Different sized features in the array and in the periphery of an
integrated circuit are patterned on a substrate in a single step. In
particular, a mixed pattern, combining two separately formed patterns, is
formed on a single mask layer and then transferred to the underlying
substrate. The first of the separately formed patterns is formed by pitch
multiplication and the second of the separately formed patterns is formed
by conventional photolithography. The first of the separately formed
patterns includes lines that are below the resolution of the
photolithographic process used to form the second of the separately
formed patterns. These lines are made by forming a pattern on photoresist
and then etching that pattern into an amorphous carbon layer. Sidewall
pacers having widths less than the widths of the un-etched parts of the
amorphous carbon are formed on the sidewalls of the amorphous carbon. The
amorphous carbon is then removed, leaving behind the sidewall spacers as
a mask pattern. Thus, the spacers form a mask having feature sizes less
than the resolution of the photolithography process used to form the
pattern on the photoresist. A protective material is deposited around the
spacers. The spacers are further protected using a hard mask and then
photoresist is formed and patterned over the hard mask. The photoresist
pattern is transferred through the hard mask to the protective material.
The pattern made out by the spacers and the temporary material is then
transferred to an underlying amorphous carbon hard mask layer. The
pattern, having features of difference sizes, is then transferred to the
underlying substrate.