chapter 10 Etching
1. Introduction to etching. 
2. Wet chemical etching: isotropic. 
3. Anisotropic etching of crystalline Si. 
4. Dry etching overview. 
5. Plasma etching mechanism. 
6. Types of plasma etch system. 
7. Dry etching issues. 
8. Dry etching method for various films. 
9. Deep Si etching (can etch through a wafer). 
1 
NE 343: Microfabrication and thin film technology 
Instructor: Bo Cui, ECE, University of Waterloo; http://ece.uwaterloo.ca/~bcui/ 
Textbook: Silicon VLSI Technology by Plummer, Deal and Griffin 
Dry etching advantages 
 Eliminates handling of dangerous acids and solvents 
 Uses small amounts of chemicals 
 Isotropic or anisotropic/vertical etch profiles 
 Directional etching without using the crystal orientation of Si 
 Faithful pattern transfer into underlying layers (little feature size loss) 
 High resolution and cleanliness 
 Less undercutting 
 Better process control 
Types of dry etching: 
 Non-plasma based - uses spontaneous reaction of appropriate reactive gas mixture. 
 Plasma based - uses radio frequency (RF) power to drive chemical reaction. 
Why dry etching? 
Dry etching disadvantages: 
 Some gases are quite toxic and corrosive. 
 Re-deposition of non-volatile compound on wafers. 
 Expensive equipment ($200-500K for R&D, few million for industrial tools ). 
2 
Non-plasma based dry etching 
4Si(s) + 2Cl
2
 (g) ---> 4SiCl
4
 (g) + 130 kcal/mole 
This is very rare. For example, 
 
Although there is a large gain in free energy, the large activation energy does 
not allow low temperature processes - reaction is only effective above  800C.  
In order to succeed with gas etching, one has to go out of equilibrium. 
The solution is plasma etching. 
One exception is room temperature XeF
2
 etching of Si. (same for BrF
3
 & ClF
3
) 
 XeF
2
 is a white powder, with vapor pressure 
3.8 Torr at 25
o
C. 
 Isotropic etching, non-polish etching (rough) 
 High selectivity for Al, SiO
2
, Si
3
N
4
, photoresist, 
and PSG (phospho-silicate glass). 
 Typical etch rate 1m/min 
 Heat is generated during exothermic reaction 
 XeF
2
 reacts with water (or vapor) to form HF 
2XeF
2
 + Si  2Xe (g) + SiF
4
 (g) 
Gas phase etching, no stiction between 
freed structure and substrate (no liquid 
involved like KOH etch, so no need of 
drying that collapses pattern due to 
capillary force). 
Popular for MEMS application. 
Xenon di-fluoride (XeF
2
) etching of Si: 
MEMS: micro electro mechanical systems 
3 
Plasma-based etching 
 Directional etching due to presence of ionic species in plasma and (self-) biased 
electric field. (The self-bias electric field is not applied externally, but is created 
spontaneously in RF plasma) 
 Two components exist in plasma 
o Ionic species result in directional etching. 
o Chemical reactive species result in high etch selectivity. 
 Control of the ratio of ionic/reactive components in plasma can modulate the dry 
etching rate and etching profile. 
Neutrals (etchant gas) 
Ions  
Free radicals  
adsorb 
react 
surface 
Gaseous products 
Plasma 
) ( ) ( 4 ) (
4
 g SiF g F s Si    
4 
RF plasma chemistry 
RF plasma is more widely used for dry etching than DC plasma  is there DC plasma dry 
etching?  
CF
4
 plasma 
Figure 10-9 
5 
 As seen in previous slide, in a plasma, unstable particles are continuously generated.  
 The concentrations of ions, radicals, active atoms, & electrons increase until their loss 
rate is equal to the generation rate, forming a steady-state plasma. 
 Recombination of ions and electrons: they attract each other and are annihilated. 
 Drift, diffusion to walls: electrons are lost at conductive surfaces, chamber walls or 
electrodes. Ions are lost (converted to neutral particles) by contact with conductive 
surfaces, especially positive electrode. 
 Recombination of radicals: e.g. 2O  O
2
. 
 Chemical reaction (what we want): e.g. 4F + Si  SiF
4
 (fluorine radical combines with 
silicon wafer to produce silicon tetra-fluoride gas. This is a typical dry etching process.) 
Loss mechanisms 
Plasma TV 
In a plasma TV, the recombination of ion-
electron or radical, or de-excitation of atom or 
molecule, generates the colorful light we see. 
In equilibrium, degree of ionization typically 10
-3
 - 
10
-6
, very low, meaning majority gas not ionized.  
(plasma density = number of ions/cm
3
  typically 10
9
 
 10
13
/cm
3
.) 
6 
Chapter 10 Etching 
NE 343: Microfabrication and Thin Film Technology 
Instructor: Bo Cui, ECE, University of Waterloo, bcui@uwaterloo.ca 
Textbook: Silicon VLSI Technology by Plummer, Deal, Griffin  
1. Introduction to etching. 
2. Wet chemical etching: isotropic. 
3. Anisotropic etching of crystalline Si. 
4. Dry etching overview. 
5. Plasma etching mechanism. 
6. Types of plasma etch system. 
7. Dry etching issues. 
8. Dry etching method for various films. 
9. Deep Si etching (can etch through a wafer). 
7 
Plasma etching mechanism overview 
 In a plasma, reactive neutral chemical species (free radicals, e.g. F atoms or molecular 
species CF
3
) are mainly responsible for the chemical reaction due to their much greater 
numbers compared to ions (e.g. CF
3
+
 is also reactive, but with low concentration in a 
plasma. But Ar
+
 is not reactive, and etches/sputters much slower than chemical etching, 
even when ion energy is high  --  generally chemical etching is much faster than physical). 
 Those free radicals and molecules also serve as primary deposition species in PECVD. 
 Those free radicals are more abundant than ions because: 1) they are generated at lower 
threshold energy (e.g. < 8eV; in comparison, Ar is ionized at 15.7eV); and 2) they 
(uncharged radicals) have longer lifetime in the plasma.  
 The neutral radicals arrive at cathode surface by diffusion (thus non-directional). 
Figure 10-10 
8 
 Charged ions are accelerated to the 
cathode due to self-bias.  
 (Unless with very high energy of >100eV 
as in ion beam/sputter etching), ion itself 
doesnt contribute significantly to the 
chemical reaction mostly due to its very 
low concentration, but ion 
bombardment can greatly enhance the 
chemical reaction in ion-enhanced 
etching.  
Chemical etch: highly selective, but isotropic  
 Due to their incomplete bonding (incomplete outer shells), free radicals (neutral, 
e.g. CF
3
 and F from CF
4
 plasma) are highly reactive chemical species. 
   
 Free radicals react with film to be etched and form volatile by-products. 
 
 Pure chemical etch is isotropic or nearly isotropic, 
and the etching profile depends on arrival angle 
and sticking coefficients of free radicals.  
 Free radicals (un-charged) in plasma systems have 
isotropic arrival angles. 
 The sticking coefficient S is very low, typically only 
S0.01 (i.e. most free radicals adsorb then just 
bounce back without reaction). 
 This leads to isotropic character of etch, as free 
radicals can etch area beneath the mask due to 
bouncing, as seen in the figure. The resulted 
profile has large undercut. 
Adsorption rate onto surface 
9 
Sticking coefficient S  
Reaction, here momentum transfer by physical 
bombardment, takes place at every shot, usually 
sputter off a few atoms, so S1. 
Most adsorbed species just left 
the adsorption site without doing 
anything, so S<<1. 
Figure 10-11 
10 
Si etching with F radicals  
Isotropic etching 
11 
Etch byproducts should have low boiling point  
Boiling points of typical etch products  
Low boiling point means very volatile, so it can be pumped away. 
This is not necessary for physical etching/sputtering, where etch product is 
sputtered off that ideally doesnt fall on the other part of the wafer (re-deposition). 
12 
Physical etch component in a plasma etch system 
(much less important than chemical etch) 
 Ionic species are accelerated toward each electrode by built-in self-bias. 
 The ionic species such as Cl
2
+
, CF
4
+
, CF
3
+
 (or Ar
+ 
in a purely physical sputter 
etch) strike wafer surface and remove the material to be etched. 
 Directional, non-selective  - similar sputter yield for different materials. 
(But CF
3
+
 can also etch Si chemically, then with high selectivity) 
 It  may result in significant re-deposition. 
Ar plasma 
Pure physical etch: sputter etching system 
 Self-bias few 100V, but low ion energy 
(order 10V) due to collision energy loss. 
 Thus very low milling rate in a sputter 
system, often for surface cleaning only. 
 Here is the case for sputter etching system 
with gas pressure order 10mTorr. 
 For a dedicated ion milling system (no 
plasma, see later slides), the pressure is 
10
-4
Torr or even lower (cannot sustain a 
plasma), leading to large mean free path, 
high ion energy and high milling rate.  
13 
Ion enhanced etching (IEE): 
chemical etch assisted by physical bombardment  
 IEE is an anisotropic (due to directional ion bombardment) and highly selective (due to 
chemical reaction) etching process. 
 Reactive ion etch (RIE) is the most popular form of IEE. 
 Ion bombardment can enhance one of the following steps during chemical etch: surface 
adsorption, etching reaction (by physically damaging/weakening the chemical bond of 
the material to be etched), by-product (inhibitor layer) removal, and removal of un-
reacted etchants. 
Inhibitor layer: e.g. fluorocarbon 
polymer formed from CHF
3
 during 
etching of SiO
2
. 
When removal rate << deposition 
rate, net deposition will occur, 
then the process becomes similar 
to PECVD!! 
Indeed, the RIE and PECVD are 
pretty similar tools, except PECVD 
is typically heated. 
Chemical etch enhanced 
by  ion bombardment 
Inhibitor removed by  
ion bombardment 
Figure 10-13 
14 
IEE: first proof of etching mechanism 
15 
Gas phase etch, with or without 
the aid of Ar ion beam. 
NO plasma. 
Very slow etch when pure 
chemical or physical etch alone 
The ion enhancement could be due to the damage/weakening of silicon lattice by 
ion bombardment, which makes the etching by XeF
2
 easier. 
The resulted profile will be anisotropic since the horizontal surfaces are much more 
bombarded than vertical ones. 
This is one example of CAIBE (chemically assisted ion beam etching), see later slides 
Ion enhanced etching 
is highly anisotropic 
 Sidewall reactions can lead to an isotropic etch 
component. 
 To prevent sidewall etching, one can build up a 
passivation (inhibitor  inhibit chemical 
reaction) layer that protects it. 
 Then there is a competition between passivating 
and etching reaction. 
 For the feature base/horizontal surfaces, etch 
rates tend to be temperature independent 
because of ion energy input (i.e. inhibitor 
sputtered away by ions). 
 On sidewall, substrate temperature can play an 
important role as sidewall passivation depends 
on the volatility of  the inhibitor that is 
controlled by temperature (cryo-etcher at below 
-100
o
C is available recently, then the sidewall 
passivation layer is not volatile). 
 Even without sidewall passivation, lower 
temperature still increases anisotropy since  
chemical attack of sidewall is suppressed at low 
temperature. (Attack of horizontal surfaces are 
assisted by ion bombardment) 
16 
High inhibitor 
deposition rate 
Low inhibitor 
deposition rate 
Example: 
etching profile of Si or SiO
2 
 Fluoropolymer (like Teflon) in CHF
3
 or CF
4
+H
2
 RIE of Si 
or SiO
2
 is the inhibitor. 
 If Ar gas is added, inhibitor is mainly removed by ion 
bombardment. So less attack of inhibitor on sidewall. 
 If O
2
 gas is added, inhibitor on sidewall is removed at 
faster rate than Ar ion, but the etch of inhibitor at 
horizontal surface is even faster. 
 Yet at very low temperature, inhibitor SiO
x
F
y
 (not act 
as inhibitor at higher temperature when it is volatile) 
forms when O
2
 is added, which is the mechanism for 
fast anisotropic etching of Si using cryo-etcher. (deep 
Si etcher, popular for MEMS  micro electro 
mechanical systems) 
Teflon 
Figure 10-14 
17 
Anisotropy due to ion bombardment: summary 
 Due to its extremely low density, ions dont contribute much to etching; neutral radicals do. 
 So even with directional ion bombardment, the overall etching can still be pretty isotropic. 
 For instance, SF
6
 etch of Si is very isotropic with large undercut like wet etch. 
 To achieve anisotropy, there are two mechanisms: 
o Energy-driven anisotropy: bombardment by ion disrupts an un-reactive substrate and 
causes damages such as dangling bonds and dislocations, resulting in a substrate more 
reactive towards etchant species (electron or photon can also induce surface activation).  
o Inhibitor-driven anisotropy: ion bombardment removes the inhibitor layer from horizontal 
surface (sidewall remain passivated), and reaction with neutrals proceed on these un-
passivated surfaces only. 
One may think that ions wont help much due to its much lower density than radicals. But ion 
has sticking coefficient S1 (every ion bombardment counts), whereas radicals S0.01 (most 
radicals hit the surface and left without doing anything). 
Energy-driven 
anisotropy 
Inhibitor-driven 
anisotropy 
18 
Chapter 10 Etching 
NE 343: Microfabrication and Thin Film Technology 
Instructor: Bo Cui, ECE, University of Waterloo, bcui@uwaterloo.ca 
Textbook: Silicon VLSI Technology by Plummer, Deal, Griffin  
1. Introduction to etching. 
2. Wet chemical etching: isotropic. 
3. Anisotropic etching of crystalline Si. 
4. Dry etching overview. 
5. Plasma etching mechanism. 
6. Types of plasma etch system. 
7. Dry etching issues. 
8. Dry etching method for various films. 
9. Deep Si etching (can etch through a wafer). 
19 
Plasma etching in barrel etchers 
Barrel etcher:  
 Chemical etching only, isotropic and selective 
like pure wet etch. 
 Use plasma shield to keep ion bombardment 
from wafers, thus very little damage. 
 Poor uniformity edge to center. 
 Used in non-critical steps such as photoresist 
removal by O
2
 plasma (Barrel asher   
Polymer + O  CO
2
 + H
2
O). 
Quartz tube 
Figure 10-15 
20 
Downstream etchers 
 Plasma is formed in a cavity which is 
separated from the etching chamber. 
 Wafers are shielded from bombardment. 
 Only neutral free radicals reach wafers. 
 Etching is completely chemical and 
isotropic. 
 High selectivity achievable - Si:SiO2 = 50:1 
 Plasma may be generated by RF 
(13.56MHz) or by microwave (2.45GHz). 
21 
Parallel plate = capacitively coupled plasma (CCP) 
You will see later on ICP : inductively coupled plasma 
Plasma etching in parallel plate systems  plasma mode 
 Similar to PECVD except that etch gas is used instead of precursor gas. 
 Equal or larger (grounded to chamber) wafer electrode (which defines plasma mode) 
gives weaker ion bombardment of wafers (smaller DC voltage drop near larger electrode). 
 The etch is more uniform than barrel, but typically etches only one or a few wafers (cassette 
for barrel etcher) at a time. 
 Both chemical and physical etch occur (wafer in contact with plasma), though the later is 
weak, particularly at higher pressure when DC voltage drop near wafer is smaller. 
 Etching is fairly isotropic and selective due to the strong chemical component. 
Figure 10-7 
22 
Very often, plasma mode etching is 
considered as just a kind of reactive 
ion etching (RIE), but done at  
higher pressure. 
Of course, both plasma mode 
etching and RIE is plasma etching. 
Parallel plate etchers (regular RIE, low density plasma) 
 Absolutely the most important form of dry 
etching, though recently ICP (see later slides) is 
becoming more and more popular. 
 Compared to plasma mode: smaller wafer 
electrode (counter electrode grounded to 
chamber wall), lower pressure (<100mTorr), more 
physical bombardment (voltage drop many 100V).  
 Ion enhanced etching mechanism, (usually) 
directional/anisotropic and selective. 
RIE using parallel plate setup is low 
density plasma system (ions 10
8
  
10
10
/cm
3
), thus low etch rate.  
Here low (ion) density plasma also 
implies low density of free radicals. 
Thus low etching rate. 
VERY roughly, one can say that plasma consists of order 
1% radicals (reactive neutral species) and 0.01% ions. 
23 
 Due to its simultaneous anisotropy and 
selectivity, RIE is intensively used. 
 Works for most semiconductors and 
dielectrics. 
 OK for few metals that form volatile etch 
products: Al (form AlCl
3
), Cu (CuCl
2
) (not 
really), Ti (TiF
4
, TiCl
4
), W (WF
6
), Cr (CrO
2
Cl
2
). 
Reactive ion etch (RIE) 
Etching mask 
Schematic RIE process 
a) Ion sputtering, b) reactive ion etching, c) 
radical formation (?), d) radical etching 
(most important) 
In RIE, ion energy is low (several 10s eV, << voltage drop near wafer surface, due to collision 
energy loss), and its number density is very low, thus negligible etching by ion bombardment. 
The name reactive ion etching is very misleading since ions dont contribute directly to 
etching  it just helps chemical etching. 
24 
Ion energy vs. pressure for a plasma  
 Lower pressure (<10mTorr) increases mean free 
path as well as voltage drop near wafer electrode, 
both of which leads to more energetic and 
directional ion bombardment, thus more 
anisotropic, but less selective and slower etching 
rate due to low ion/free radicals density. 
 High pressure (>100mTorr), short mean free path, 
low voltage drop, isotropic chemical etching. 
 Thus it is desirable to have a low pressure plasma 
with high ion density. 
Plasma mode: >100mTorr 
RIE mode: 10-100mTorr 
Sputter etching: pressure as low as possible, as long as 
plasma can be sustained, but still very slow etching rate. 
RIE with tilted wafer, will etch vertically or not? 
25 
Etching in high density plasma (HDP) systems 
 Ion flux and ion bombarding energy can be independently controlled. For regular RIE, 
they are tightly coupled (e.g. higher power increases both). 
 High plasma (ion) density (> 10
11
) enhances etch rate. 
 Since ionization is much more efficient, can operate at lower pressure, which leads to less 
ion collision, so more directional/anisotropic, thus enhances profile control. 
 As ion energy is independently controlled, it can be kept low if desirable. 
 Then the extent and amount of damage will be reduced, without sacrificing etching rate 
that is still high for high density plasma. 
 Currently HDP represents an optimum compromise in high etch rates, good selectivity, 
good directionality, while low ion energy and damage (??). 
 (What I think) For sidewall profile control and selectivity, hard to say which one (regular 
RIE vs. HDP) is better. But if wanted one can always turn off the HDP power, then the 
machine operates like a regular RIE. 
 The bottom line: for deep etching (>>1m) that needs very high etching rate, HDP is the 
only choice. 
26 
ECR was introduced in 1985. 
ICP was introduced much later (1991- 1995). 
Electron cyclotron resonance (ECR) 
and inductively coupled plasma (ICP) 
Dual plasma source: 
Top one (ECR or ICP RF power) generates HDP, 
determines ion density/current. 
Bottom one (CCP RF power) generates bias voltage like 
regular RIE, determines ion energy. 
CCP: capacitively coupled plasma, parallel plate, used for conventional regular RIE. 
Typical parameters for HDP and conventional plasma etcher 
ions/cm
3 
should be lower
 
27 
 High magnetic field in the coil, so electrons move in circles with long path, leading to 
higher collision and ionization probability, and much less electron loss to chamber wall 
and the bottom plate where sit the wafer. Moreover, 
 For ICP, AC magnetic field induces circular electrical field, which accelerates electrons. 
 For ECR, DC magnetic field, electron cyclotron =qB/m; electrons accelerated if this 
frequency matches the microwave frequency. 
Inductively coupled plasma (ICP) 
(four systems at Waterloo) 
ICP RF power 
(for dense plasma) 
RF bias power 
(similar to RIE, parallel plate) 
plasma 
Electron cyclotron resonance plasma 
(less common nowadays) 
ECR and ICP 
28 
Microwave source  2.45 MHz 
Wave guide 
Diffuser 
Quartz window 
Electrostatic chuck 
Cyclotron magnet 
Plasma chamber 
Wafer 
Additional magnet 
13.56 MHz 
Vacuum system 
Schematic of ECR etcher 
30 
Electromagnet 
Dielectric 
window 
Inductive coil 
Biased wafer chuck 
RF generator 
Bias RF generator 
Plasma 
chamber 
Schematic of ICP etcher 
As you see, there is practically no top plate as in parallel plate regular RIE.  
The wafer sees the  ICP power  the two power sources are not physically separated. 
Otherwise, even though the plasma density in the upper part is high, it will get lost due 
to re-combination and de-excitation when it travels through the bottom part. 
31 
Electromagnet 
(1 of 4)  
13.56 MHz 
Biased wafer chuck 
Wafer 
Magnetically enhanced reactive ion etch (MERIE) 
Like regular parallel plate RIE, but magnetic field forces electron to go circles, increasing 
collision with gas molecules and decreasing loss to chamber walls or top/bottom plates. 
However, now that electrons dont loss to bottom plate, no or little bias voltage  need to 
apply an external bias to accelerate ions. 
I havent seen any MERIE, so 
it is not popular. 
On the contrary, magnetron 
sputtering is very popular. 
This is probably because 
there are many ways to 
increase etching rate; but 
sputter without magnetron 
is always very slow:  
few nm/min, vs. 10s to 100s 
nm/min RIE etching rate. 
32 
Sputter etching and ion milling 
Sputter etching: (etch inside plasma) 
 The etch mechanism is purely physical and ion 
energies are greater than 500 eV.  
 Very similar in principle to sputter deposition, but 
now the target becomes substrate to etch. 
 Poor selectivity (2:1 or 1:1), very anisotropic. 
 Sputtering rate depends on sputter yields which can 
be a function of incident angle. 
 Problems include faceting (sputter yield is a    
function of incident angle), trenching, re-deposition, 
charging and ion path distortion, radiation damage. 
 Not popular, etches too slow, though reactive gas 
(CF
4
, CCl
4
, O
2
) can be added to slightly improve 
selectivity and etching rate. 
Figure 10-8 Problems associated with 
sputter etching (or any etching that has 
a high degree of physical/ionic 
etching): a) trenching at bottom of 
sidewalls; b) redeposition of 
photoresist and other materials; c) 
charging and ion path distortion. 
33 
 Physical milling when using heavy inert gases (Ar). 
 Plasma is used to generate ion beam (Ar
+
), which is extracted and accelerated to etch 
the sample. (i.e. sample outside of plasma) 
 Thus the ion density (determined by plasma source) and ion energy (determined by 
DC acceleration voltage  bias by applied DC voltage, not by RF bias as in high density 
plasma etching system), can be controlled independently. 
 Low pressure 10
-4
Torr (>1 order lower than RIE), so large mean free path and less 
energy loss due to collision. (such low pressure cannot sustain a plasma, so ion 
milling is not plasma etching) 
 High acceleration voltage (>1kV), leading to mill rate 10-30nm/min. 
 Despite the high voltage and low pressure, such a rate is still < typical RIE rate where 
chemical etching dominates. 
 Used whenever RIE is not possible (due to the lack of volatile species formation). 
Usually employed to etch Cu, Ni, Au, superconducting materials containing metals  
Ion milling or ion beam etching (IBE) 
Used to call ion milling, seems now more called as ion beam etching. 
34 
RF plasma ion beam source 
(here reactive gas added, so it is 
actually a CAIBE, see next slide) 
Ion beam etching system: 
triode configuration 
DC plasma ion beam source 
Electrons sprayed to sample to 
neutralize ions. 
Tilted sample to greatly increase 
milling rate. 
But then shadowing may become 
a problem when milling high 
aspect ratio structures. 
Electron beam is first generated 
by hot filament. 
Ions are generated by electron 
bombardment, then accelerated 
to bombard the substrate. 
35 
 CAIBE: chemically assisted ion beam etching, 
inert Ar ion, neutral reactive gas is introduced 
into lower chamber, so not ionized, though 
some may be ionized due to backflow into 
plasma region or bombardment by Ar ion. 
 RIBE: reactive IBE, reactive gases are 
introduced into plasma region together with 
Ar gas, so they are ionized. RIEB is virtually 
the only example where the same ion has 
both a physical (ion impact) and chemical 
(reactive etching) component.  
Chemically assisted ion beam etching system 
 Adding reactive gases (CF
4
, CCl
4
, O
2
, Cl
2
) to increase etching rate and selectivity. 
 Usually physical etching still dominates, no need of volatile etch product. 
 But for some special situations, like gas phase (no plasma) XeF
2
 etching of Si assisted by 
ion bombardment, chemical etching dominates with very high etching rate. But there the 
etch product SiF
4
 is volatile. 
 Here it is chemically assisted physical etching, different from RIE that is a kind of physically 
assisted chemical etching. 
36 
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Pressure 
Selectivity 
Energy (power) 
Anisotropicity 
Summary: plasma etching mechanism 
 Chemical etching: free radicals react with material to be removed. E.g. plasma etching at high 
pressure close to 1Torr. 
 Physical etching or sputtering: ionic species, accelerated by the built-in electric field (self-bias), 
bombard the materials to be removed. E.g. sputter cleaning using Ar gas in sputter deposition 
system. 
 Ion enhanced etching: combined chemical and physical process, higher material removal rate 
than each process alone. E.g. reactive ion etching (RIE), which is the most widely used dry 
etching technique. 
37 
Figure 10-19 
Dry etching techniques: summary 
38 
Three etch process 
(e.g. XeF
2
 gas etch Si even without plasma) 
(e.g. ion beam etching/milling using Ar
+
) 
Here strip 
and PR 
(photoresist) 
etch refers to 
barrel or 
downstream 
etch. 
Etch rate and selectivity 
conflict in RIE 
39 
Modes of plasma etching 
40 
Dry etching techniques: summary 
41 
Configurations  Activity 
Pressure 
(Torr) 
Arrangement 
High 
Density 
Plasma 
Biasing 
Bias 
Source 
Profile 
Barrel  Reactive  10
-1
 to 1 
Coil or electrodes outside 
vessel 
No  In cassette (bulk)  RF  Isotropic 
Parallel Plate (Plasma)  Reactive  10
-1
 to 1  Planar diode (two electrodes)  No 
On powered 
electrode (anode) 
RF  Anisotropic 
Downstream Plasma  Reactive  10
-1
 to 1 
Coil or electrodes outside 
vessel 
No 
In cassette (bulk) 
downstream of 
plasma 
RF or 
Microwave 
Isotropic 
Triode Planar  Reactive  10
-3
  Triode (three electrodes)  No 
On platform 
electrode 
  Anisotropic 
Ion Beam Milling  Inert  10
-4
  Planar triode  No 
On powered 
electrode (anode) 
  Anisotropic 
Reactive Ion Etch 
(RIE) 
Reactive  < 0.1  Planar or cylindrical diode  No  On cathode    Anisotropic 
Electron Cyclotron 
Resonance (ECR) 
Reactive 
10
-4 
to 10
-
3
 
(low) 
Magnetic field in parallel with 
plasma flow 
Yes  On cathode  RF or DC  Anisotropic 
Distributed ECR  Reactive  (low) 
Magnets distributed around 
central plasma 
Yes  On cathode  RF or DC  Anisotropic 
Inductively Coupled 
Plasma (ICP) 
Reactive  (low) 
Spiral coil separated from 
plasma by dielectric plate 
Yes  On cathode  RF or DC  Anisotropic 
Helicon Wave  Reactive  (low) 
Plasma generated by 
electromagnets and plasma 
density maintained at wafer by 
magnetic field  
Yes  On cathode  RF or DC  Anisotropic 
Dual Plasma Source  Reactive  (low) 
Independent plasma and wafer 
biasing 
Yes  On cathode  RF or DC  Anisotropic 
Magnetically 
Enhanced RIE 
(MERIE) 
Reactive  (low) 
Planar diode with magnetic 
field confining plasma 
Yes  On cathode  RF or DC  Anisotropic 
 
Dry etcher configurations 
42