Apparatus and methods for finding a best aperture and mode to enhance defect detection

1. A method for optimizing a mode of an inspection tool, comprising:

obtaining a first image or signal for each of a plurality of first apertures of the inspection tool, wherein each first image or signal pertains to a defect area;

for each of a plurality of combinations of the first apertures and their first images or signals, obtaining a composite image or signal by combining the first images or signals obtained for each individual aperture in such combination;

analyzing each composite image or signal to determine an optimum one of the combinations of the first apertures based on a defect detection characteristic of each composite image, wherein determining an optimum one of the combinations of the first apertures includes selecting a set of one or more individual apertures that result in the highest signal to noise ratio for the defect area; and

setting the optimum combination of the first apertures on the inspection tool and inspecting a sample using such optimum combination of the first apertures.

2. The method of claim 1 , wherein each first image or signal is obtained from experimental data from a sample using each of the first apertures in the inspection.

3. The method of claim 1 , wherein each first image or signal is obtained from a simulation model for the inspection tool obtaining the first image or signal using each first aperture.

4. The method of claim 1 , wherein the first apertures are positioned at a plurality of positions across a pupil or Fourier plane of the inspection tool.

5. The method of claim 4 , wherein the first apertures are positioned to provide full angular coverage for an incident beam generated by the inspection tool that impinges on the defect area, wherein the first apertures have a number that is greater than 100.

6. The method of claim 1 , wherein the first apertures together cover a substantial portion of the pupil or Fourier plane of the inspection tool.

7. The method of claim 1 , wherein the composite images are obtained for all combinations of the first apertures by summing the first images for each combination.

8. The method of claim 1 , wherein the first images are further obtained for a plurality of modes having different combinations of wavelength range settings, focus offset settings, and input and output polarization states, and wherein the composite images are further obtained for each of the modes.

9. The method of claim 8 , wherein the first images are obtained for a plurality of defect classes, and wherein the composite images are further obtained for each of the defect classes.

10. The method of claim 8 , wherein a plurality of optimum combinations of the first apertures are determined for two or more optimum ones of the modes that will together result in a separation of defect classes.

11. An inspection system for inspecting a photolithographic reticle or wafer for defects, comprising:

a light source for generating an incident beam;

a configurable illumination pupil aperture module having a plurality of configurable apertures for receiving the incident beam;

an illumination optics module for directing the incident beam through the illumination aperture and onto a sample;

a collection optics module for directing an output beam that is emitted from the sample in response to the incident beam;

a sensor for detecting the output beam and generating an image or signal for the output beam; and

a controller that is configured to perform the following operations:

obtaining a first image or signal for each of the configurable apertures, wherein each first image or signal pertains to a defect area;

for each of a plurality of combinations of the configurable apertures and their first images or signals, obtaining a composite image or signal by combining the first images or signals obtained for each configurable aperture in such combination;

analyzing each composite image or signal to determine an optimum one of the combinations of the configurable apertures based on a defect detection characteristic of each composite image, wherein determining an optimum one of the combinations of the configurable apertures includes selecting a set of one or more of the configurable apertures that result in the highest signal to noise ratio for the defect area; and

setting the optimum combination of the configurable apertures on the inspection system and inspecting a sample using such optimum combination of the configurable apertures.

12. The system of claim 11 , wherein each first image or signal is obtained from experimental data from a sample using each of the configurable apertures in the inspection.

13. The system of claim 11 , wherein each first image or signal is obtained from a simulation model for the inspection tool obtaining the first image or signal using each configurable aperture.

14. The system of claim 11 , wherein the configurable apertures are positioned at a plurality of positions across a pupil or Fourier plane of the inspection system and wherein the configurable apertures are positioned to provide full angular coverage for an incident beam generated by the inspection system that impinges on the defect area, wherein the configurable apertures have a number that is greater than 100.

15. The system of claim 11 , wherein composite images are obtained for all combinations of the configurable apertures by summing the first images for each combination.

16. The system of claim 11 , wherein the first images are further obtained for a plurality of modes having different combinations of wavelength range settings, focus offset settings, and input and output polarization states, and wherein the composite images are further obtained for each of the modes.

17. The system of claim 16 , wherein the first images are obtained for a plurality of defect classes, and wherein the composite images are further obtained for each of the defect classes.

18. The system of claim 16 , wherein a plurality of optimum combinations of the configurable apertures are determined for two or more optimum ones of the modes that will together result in a separation of defect classes.