For the fabrication of a multilevel resist (MLR) based on a very thin, physical-vapor-deposited (PVD) amorphous carbon (a-C) layer, the etching characteristics of the PVD a-C layer with a SiOx hard mask were investigated in a dual-frequency superimposed capacitively coupled plasma etcher by varying the following process parameters in O2∕N2∕Ar plasmas: high-frequency/low-frequency combination (fHF∕fLF), HF/LF power ratio (PHF∕PLF), and O2 and N2 flow rates. The very thin nature of the a-C layer helps to keep the aspect ratio of the etched features low. The etch rate of the PVD a-C layer increased with decreasing fHF∕fLF combination and increasing PLF and was initially increased but then decreased with increasing N2 flow rate in O2∕N2∕Ar plasmas. The application of a 30nm PVD a-C layer in the MLR structure of ArF PR∕BARC∕SiOx∕PVD a-C∕TEOS oxide supported the possibility of using a very thin PVD a-C layer as an etch-mask layer for the TEOS-oxide layer.
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