Methods and apparatus for calibrating programmable material consolidation apparatus

Abstract

A programmed material consolidation apparatus includes at least one fabrication site and a material consolidation system associated with the at least one fabrication site. The at least one fabrication site may be configured to receive one or more fabrication substrates, such as semiconductor substrates. A machine vision system with a translatable or locationally fixed camera may be associated with the at least one fabrication site and the material consolidation system. A cleaning component may also be associated with the at least one fabrication site. The cleaning component may share one or more elements with the at least one fabrication site, or may be separate therefrom. The programmed material consolidation apparatus may also include a substrate handling system, which places fabrication substrates at appropriate locations of the programmed material consolidation apparatus.

1 . A method for calibrating a programmable material consolidation apparatus, comprising: 
 viewing at least one location substantially at a consolidation elevation of a fabrication site of the programmable material consolidation apparatus from a location above the consolidation elevation;    evaluating data obtained from viewing the at least one location; and    determining an amount of adjustment to be made to at least one component of the programmable material consolidation apparatus, in response to the act of evaluating.    
   
   
       2 . The method of  claim 1 , wherein viewing is effected substantially at the consolidation elevation.  
   
   
       3 . The method of  claim 1 , wherein evaluating comprises comparing the data to at least one expected data value.  
   
   
       4 . The method of  claim 1 , wherein determining comprises determining that no adjustment of the at least one component need be made.  
   
   
       5 . The method of  claim 1 , further comprising: 
 adjusting the at least one component by the amount of adjustment.    
   
   
       6 . The method of  claim 1 , further comprising: 
 adjusting the at least one component of the programmable material consolidation apparatus by at least a portion of the amount of adjustment.    
   
   
       7 . The method of  claim 1 , further comprising: 
 fabricating at least one feature substantially at the consolidation elevation.    
   
   
       8 . The method of  claim 7 , wherein viewing comprises viewing the at least one feature.  
   
   
       9 . The method of  claim 8 , wherein fabricating includes fabricating a plurality of reference pixels substantially at the consolidation elevation.  
   
   
       10 . The method of  claim 9 , wherein evaluating data comprises comparing actual locations of the plurality of reference pixels to anticipated locations for the plurality of reference pixels.  
   
   
       11 . The method of  claim 10 , further comprising: 
 adjusting reference grid data by at least a portion of the amount of adjustment.    
   
   
       12 . The method of  claim 10 , further comprising: 
 adjusting a material consolidation element of the programmable material consolidation apparatus by at least a portion of the amount of adjustment.    
   
   
       13 . The method of  claim 12 , further comprising: 
 adjusting reference grid data by at least a portion of the amount of adjustment.    
   
   
       14 . The method of  claim 1 , wherein viewing comprises moving a viewpoint from which viewing is effected along a path of a plurality of spaced apart reference pixels, each having a common, known dimension.  
   
   
       15 . The method of  claim 14 , further comprising: 
 positioning a calibration plate including the plurality of spaced apart reference pixels substantially at the consolidation elevation.    
   
   
       16 . The method of  claim 14 , wherein moving is effected substantially linearly.  
   
   
       17 . The method of  claim 14 , wherein viewing further comprises detecting transitions in contrast.  
   
   
       18 . The method of  claim 14 , wherein viewing further comprises determining a number of reference pixels viewed as the viewpoint is moved a particular distance.  
   
   
       19 . The method of  claim 18 , wherein evaluating data comprises evaluating the particular distance, the number of reference pixels viewed, and the common, known dimension of the reference pixels to determine a magnification at the viewpoint.  
   
   
       20 . The method of  claim 19 , further comprising: 
 repeating the acts of moving, viewing, and evaluating at least once to verify the magnification at the viewpoint.    
   
   
       21 . The method of  claim 19 , further comprising: 
 using the magnification at the viewpoint to control operation of a material consolidation element of the programmable material consolidation apparatus.    
   
   
       22 . The method of  claim 1 , further comprising: 
 directing selectively consolidating energy toward a plurality of locations of the consolidation elevation.    
   
   
       23 . The method of  claim 22 , wherein directing includes directing the selectively consolidating energy toward at least one location proximate a corner or an edge of a rectangular field of exposure at the consolidation elevation.  
   
   
       24 . The method of  claim 22 , wherein at least some of the plurality of locations are in substantially linear alignment.  
   
   
       25 . The method of  claim 22 , wherein viewing comprises viewing actual locations of the consolidation elevation to which the selectively consolidating energy is directed.  
   
   
       26 . The method of  claim 25 , further comprising: 
 placing at least one light-sensitive element substantially at the consolidation elevation, the viewing being effected with the at least one light-sensitive element.    
   
   
       27 . The method of  claim 25 , wherein evaluating data comprises comparing the actual locations to anticipated locations of the consolidation elevation where selectively consolidating energy was expected to be directed.  
   
   
       28 . The method of  claim 22 , further comprising: 
 adjusting a material consolidation element of the programmable material consolidation apparatus by at least a portion of the adjustment amount to increase a linearity of a path of consolidating energy generated by the material consolidation element.    
   
   
       29 . A calibration system for use with a programmable material consolidation apparatus, comprising: 
 at least one imaging element configured to be positioned above a consolidation elevation of the programmable material consolidation apparatus; and    a controller in communication with the at least one imaging element and programmable to effect at least one calibration program that facilitates adjustment of at least one feature of the programmable material consolidation apparatus to calibrate the same.    
   
   
       30 . The calibration system of  claim 29 , wherein the at least one imaging element comprises a machine vision system associated with the programmable material consolidation apparatus.  
   
   
       31 . The calibration system of  claim 29 , wherein the at least one imaging element comprises at least one light-sensitive element configured to be positioned at a location of the programmable material consolidation apparatus at which material consolidation is to occur.  
   
   
       32 . The calibration system of  claim 31 , wherein the at least one light-sensitive element is positioned at corners or edges of a field of exposure of the programmable material consolidation apparatus.  
   
   
       33 . The calibration system of  claim 31 , comprising a plurality of light-sensitive elements.  
   
   
       34 . The calibration system of  claim 29 , further comprising: 
 a calibration plate including reference features thereon, the calibration plate being configured for placement at a location of the programmable material consolidation apparatus at which material consolidation is to occur.    
   
   
       35 . The calibration system of  claim 29 , further comprising: 
 at least one actuator for moving the at least one imaging element to a plurality of locations above the consolidation elevation.