Inference Model Training With Subset Selection for Metrology Accuracy

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Solution Overview

Problem

Existing metrology techniques for measuring small features in lithographic processes are inaccurate and time-consuming, as they rely on indirect measurements from larger targets that do not replicate the distortions and processing of actual product structures, and methods using shorter wavelengths are not feasible or efficient.

Innovation Solution

Training an inference model using a selected subset of measurements from a dataset, optimizing the selection process to minimize computational cost while maintaining accuracy, and applying a reproduction function to generate reproduced values for training.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If indirect measurements from larger metrology targets are used, then measurement process is simplified, but measurement precision deteriorates because targets do not replicate actual product structure distortions

Engineering Contradiction:
Improvemeasurement process simplicityVSAvoidfeature size measurement accuracy
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

The patent creates physical copies of actual product structures as metrology targets. These targets are fabricated using the same lithographic process and contain identical features (e.g., lines, spaces, holes) at the same dimensions as the product structures. By copying the actual product geometry, the targets replicate the same optical distortions, focus variations, and process effects, enabling accurate inference of product feature dimensions while maintaining measurement simplicity.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The metrology targets are prepared in advance during the lithographic fabrication process itself, before the actual product structures are measured. The targets are formed simultaneously with product features using the same exposure and development steps, ensuring they experience identical process conditions. This preliminary creation of measurement references eliminates the need for separate target fabrication and ensures targets represent actual product state.

Inventive Principle:
Principle #10Preliminary action

2Measurement precision

If measurements of all dataset are used for training, then model accuracy is improved, but computational resources and training time increase

Engineering Contradiction:
Improveinference model accuracyVSAvoidtraining throughput
Core Design Contradiction:
Measurement precisionVSProductivity

Solution Approach 1:

The patent extracts and removes redundant measurements from the training dataset. By analyzing the dataset, it identifies measurements that do not contribute meaningfully to model learning (such as measurements from non-representative targets or duplicate information) and excludes them. This extraction of essential information reduces dataset size while preserving the key patterns needed for accurate inference, thereby decreasing computational burden and training time.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies partial action by using only the necessary subset of measurements for training rather than the complete dataset. It determines that a portion of the measurements is sufficient to achieve the required model accuracy, avoiding the excessive computation that would result from processing all available measurements. This selective approach maintains inference quality while improving training efficiency.

Inventive Principle:
Principle #16Partial or excessive action

3Measurement precision

If shorter wavelength radiation is used for metrology, then measurement precision for small features is improved, but device complexity and cost increase

Engineering Contradiction:
Improvesmall feature measurement capabilityVSAvoidmetrology system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent changes the parameter of target size rather than radiation wavelength to achieve measurement precision. Instead of using shorter wavelengths (which would require complex EUV or X-ray metrology systems), it creates metrology targets with feature sizes that match the product structures and uses conventional optical wavelengths. This parameter change in target geometry allows standard optical equipment to accurately measure small features by directly imaging targets at the same scale as products.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS20250355365A1Inference model training
Publication Date: 2025.11.20 ASML NETHERLANDS BV
  • US20250355365A1 patent drawing
  • US20250355365A1 patent drawing
  • US20250355365A1 patent drawing

AI summary

A method of training an inference model to determine one or more parameters of a product of a fabrication process from measurements of the product. The method includes obtaining a dataset of measurements of one or more products of the fabrication process, each of the measurements including an array of values obtained by measuring a corresponding one of the products. The method further includes selecting a proper subset of the dataset for use in training the inference model, the subset selected by applying an optimization procedure to an objective function providing a measure of differences between each measurement in the dataset and corresponding reproduced values of the measurements obtained using a reproduction function having a domain including the measurements in the subset and excluding the measurements not in the subset. The method also includes training the inference model using the proper subset of the dataset.