A method of fabricating a gate structure (such as a floating gate) of a
nonvolatile (e.g., flash) memory is described. After a polysilicon layer
and a mask layer (e.g., silicon nitride) are formed on a semiconductor
substrate, the silicon nitride layer is patterned and the polysilicon
layer is partially etched. Then, a sidewall spacer is formed on sidewalls
of the partially etched polysilicon layer and the patterned mask layer.
The partially etched polysilicon layer is then fully etched, maintaining
a partially etched shape at its top edge due to the sidewall spacer. The
mask layer and the sidewall spacer are removed, to form a floating gate
having a near-round edge shape. After full etching, the polysilicon layer
may be heat-treated such that its top edge shape may become more rounded,
fluent and/or stress- and/or strain-relieving.