Creating 1 Um Features The Hacker Way

August 6, 2024 by Julian Scheffers 9 Comments

[Breaking Taps] has done some lithography experiments in the past, including some test patterns and a rudimentary camera sensor. But now, it’s time to turn it up a notch with 1µm garage semiconductor ambitions.

The e-beam lithography he’s done in the past can achieve some impressive resolutions, but they aren’t very fast; a single beam of electrons needs to scan over the entire exposure area, somewhat like a tiny crayon. That’s not very scalable; he needed a better solution to make 1µm semiconductors.

In his quest, he starts by trying to do maskless photolithography, using a literal projector to shine light on the target area all at once. After hacking a projector devkit apart, replacing blue with ultraviolet and adding custom optics, it’s time for a test. The process works for the most part but can’t produce fine details the way [Breaking Taps] needs. Unfortunately, fixing that would mean tearing the whole set-up apart for the umpteenth time.
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Silicon Photolithography The PCB Way

October 17, 2023 by Dan Maloney 3 Comments

[ProjectsInFlight] has been doing some fantastic work documenting his DIY semiconductor fab lately. Next up: exploring down-and-dirty photolithography methods.

If you’ve been following along with this series — and why wouldn’t you? — you’ll recall [ProjectsInFlight]’s earlier experiments, like creating oxide layers on silicon chips with a homebrew tube furnace and exploring etchants that can selectively remove them. But just blasting away the oxide layer indiscriminately isn’t really something you need to do when etching the fine features needed to fabricate a working circuit. The trouble is, most of the common photoresist solutions used by commercial fabs are unobtainium for hobbyists, leading to a search for a suitable substitute.

Surprisingly, PCB photoresist film seemed to work quite well, but not without a lot of optimization by [ProjectsInFlight] to stick it to the silicon using a regular laminator. Also in need of a lot of tweaking was the use of a laser printer to create masks for the photolithography process on ordinary transparency film, including the surprisingly effective method of improving the opacity of prints with acetone vapor. There were also extensive experiments to determine the best exposure conditions, a workable development process, and the right etchants to use. Watch the video below for a deep dive into all those topics as well as the results, which are pretty good.

There’s a lot to be said for the methodical approach that [ProjectsInFlight] is taking here. Every process is explored exhaustively, with a variety of conditions tested before settling on what works best. It’s also nice to see that pretty much all of this has been accomplished with the most basic of materials, all of which are easily sourced and pretty cheap to boot. We’re looking forward to more of the same here, as well as to see what others do with this valuable groundwork.

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3D Printing Gets Small In A Big Way

October 26, 2022 by Al Williams 8 Comments

If you have a 3D printer in your workshop, you probably fret more about how to get bigger objects out of it. However, the University of Amsterdam has a new technique that allows for fast large-scale printing with sub-micron resolution. The technique is a hybrid of photolithography and stereolithography.

One of the problems with printing with fine detail is that print times become very long. However, the new technique claims to have “acceptable production time.” Apparently, bioprinting applications are very much of interest to the technology’s first licensee. There is talk of printing, for example, a kidney scaffold in several hours or a full-sized heart scaffold in less than a day.

Another example application is the production of a chromatography instrument with 200 micron channels and 20 micron restrictions. This requires a printer capable of very fine detail. There are also applications in semiconductors and mechanical metamaterials. Of course, we always take note of photolithography processes because we use them to make PC boards and even integrated circuits. A desktop printer that could do photolithography might open up new ideas for producing electronic circuitry.

If you want to play with photolithography today, [Ben Krasnow] has some advice. Of course, there are several ways to produce PC boards, even with a garden-variety 3D printer.

Making OLED Displays In The Home Lab

September 4, 2021 by Dan Maloney 13 Comments

Just a general observation: when your project’s BOM includes ytterbium metal, chances are pretty good that it’s something interesting. We’d say that making your own OLED displays at home definitely falls into that category.

Of course, the making of organic light-emitting diodes requires more than just a rare-earth metal, not least of which is the experience in the field that [Jeroen Vleggaar] brings to this project. Having worked on OLEDs at Philips for years, [Jeroen] is well-positioned to tackle the complex process, involving things like physical vapor deposition and the organic chemistry of coordinated quinolones. And that’s not to mention the quantum physics of it all, which is nicely summarized in the first ten minutes or so of the video below. From there it’s all about making a couple of OLED displays using photolithography and the aforementioned PVD to build up a sandwich of Alq3, an electroluminescent organic compound, on a substrate of ITO (indium tin oxide) glass. We especially appreciate the use of a resin 3D printer to create the photoresist masks, as well as the details on the PVD process.

The displays themselves look fantastic — at least for a while. The organic segments begin to oxidize rapidly from pinholes in the material; a cleanroom would fix that, but this was just a demonstration, after all. And as a bonus, the blue-green glow of [Jeroen]’s displays reminds us strongly of the replica Apollo DSKY display that [Ben Krasnow] built a while back. Continue reading “Making OLED Displays In The Home Lab” →

Interference Patterns Harnessed For Optical Logic Gates

January 16, 2021 by Dan Maloney 16 Comments

The basics of digital logic are pretty easy to master, and figuring out how the ones and zeroes flow through various kinds of gates is often an interesting exercise. Taking things down a level and breaking the component AND, OR, and NOR gates down to their underlying analog circuits adds some complexity, but the flow of electrons is still pretty understandable. Substitute all that for photons, though, and you’ll enter a strange world indeed.

At least that’s our take on [Jeroen Vleggaar]’s latest project, which is making logic gates from purely optical components. As he himself admits in the video below, this isn’t exactly unexplored territory, but his method, which uses constructive and destructive interference, seems not to have been used before. The basic “circuit” consists of a generator, a pair of diffraction patterns etched into a quartz plate, and an evaluator, which is basically a pinhole in another plate positioned to coincide with the common focal point of the generator patterns. An OR gate is formed when the two generators are hit with in-phase monochromatic light. Making the two inputs out of phase by 180° results in an XOR gate, as destructive interference between the two inputs prevents any light from making it out of the evaluator.

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[Ben Krasnow] Rolls Old School Camera Out For Photolithography

March 26, 2020 by Dan Maloney 14 Comments

In a time when cameras have been reduced to microchips, it’s ironic that the old view camera, with its bellows and black cloth draped over the viewscreen for focusing, endures as an icon for photography. Such technology appears dated and with no application in the modern world, but as [Ben Krasnow] shows us, an old view camera is just the thing when you want to make homemade microchips. (Video, embedded below.)

Granted, the photolithography process [Ben] demonstrates in the video below is quite a bit upstream from the creation of chips. But mastering the process on a larger scale is a step on the way. The idea is to create a high-resolution photograph of a pattern — [Ben] chose both a test pattern and, in a nod to the season, an IRS tax form — that can be used as a mask. The camera he chose is a 4×5 view camera, the kind with lens and film connected by adjustable bellows. He found that modifications were needed to keep the film fixed at the focal plane, so he added a vacuum port to the film pack to suck the film flat. Developing film has always been magical, and watching the latent images appear on the film under the red light of the darkroom really brings us back — we can practically smell the vinegary stop solution.

[Ben] also steps through the rest of the photolithography process — spin coating glass slides with photoresist, making a contact print of the negative under UV light, developing the print, and sputtering it with titanium. It’s a fascinating process, and the fact that [Ben] mentions both garage chip-maker [Sam Zeloof] and [Justin Atkin] from the Thought Emporium means that three of our favorite YouTube mad scientists are collaborating. The possibilities are endless.

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Homemade Integrated Circuits Hack Chat

August 12, 2019 by Dan Maloney 6 Comments

Join us on Wednesday, August 14th at noon Pacific for the Homemade Integrated Circuits Hack Chat with Sam Zeloof!

While most of us are content to buy the chips we need to build our projects, there’s a small group of hackers more interested in making the chips themselves. What it takes the big guys a billion-dollar fab to accomplish, these hobbyists are doing with second-hand equipment, chemicals found in roach killers and rust removers, and a lot of determination to do what no DIYer has done before.

Sam Zeloof is one of this dedicated band, and we’ve been following his progress for years. While he was still in high school, he turned the family garage into a physics lab and turned out his first simple diodes. Later came a MOSFET, and eventually the Z1, a dual-differential amp chip that is the first IC produced by a hobbyist using photolithography.

Sam just completed his first year at Carnegie-Mellon, and he’s agreed to take some precious summer vacation time to host the Hack Chat. Join us as we learn all about the Z1, find out what improvements he’s made to his process, and see what’s next for him both at college and in his own lab.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, August 14 at 12:00 PM Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.