Micromachining using focused high energy ion beams: Deep Ion Beam Lithography

The combination of deep X-ray lithography with electroforming and micromoulding (i.e., LIGA) has been shown to offer high potential for the production of high aspect-ratio microstructures. The LIGA technique, employing synchrotron light and a suitable X-ray mask, allows production of 3D microstructures in PMMA with aspect ratios around 100. Here we demonstrate that the novel technique of Deep Ion Beam Lithography (DIBL), a direct process utilizing a focused beam of MeV ions scanned in a predetermined pattern over a suitable resist material, can produce three dimensional microstructures with sub-micrometer feature sizes. Microstructures extending up to 100 mu m from the substrate with aspect ratios approaching 100 can be produced. Multiple exposures at different ion energies allow production of multilayer structures in single resist layers of SU-8, a newly developed, chemically accelerated, negative tone, near UV, photoresist. (C) 1999 Elsevier Science B.V. All rights reserved.