Fabrication of Si photonic waveguides by electron beam lithography using improved proximity effect correction

In this work, electron beam lithography proximity effect correction (PEC) was experimentally studied for patterning of Si photonic waveguides with a relatively thick resist mask. Beam’s energy density distribution (EDD) was experimentally extracted by the line exposure method; however, exposure lines in this work were developed after cleavage with a high-contrast process to reduce developer-related effects. The measured line spread function was fitted to a 4-Gaussian function to model mid-range energy densities accurately. The extracted EDD showed less proximity effects compared to conventional Monte-Carlo simulation performed by a commercial software. PEC processes with both techniques were experimentally compared for a Si photonic waveguide pattern with different side-cladding trench widths. Microscopic images confirmed that the presented calibration method could achieve better development conditions near the required clearance dosage. Single-mode propagation loss for a 500 × 220 nm Si wire waveguide was reduced from 3.2 to 2.4 dB cm −1 using the presented process.