The present disclosure provides a method for fabricating high
aspect ratio patterns as elements of a photonic device in a
semiconductor substrate by using a continuous
metal mesh and
etching in the presence of air and an etchant in a
continuous flow. In one method, a stable catalyst that forms a stable
metal-
semiconductor alloy allows
etching of the substrate in the vertical direction even under conditions of very low oxidant concentration (e.g., the oxidant species present in air) without any
external bias or
magnetic field, thereby achieving very high
aspect ratio structures in the
semiconductor substrate. The
metal layer on the semiconductor substrate reacts with the oxidant contained in the air and catalyzes semiconductor
etching through the etchant. In one method, the etchant is supplied by evaporating a water-diluted HF solution. The
continuous flow of air near the metal layer allows a constant oxidant concentration to be maintained near the metal layer. This facilitates the
mass transfer of reactant species and etching by-products, and thus the process can continue for a long time to form very high
aspect ratio structures. Once the etched
semiconductor structure is formed, the continuous air flow supports the
diffusion of reactant species through the etched
semiconductor structure, thereby maintaining a uniform
etching rate for the high aspect ratio structure. The continuous air flow supports the
diffusion of reaction by-products, thus avoiding inhibition of the etching reaction. Structures with an aspect ratio of about 10,000:1 can be obtained by this method. The method has excellent pattern
transfer ability at the nanoscale. Since the oxidant can be provided by ordinary air, the
system has particular implementation advantages because it does not require any handling of hazardous and flammable gases (such as O2 gas) or unstable chemicals (such as H2O2).