Fabrication of SiCN MEMS by photopolymerization of pre-ceramic polymer

This paper describes the use of photopolymerization of a liquid polysilazane as a novel, versatile and cost-effective means of fabricating SiCN ceramic MEMS. SiCN is a new class of polymer-derived ceramics whose starting material is a liquid-phase polymer. By adding a photo initiator to the precursor, photolithographical patterning of the pre-ceramic polymer can be accomplished by UV exposure. The resulting solid polymer structures are then crosslinked under isostatic pressure, and pyrolyzed to form an amorphous ceramic capable of withstanding over 1500°C. By adding and curing successive layers of liquid polymer on top of one another, multi-layered ceramic MEMS can be easily fabricated. The use of photopolymerization can also be used to make thin, membrane-like ceramic structures. Key issues concerning the fabrication process are discussed. By combining photopolymerization with other in-house developed techniques such as polymer-based bonding and flip-chip bonding, three SiCN MEMS devices for high-temperature applications have been fabricated: an electrostatic actuator, a pressure transducer, and a combustion chamber. These represent a wide range of MEMS, demonstrating the versatility of this technique.