Nikon was the star of the VLSI Technology Research Association (VLSI Labs) established by Japan’s Ministry of International Trade in Industry (MITI) in 1976 to develop technology that could compete with the US semiconductor equipment industry. VLSI Labs asked Nikon to build a machine that could reduce the size of IC patterns by a factor of ten.
Nikon, which like its fellow camera-maker Canon could make high-quality lenses but which also had precise high-speed stage positioning technology, produced a device that, in Nikon’s words, “was accurate enough to hit a tennis ball with an arrow on the top of Mt Fuji all the way from Tokyo.”
The device was a step-and-repeat IC lithography system – a “stepper,” which stepped across the wafer one chip at a time, enabling higher resolution than the mask aligners they replaced.
Aligners, which use a mask that covers the entire surface of the wafer, were faster than the first steppers but could not keep up with IC miniaturization – the rapid shrinking of feature sizes described by Moore’s Law (the observation by Gordon Moore, co-founder of Fairchild Semiconductor and Intel, that the number of transistors on an integrated circuit doubles every two years).
Nikon delivered a prototype in 1978 and shipped its first stepper for commercial use in 1980, a machine with one micrometer (one micron, or 1,000nm) resolution and highly accurate alignment. The first shipment to the US was made in 1982. By the end of the 1980s, mask aligners and the American companies that made them, Perkin-Elmer and GCA, had been largely displaced by Japanese steppers.
In the 1990s, steppers were replaced by step-and-scan systems – scanners, which expose only part of the mask as they move. This made it possible to use a smaller lens, which reduced both aberrations and cost while enabling an increase in resolution.