Optimized Overlay Metrology Marks: Theory and Experiment

In this paper, we provide a detailed analysis of overlay metrology mark and find the mapping between various properties of mark patterns and the expected dynamic precision and fidelity of measurements. We formulate the optimality criteria and suggest an optimal overlay mark design in the sense of minimizing the Cramer-Rao lower bound on the estimation error. Based on the developed theoretical results, a new overlay mark family is proposed-the grating marks. A thorough testing performed on the new grating marks shows a strong correlation with the underlying theory and demonstrate the superior quality of the new design over the overlay patterns used today.