A Valuable and Low‑Budget Process Scheme of Equivalized 1 nm Technology Node Based on 2D Materials

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A Valuable and Low‑Budget Process Scheme of Equivalized 1 nm Technology Node Based on 2D Materials
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A Valuable and Low-Budget Process Scheme of Equivalized 1 nm Technology Node Based on 2D Materials - Nano-Micro Letters

Emerging two-dimensional (2D) semiconductors are among the most promising materials for ultra-scaled transistors due to their intrinsic atomic-level thickness. As the stacking process advances, the complexity and cost of nanosheet field-effect transistors (NSFETs) and complementary FET (CFET) continue to rise. The 1 nm technology node is going to be based on Si-CFET process according to international roadmap for devices and systems (IRDS) (2022, https://irds.ieee.org/ ), but not publicly confirmed, indicating that more possibilities still exist. The miniaturization advantage of 2D semiconductors motivates us to explore their potential for reducing process costs while matching the performance of next-generation nodes in terms of area, power consumption and speed. In this study, a comprehensive framework is built. A set of MoS2 NSFETs were designed and fabricated to extract the key parameters and performances. And then for benchmarking, the sizes of 2D-NSFET are scaled to a extent that both of the Si-CFET and 2D-NSFET have the same average device footprint. Under these conditions, the frequency of ultra-scaled 2D-NSFET is found to improve by 36% at a fixed power consumption. This work verifies the feasibility of replacing silicon-based CFETs of 1 nm node with 2D-NSFETs and proposes a 2D technology solution for 1 nm nodes, i.e., “2D eq 1 nm” nodes. At the same time, thanks to the lower characteristic length of 2D semiconductors, the miniaturized 2D-NSFET achieves a 28% frequency increase at a fixed power consumption. Further, developing a standard cell library, these devices obtain a similar trend in 16-bit RISC-V CPUs. This work quantifies and highlights the advantages of 2D semiconductors in advanced nodes, offering new possibilities for the application of 2D semiconductors in high-speed and low-power integrated circuits.

As the IRDS roadmap eyes Si-CFET for the 1 nm generation, the mask count, 3-D stacking and parasitic capacitance required threaten to explode cost and complexity. Now a Fudan–Tsinghua–ECNU team led by Prof. Wenzhong Bao, Prof. Yabin Sun and Prof. He Tian proposes a lateral-scaling alternative: “2D eq 1 nm”—a MoS2 nanosheet-FET (NSFET) flow that needs only half the photomasks and no vertical PMOS/NMOS stacking yet outperforms Si-CFET in power, speed and area.

Why 2D-NSFET Matters

  • Horizontal Scaling Instead of Vertical Stacking
    – CGP shrinks from 40 nm (Si-CFET) to 20 nm; L scales to 6 nm while keeping SS ≤ 61 mV dec-1and DIBL ≤ 42 mV V-1—24 mV dec-1 and 78 mV V-1 better than Si at the same gate length.
  • 36 % Frequency Gain @ Iso-Power
    – Calibrated BSIM-CMG ring-oscillator runs 36 % faster than 1 nm Si-CFET and 28 % faster than 3 nm Si-NSFET at identical 0.65 V supply and power.
  • Mask-Count & Cost Reduction
    – Eliminating CFET’s 3-D integration slashes >50 masks; EUV layers drop from ~18 to ~9, cutting lithography cost by ≈ 40 %.
  • Proven Device Uniformity
    – Wafer-scale CVD 3-layer MoS₂ arrays deliver I ≈ 1.3 mA μm-1, I ≈ 109and σ(V) < 80 mV across 200 mm substrate.

Cross-Scale Simulation Framework

DFT → TCAD → SPICE → 16-bit RISC-V CPU:

  • Material: DFT-computed multi-valley DOS for WS2(electron mass 0.34 m0, ΔE = 0.18 eV) fed into TCAD.
  • Device: Quantum-corrected drift-diffusion calibrated against fabricated 6 nm LG MoS2 NSFETs (EOT = 0.9 nm, R = 180 Ω μm).
  • Circuit: 15-stage RO and 9-standard-cell library (AOI22, XOR2, MUX21…) synthesized at 0.65 V; extracted C 20 % lower, I 30 % higher than Si-CFET.
  • System: Open-source 16-bit RISC-V core shows 48 % frequency boost and 17 % power reduction versus 1 nm Si-CFET at iso-area.

Process Flow & Scalability

  1. 40 nm-deep trench etch → Au back-gate
  2. 15 nm ALD HfO2 gate dielectric
  3. CVD 3-layer MoS2 transfer, litho/etch channel
  4. Self-aligned 5 nm Ti / 40 nm Au S/D
  5. Repeat for 2nd nanosheet; 110 nm Au top-gate
  6. Via etch & metallization connect dual channels

All steps use laser-direct-write lithography (≤ 300 nm overlay) and are foundry-compatible; yield-limiting steps (uniform MoS2 growth, low-R contact) are flagged for ongoing optimization.

Challenges & Outlook

Contact resistance below 150 Ω μm and >900 cm2 V-1 s-1 mobility must co-exist at 6 nm LG to hit the simulated PPA. The team is now integrating semi-metallic Sb contacts and sub-1 nm EOT ZrO2 to close the gap, while foundry partners target 2026 pilot-line insertion at the 3 nm (2D+) node.

By replacing 3-D CFET complexity with atomic-thin lateral scaling, the “2D eq 1 nm” scheme offers a lower-cost, higher-speed route to keep Moore’s law alive—without the Moore’s tax.

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Two-dimensional Materials
Physical Sciences > Materials Science > Condensed Matter > Semiconductors > Two-dimensional Materials
Semiconductors
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Nanoscale Design, Synthesis and Processing
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  • Nano-Micro Letters Nano-Micro Letters

    Nano-Micro Letters is a peer-reviewed, international, interdisciplinary and open-access journal that focus on science, experiments, engineering, technologies and applications of nano- or microscale structure and system in physics, chemistry, biology, material science, and pharmacy.