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Published online by Cambridge University Press: 22 February 2011
Two techniques for fabricating through-wafer via holes in 2-4 mil thick GaAs substrates were examined. In the first, Ni or thick photoresist masks were used for patterning 30 μm diameter vias by ECR-rf dry etching using low pressure (10-20 mTorr), low bias (– 150V) BCI3/C12 discharges. Microwave enhancement of these discharges produced faster etch rates but a greater degree of isotropic material removal at a given pressure. Reducing the process pressure produces extremely anisotropic features with high aspect ratio. The BC13-to-C12 ratio must be kept to ≥5:1 to maintain the anisotropy. A novel laser drilling technique was also examined - in this case a Q-switched beam with high energy density was used to ablate material in each pass of the beam, producing a via in approximately 40 passes. This is a maskless procedure capable of producing any desired via hole pattern, but currently there is no selectivity for ablating GaAs over a front-side metal film.