A narrowly defined range of zinc silicate glass compositions is found to
produce High Energy Beam Sensitive-glass (HEBS-glass) that possesses the
essential properties of a true gray level mask which is necessary for the
fabrication of general three dimensional microstructures with one optical
exposure in a conventional photolithographic process. The essential
properties are (1) A mask pattern or image is grainiless even when
observed under optical microscope at 1000.times. or at higher
magnifications. (2) The HEBS-glass is insensitive and/or inert to photons
in the spectral ranges employed in photolithographic processes, and is
also insensitive and/or inert to visible spectral range of light so that a
HEBS-glass mask blank and a HEBS-glass mask are permanently stable under
room lighting conditions. (3) The HEBS-glass is sufficiently sensitive to
electron beam exposure, so that the cost of making a mask using an e-beam
writer is affordable for at least certain applications. (4) The e-beam
induced optical density is a unique function of, and is a very
reproducible function of electron dosages for one or more combinations of
the parameters of an e-beam writer. The parameters of e-beam writers
include beam acceleration voltage, beam current, beam spot size,
addressing grid size and number of retraces.
A method of fabricating three-dimensional microstructures using HEBS-glass
gray scale photomask for three dimensional profiling of photoresist and
reproducing the photoresist replica in the substrate with the existing
microfabrication methods normally used for the production of
microelectronics is described.