Past exam of the MPhil in micro- and nanotechnology enterprise course of the University of Cambridge / 2018 / Paper 1 / Section A(ii) / 4 / i / a / 1

Expect appreciable but nonuniform sidewall coverage, rounded upper edges and possible narrowing near the opening mouth. In sputtering, gas collisions and the extended source distribute arriving material over a broader range of directions than simple high-vacuum evaporation. At the specified pressure, the extent of that redistribution also depends on source-to-substrate distance and particle energies; pressure alone does not determine a unique sidewall thickness.

The top surfaces receive the nominal film. Oblique rays coat accessible walls, while the tall opening shadows some directions from its lower portions. Growth at the mouth can further shadow the floor or form an overhang. The sidewall film is therefore neither guaranteed zero nor guaranteed as thick as the horizontal film. This step coverage is generally unfavorable for clean lift-off process if it connects the film on the resist to the film on the substrate.