Proces s-dependent kinoform performanceJ.A. Cox, B. Fritz, T. WernerHoneywell Systems & Research Center10701 Lyndale Avenue SouthBloomington, MN 55420ABSTRACTWe present results of an on-going experimental program to charac-terize the effects of processing errors on kinoform performance.Diffraction efficiency and modulation transfer function data aregiven for various types of processing errors present in staircasekinoforms of a f/10 Fresnel phase lens having two and four 1ev-els. Processing errors include etch depth, linewidth, and maskalignment. Processing errors, especially mask alignment, areshown to have the greatest impact on diffraction efficiency andvery little effect on image quality.1. INTRODUCTIONThe use of lithographic and etching techniques to fabricatekinoforms was first demonstrated by d'Auria et a11 and has nowbecome very popular following the great improvements in thetechnology driven by the microelectronics industry. In the usualapproach described by Veldkamp and Swanson2, a staircase approxi-mation to the ideal continuous phase profile is implemented inthe substrate using a binary mask-and-etch sequence in which thenumber of phase levels generated is a power of two. Kinoformperformance is usually discussed in terms of diffraction effi-ciency and image quality, and Dammann3 first showed how to calcu-late diffraction efficiency for the staircase structures usingthe Fourier theory. Subsequently, Petit et al.4 and Gaylord andMoharam5 applied rigorous vector-field theory to calculate theefficiency of general periodic structures and treated the stair-case profiles as special cases. Image quality, for those kino-forms which form images, has been modeled either using raytracecodes with an infinite index approximation6'7'8 or using brute-force integration of the scalar Kirchhoff equation8'9.In all of the cases cited above, kinoform performance was calcu-lated only for geometrically perfect profiles without consideringthe unavoidable effects of processing errors. Such predictionsthus represent an upper limit on the performance expected forreal kinoforms. The effects of processing errors on diffractionefficiency have been investigated both theoretically and experi-mentally by the authors10, and an independent theoretical treat-ment has been given at the same time by Farn and Goodman11. Thekinoforms in both cases were the staircase type. Cox et al.'°showed conclusively that mask alignment error was the most sig-1W