October 2024
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This work investigates the impact of the Silicon (Si) loading effect induced by Deep Reactive Ion Etching (DRIE) on UV-nanoimprint lithography (NIL) patterning of nanofeatures. Silicon was chosen for its known stiffness, ability to achieve very small pattern sizes down to 6 nm with a high aspect ratio, and cost-effectiveness. However, creating a stamp for nanoimprint lithography with complex patterns presents challenges due to the silicon loading problem. Silicon molds, patterned with metasurface features of varying widths from 270 nm to 60 nm, were analyzed using Focused Ion Beam Scanning Electron Microscopy (FIB-SEM) and Atomic Force Microscopy (AFM). The Si loading effect, characterized by variations in feature depth, showed that smaller features etch more slowly due to difficulties in etchant penetration and byproduct diffusion. Silicon's excellent etching properties and ability to maintain feature integrity at sub-10 nm scales make it an ideal choice for NIL despite these challenges. Our results are crucial for advancing NIL in commercial applications, ensuring high-quality pattern transfer for diverse nanostructures. Figure 4. Optical setup used to characterize the optical behavior of the NIL-fabricated metalens. The setup includes a laser source, a series of lenses, and a camera. Images of the focal point were obtained and analyzed to study the intensity distribution. Each image corresponds to a different lens, highlighting the focal point characteristics. METALENS DESIGN METHOD-10-5 0 5 10 0.0 0.5 1.0 Normalized Intensity (a.u.) x (µm) 0°0 .460mm Metalens FDTD Results Unit-Cell RESULTS AND DISCUSSION [1]. Baracu, A., et al; Silicon Metalens Fabrication from Electron Beam to UV-Nanoimprint Lithography. Nanomaterials, 11(9), pp.2329-2329. [2].. Alnakhli, Z., et al., UV-assisted nanoimprint lithography: the impact of the loading effect in silicon on nanoscale patterns of metalens. Nanoscale Advances, 2024. 6(11): p. 2954-2967. Figure 3. Effects of silicon loading on metalens fabrication. The silicon master mold, processed by Bosch-DRIE, shows that minimal silicon loading ensures successful metalens creation. AFM characterization and precise removal of the photoresist residual layer are critical to the process. Significant silicon loading and improper residual layer removal hinder successful fabrication. VS We utilized UV-assisted NIL to fabricate metalenses, beginning with the creation of a silicon master mold. The process included: Master Mold Creation: Patterning of silicon with metasurface features using DRIE. Stamp Mold Preparation: Using a glass plate and prepolymer mixture cured with UV light to form the stamp mold. Our study revealed that the Si loading effect significantly impacts the etching uniformity in DRIE. Specifically, areas with higher silicon loading exhibited slower etch rates and increased byproduct accumulation, leading to variations in feature depth. This finding emphasizes the need for optimized etching parameters to achieve uniform nanostructures. Optimizing DRIE parameters for silicon master molds is crucial for achieving high-quality NIL patterning. Our findings provide valuable insights into controlling the Si loading effect, paving the way for advanced nanofabrication techniques in commercial applications. REFERENCES