The etching of a material in a vapor phase etchant is disclosed where a vapor
phase etchant is provided to an etching chamber at a total gas pressure of 10 Torr
or more, preferably 20 Torr or even 200 Torr or more. The vapor phase etchant can
be gaseous acid etchant, a noble gas halide or an interhalogen. The sample/workpiece
that is etched can be, for example, a semiconductor device or MEMS device, etc.
The material that is etched/removed by the vapor phase etchant is preferably silicon
and the vapor phase etchant is preferably provided along with one or more diluents.
Another feature of the etching system includes the ability to accurately determine
the end point of the etch step, such as by creating an impedance at the exit of
the etching chamber (or downstream thereof) so that when the vapor phase etchant
passes from the etching chamber, a gaseous product of the etching reaction is monitored,
and the end point of the removal process can be determined. The vapor phase etching
process can be flow through, a combination of flow through and pulse, or recirculated
back to the etching chamber. A first plasma or wet chemical etch (or both) can
be performed prior to the vapor phase etch.