Professional Documents
Culture Documents
II
Winter2009
Prof.MarcMadou
http://www.almaden.ibm.com:
80/vis/stm/gallery.html
INTRODUCTION:FromICstoMEMS
andNEMS
http://www.almaden.ibm.c
om
:80/vis/stm/gallery.html
NovaSensorAccelerometer
FundamentalsofMicrofabrication
I.FromICstoMEMSandNEMS
Todayscardiffersfromthoseoftheimmediatepostwaryearson
anumberofcounts.Butsupposeforamomentthattheautomobile
industryhaddevelopedatthesamerateascomputersandoverthe
sameperiod:howmuchcheaperandmoreefficientwouldcurrent
modelsbe?TodayyouwouldbeabletobuyaRolceRoycefor$
2.15,itwoulddothreemillionmilestothegallon,anditwould
deliverenoughpowertodrivetheQueenElizabethII.Andifyou
wereinterestedinminiaturization,youcouldplacehalfadozenof
themonapinhead
ChristopherEvans,1979
Content
DefinitionsofICs
MEMS
Whyminiaturization?
TaxonomyofMicrofabricationProcesses
Accuracy/precision
Accuracy/precisionandstandarddeviation
Relativevs.absolutetoleranceinmanufacturing
Mergingoftwoapproaches:Topdownandbottomupmachining
methodologies
Biomimetics
Afewconcludingwordsaboutmanufacturingmethods
DefinitionsofICs
Thetransistorwasinvented1948
bythreeBellLaboratoryengineers
andphysicists.JohnBardeenwas
thephysicist,WalterBrattainthe
experimentalist,andWilliam
Shockley,whobecameinvolved
laterinthedevelopment,wasthe
instigatorandideaman.Theteam
wonthe1956NobelPrizein
physicsfortheirefforts.The
transistordemonstratedforthe
firsttimethatamplificationin
solidswaspossible.
DefinitionsofICs
Diodes
DefinitionsofICs
Therearemanydifferenttypes
oftransistors,butthebasic
theoryoftheiroperationisall
thesame.Thethreeelementsof
thetwojunctiontransistorare
(1)theEMITTER,whichgives
off,oremits,"currentcarriers
(electronsorholes);(2)the
BASE,whichcontrolstheflow
ofcurrentcarriers;and(3)the
COLLECTOR,whichcollects
thecurrentcarriers.
DefinitionsofICs
Thearrowalwayspointsinthe
directionofholeflow,orfrom
thePtoNsections,nomatter
whetherthePsectionisthe
emitterorbase.Ontheother
hand,electronflowisalways
towardoragainstthearrow,
justlikeinthejunctiondiode.
DefinitionsofICs
AforwardbiasedPNjunctioniscomparabletoalowresistance
circuitelementbecauseitpassesahighcurrentforagivenvoltage.
Inturn,areversebiasedPNjunctioniscomparabletoahigh
resistancecircuitelement.ByusingtheOhm'slawformulafor
power(P=I2R)andassumingcurrentisheldconstant,youcan
concludethatthepowerdevelopedacrossahighresistanceisgreater
thanthatdevelopedacrossalowresistance.Thus,ifacrystalwereto
containtwoPNjunctions(oneforwardbiasedandtheotherreverse
biased),alowpowersignalcouldbeinjectedintotheforwardbiased
junctionandproduceahighpowersignalatthereversebiased
junction.Inthismanner,apowergainwouldbeobtainedacrossthe
crystal.Thisconceptisthebasictheorybehindhowthetransistor
amplifies.
DefinitionsofICs
DefinitionsofICs
ThetermtransistorisderivedfromthewordsTRANSferand
resISTOR.Thistermwasadoptedbecauseitbestdescribesthe
operationofthetransistorthetransferofaninputsignalcurrent
fromalowresistancecircuittoahighresistancecircuit.
Basically,thetransistorisasolidstatedevicethatamplifiesby
controllingtheflowofcurrentcarriersthroughitssemiconductor
materials.
DefinitionsofICs
Typesoftransistors:
BipolarJunction
Transistor(BJT)
MOStransistor[see
MetalOxide
Semiconductor(MOS)
Capacitor]
DefinitionsofICs
Achiporanintegratedcircuit(IC)isasmallelectronicdevice
madeoutofasemiconductormaterial.Theintegratedcircuit
consistsofelementsinseparablyassociatedandformedonor
withinasingleSUBSTRATE(mountingsurface).Inotherwords,
thecircuitcomponentsandallinterconnectionsareformedasa
unit.Thefirstintegratedcircuitwasdevelopedinthe1950sby
JackKilbyofTexasInstrumentsandRobertNoyceofFairchild
Semiconductor.
DefinitionsofICs
Integratedcircuitsareoftenclassifiedbythenumberof
transistorsandotherelectroniccomponentstheycontain:
SSI(smallscaleintegration):Upto100electronic
componentsperchip
MSI(mediumscaleintegration):From100to3,000
electroniccomponentsperchip
LSI(largescaleintegration):From3,000to100,000
electroniccomponentsperchip
VLSI(verylargescaleintegration):From100,000to
1,000,000electroniccomponentsperchip
ULSI(ultralargescaleintegration):Morethan1million
electroniccomponentsperchip
DefinitionofMEMS
Microelectromechanicalsystems(MEMS),or
micromachining(alsomicromanufacturingand
microfabrication),inthenarrowsense,comprises
theuseofasetofmanufacturingtoolsbasedon
batchthinandthickfilmfabricationtechniques
commonlyusedintheintegratedcircuitindustry
orICindustry.ThisinvolvedoriginallymainlySi
basedmechanicaldevices.
DefinitionofMEMS
MEMS:Microelectromechanicalsystems.Inrecentyears,ithas
becomeobviousthatSiisnotalwaystherightsubstrate,that
batchisoftennotgoodenoughandthatamodularapproachis
sometimesbetterthananintegratedone.Thishasespecially
becomeclearinthecaseofbiomedicalapplications(see
BIOMEMScourse).Thescienceofminiaturizationhas
becomeamuchmoreappropriatenamethanMEMSandit
involvesagoodunderstandingoftheintendedapplication,
scalinglaws,differentmanufacturingmethodsandmaterials.
DefinitionofMEMS
Whyminiaturization?
Minimizingenergyandmaterialsuseinmanufacturing
Redundancyandarrays
Integrationwithelectronics,simplifyingsystems(e.g.,single
pointvs.multipointmeasurement)
Reductionofpowerbudget
Fasterdevices
Increasedselectivityandsensitivity
Widerdynamicrange
Exploitationofneweffectsthroughthebreakdownofcontinuum
theoryinthemicrodomain
Whyminiaturization?
Cost/performance
advantages
Improvedreproducibility
(batchconcept)
Improvedaccuracyand
reliability
Minimalinvasive(e.g.
mosquitoproject)
Dowehaveachoice?(see
nextviewgraphtheLaw
ofAcceleratingReturns)
probiscusisabout75m
Whyminiaturization?
Evolution(sophistication)oflifeformsortechnologyspeeds
upbecausetheyarebuildontheirownrecordeddegreeof
order.RayKurzweilcallsthisTheLawofAccelerating
Returns*
ThisLawofAcceleratingReturnsgaveusevergreaterorder
intechnologywhichledtocomputationtheessenceof
order.
ForlifeformsDNAprovidestherecord.Inthecaseof
technologyitistheeverimprovingmethodstorecord
information.
*RayKurzweilinTheAgeofSpiritual
Machines
Whyminiaturization?
Whyminiaturization?
Mooreslaw(basedonatemporary
methodologyi.e.,lithography)isonlyan
exampleoftheLawofAccelerating
Returns.Beyondlithographywemay
expectfurtherprogressinminiaturization
basedonDNA,quantumdevices,AFM
lithography,nanotubes,etc.
Whyminiaturization?
MooresLaw:Theamountsofinformationstorable
onagivenamountofsiliconroughlydoubledevery
yearsincethetechnologywasinvented.Thisrelation,
firstmentionedin1964bysemiconductorengineer
GordonMoore(whocofoundedIntelfouryears
later)helduntilthelate1970s,atwhichpointthe
doublingperiodslowedto18months.Thedoubling
periodremainedatthatvalueuptolate1999.Moore's
Lawisapparentlyselffulfilling.
Whyminiaturization?
TaxonomyofMicrofabricationProcesses
Accuracy/precision
Accuracyisthedegreeof
correctnesswithwhicha
measuringsystemyieldsthe
truevalueofameasured
quantity(e.g.bullseye).
Accuracyistypicallydescribed
intermsofamaximum
percentageofdeviationexpected
basedonafullscalereading.
http://ull.chemistry.uakron.
edu/analytical/animations/
Accuracy/precision
QuickTime and a
Graphics decompressor
are needed to see this picture.
Precisionisthedifference
betweentheinstruments
reportedvaluesduring
repeatedmeasurementsof
thesamequantity
Precisionistypically
determinedbystatistical
analysisofrepeated
measurements
http://ull.chemistry.uakron.
edu/analytical/animations/
Accuracy/precision
Accuracy,precisionandstandarddeviation
Ameasurementcanbeprecise,but
Qui ckTi me and a
Graphi cs decompressor
maynotnotbeaccurate.
are needed t o see t hi s pi ct ure.
Thestandarddeviation(s)isa
statisticalmeasureoftheprecision
inaseriesofrepetitive
measurements(alsooftengivenas
withNthenumberofdata,xiis
eachindividualmeasurement,andx
themeanofallmeasurements.
X
Thevaluexiiscalledtheresidual
foreachmeasurement.
Relativevs.absolutetoleranceinmanufacturing
Lithographyisexcellentforachievingsmallabsolutetolerances
wecanmakemuchsmallerdeviceswithlithographythanwith
mechanicalmachining.Therelativetoleranceonthosedimensions
thoughisnotsogood;ona100mlinewemightperhapsachieve1
%.Inmechanicalmachiningtermsthisdoesnotevenqualifyas
precisionmachining!
Forasmallrelativetolerance,ultrafinediamondmillingisbetter.
Canbebetterthan0.01%.Ofcoursewecannotmakethingsassmall
aswecanwithlithography.
Theaboveargumentmightdecideyourchoiceofmachining
approachordecidethesizeofthedeviceyouwanttomake.
Relativevs.absolutetolerancein
manufacturing
Lithography(e.g.Si
micromachining)is
excellentforsmall
absolutetolerances
Forrelativetolerances,
ultrafinediamondmilling
isbetter
Insomecaseswemight
wanttokeepour
micromachinesomewhat
largertooptimizerelative
tolerances(seeMass
Spectrometerexample)
100
10
0.1
0.01
1
1
0.01
100
1%
10
0.1
km
m
cm
mm
m
nm
m
cm
m
km
m
cm
m
%
m
%
m
m
m
m
m
%
%%
Absolute
Linear
Optic
Arm
House
City
Relative
Atom
Virus
Bacteria
Precision
0.0001
dimension
size
tolerance
Tolerance
tolerances
Machining
for building
Precision
Machining
Application Domain
al house and a lithography based
a
fiber
micromachine
Relativevs.absolutetoleranceinmanufacturing
LawrenceLivermore
NationalLaboratories
(LLNL),atonepointused
LIGAtomakethenext
generationmass
spectrometer
Thepicturebelowshowsan
arrayofholesinPMMAto
electroplateNiposts(poles)
Thediameterofeachholeis
40m!!
Alargermassspectrometer
ismachinedwith
traditionalultrafine
diamondmillingatJPL
Relativetoleranceisbetter
thanwiththeLIGA
machinedone,soits
performanceisbetter
Relativevs.absolutetolerancein
manufacturing
Mergingoftwoapproaches:Topdownandbottom
upmachiningmethodologies
Mosthumanmanufacturingmethodsofsmalldevicesinvolvetop
downapproaches.Startingfromlargerblocksofmaterialwemake
smallerandsmallerthings.Natureworkstheotherway,i.e.,from
thebottomup.Alllivingthingsaremadeatombyatom,molecule
bymolecule;fromthesmalltothelarge.Asmanufacturingofvery
smallthingswithtopdowntechniques(NEMSornano
mechanicaldevices)becometooexpensiveorhitotherbarrierswe
arelookingatnatureforguidance(biomimetics).
Natureandmankindhavedevelopedcompetitivemanufacturing
methodsonthemacrolevel(e.g.,steelversusbone).Biomimetics
mostlyfailedinthelargerworld(seeIcarus).Backgroundreading:
CatsPawsandCatapultsbyStevenVogel(Efficiencyof
mechanicalsystemsinbiologyandhumanengineeringinthe
macroworld).
Mergingoftwoapproaches:Topdownand
bottomupmachiningmethodologies
Onthenanoscalenatureis
outperformingusbyfar(perhaps
becausenaturehashadmoretime
workingtowardsbiological
molecules/cellsthantowards
makinglargerorganismssuchas
treesandus).
Furtherminiaturizationmightbe
inspiredbybiologybutwillmost
likelybedifferentagainfromnature
thedriversforhumanand
naturalmanufacturingtechniques
areverydifferent.
Mergingoftwoapproaches:Topdownand
bottomupmachiningmethodologies
Mergingoftwoapproaches:Topdownand
bottomupmachiningmethodologiesNEMS
MEMSlittlebrotherisNEMS,thetopdown
approachtonanodevices.Thisbiomimetic
approachtonanodevicesIliketocall
nanochemistry.Tosucceedinthelatterwe
willneed:
selfassemblyanddirectedassembly(e.,g,
usingelectricalfieldsseenextviewgraph)
massiveparallelism
understandingofmolecularmechanisms
chemomechanics
engineers/scientistswhounderstandwet
anddrydisciplines
Seeman
Eigler
Montemagno
DaunertMadou
Mergingoftwoapproaches:Topdownand
bottomupmachiningmethodologiesNEMS
Examplenanochemistryapproaches:
Naturalpolymers:e.g.,NAsandproteinsnot
onlyassensorsbutalsoasactuatorsand
buildingblocks(GeneticengineerNAsand
proteinsrelyonextremophilesforguidance)
Mechanosynthesis
NEMS/biologyhybridstolearnonly
Biomimetics
Bimimetics:
Manyexamplesinnatureprovidehints
forfuturemanufacturingmethodsbutas
statedearlierthepurposefortheir
developmentisdifferentfromthe
reasonsforhumanmanufacturing
methods(e.g.,teethandseashellsmight
beexcellentstrongbuildingmaterials
buttheirgrowthistypicallywaytoo
slowtobeattractiveforhuman
manufacturing)
Afewconcludingwordsaboutmanufacturing
methods
Serialversusbatchversus
continuousmanufacturing
methods
Projectedversustruly3D
Additiveprocessversus
subtractiveprocess
Topdownversusbottom
up
Somethingtothinkabout
Lookingbackattheworsttimes,italwaysseemsthattheyweretimesin
whichtherewerepeoplewhobelievedwithabsolutefaithandabsolute
dogmatisminsomething.Andtheyweresoseriousinthismatterthat
theyinsistedthattherestoftheworldagreewiththem.Andthenthey
woulddothingsthatweredirectlyinconsistentwiththeirownbeliefs
inordertomaintainthatwhattheysaidwastrue.
FromRichardP.FeynmaninTheMeaningofitAll.
IfinthecourseoftheselecturesIcanmakeyoudoubtmostofthethings
youhavecometobelievethenIprobablyputyouonthepathof
becomingatruescientist/engineer.
Somethingtothinkabout
Homework
Describetoa12yearold,intheshortestandclearest
fashionhowatransistorworksandwhyitisso
importantinapplicationsallaroundus(figureisok
butwordsarerequired).
Characterizeusingthefollowingcriteria:
projectedversus3D,
serial,batchorcontinuous
topdownversusbottomup
Lasermachining
Mechanicalmachining
Ebeammachiningandplasticmolding.
Calculatethenumberatomsina100mlongAg
line(1mwideand1mheigh).Ifweputone
atomdownpersecond(e.g.,usinganSTM)how
longwillittaketofinishthisAgline?