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104 JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, VOL. 20, NO. 1, FEBRUARY 2011 Modeling and Characterization of CMOS-Fabricated Capacitive Micromachined Ultrasound Transducers Christopher B. Doody, Member, IEEE, Member, ASME, Xiaoyang Cheng, Member, IEEE, Collin A. Rich, Member, IEEE, David F. Lemmerhirt, Member, IEEE, and Robert D. White, Member, IEEE, Member, ASME Abstract—This paper describes the fabrication, characteriza- tion, and modeling of complementary metal–oxide–semiconductor (CMOS)-compatible capacitive micromachined ultrasound trans- ducers (CMUTs). The transducers are fabricated using the inter- connect and dielectric layers from a standard CMOS fabrication process. Unlike previous efforts toward integrating CMUTs with CMOS electronics, this process adds no microelectromechanical systems-related steps to the CMOS process and requires no critical lithography steps after the CMOS process is complete. Efficient computational models of the transducers were produced through the combined use of finite-element analysis and lumped-element modeling. A method for improved computation of the electrostatic coupling and environmental loading is presented without the need for multiple finite-element computations. Through the use of laser Doppler velocimetry, transient impulse response and steady-state frequency sweep tests were performed. These measurements are compared to the results predicted by the models. The performance characteristics were compared experimentally through changes in the applied bias voltage, device diameter, and medium properties (air, vacuum, oil, and water). Sparse clusters of up to 33 elements were tested in transmit mode in a water tank, achieving a center frequency of 3.5 MHz, a fractional bandwidth of 32%–44%, and pressure amplitudes of 181–184 dB re 1 μPa rms at 15 mm from the transducer on axis. [2009-0230] Index Terms—Acoustic models, acoustic transducers, capacitive micromachined ultrasound transducers (CMUTs), finite-element analysis (FEA), lumped-element modeling, ultrasound. I. I NTRODUCTION D IAGNOSTIC medical ultrasound requires arrays of ul- trasound transducers to transmit acoustic energy into the body and to receive echo information for imaging. Piezoelec- tric crystals or piezocomposites are utilized for most existing commercial ultrasound technology [1], [2]. Due to the fact that piezoelectric transducers have an acoustic impedance of the same order of magnitude as that of many stiff solids, Manuscript received September 21, 2009; revised October 12, 2010; accepted October 23, 2010. Date of publication December 20, 2010; date of current version February 2, 2011. This work was supported in part by the National Science Foundation under Grant IIP-0450493 and in part by the Michigan Economic Development Corporation. Subject Editor D. L. DeVoe. C. B. Doody was with Tufts University, Medford, MA 02155 USA. He is now with STD Med, Inc., Stoughton, MA 02072 USA (e-mail: [email protected]). X. Cheng, C. A. Rich, and D. F. Lemmerhirt are with Sonetics Ultra- sound, Ann Arbor, MI 48103 USA (e-mail: [email protected]; [email protected]; [email protected]). R. D. White is with the Mechanical Engineering Department, Tufts Univer- sity, Medford, MA 02155 USA (e-mail: [email protected]). Color versions of one or more of the figures in this paper are available online at http://ieeexplore.ieee.org. Digital Object Identifier 10.1109/JMEMS.2010.2093559 piezoelectric transducers are an ideal choice for performing ultrasonic investigations directly on solids for applications such as nondestructive evaluation. However, when the objective is to excite and detect ultrasound in human or animal tissue, which has acoustic properties more similar to water than rigid solids, the impedance mismatch between piezoelectrics and tissue results in energy loss [3], [4]. In the case of tissue- or fluid-coupled applications, matching layers are usually placed between the piezoelectric transducer and the medium [3]. However, this solution introduces its own set of problems. Often, materials with the necessary charac- teristic impedance are hard to find or nonexistent, resulting in the common use of nonoptimal matching layers. In addition, high-frequency transducers require impractically thin matching layers for optimal effect [5]. Recently, capacitive micromachined ultrasound transducers (CMUTs) have been developed as an alternative to piezoelec- tric transducers [5]–[14]. CMUTs have become a competing microelectromechanical systems (MEMS) technology due to their ability to overcome some of the drawbacks of piezoelectric transducers. Because the structure of a CMUT consists of a flexible thin-film membrane, the device structure is inherently better acoustically matched to tissue compared to rigid piezo- electric crystals. Also, CMUTs exhibit some attractive features such as the possibility of integrating signal processing, signal routing, and power electronics on a chip with the transducers and the possibility of increased bandwidth, which impacts axial resolution [15]. The design of capacitive acoustic transducers for transmit and receive operations in air can be traced back at least to the early part of the 20th century (e.g., [16] and [17]). The earliest example of the use of an electrostatic transducer in submerged operation is by Cantrell et al. in the late 1970s [18], [19]. Modern micromachining methods were first applied to elec- trostatic in-air microphone design by Hohm and Hess in 1989, soon followed by the demonstration of surface-micromachined CMUTs in air by Haller and Khuri-Yakub in 1994 [6], [8] and for submerged operation by Ladabaum et al. and Soh et al. in 1996 [5], [9]. Researchers have described a variety of CMUT designs and computational models. Both lumped-element modeling and finite-element analysis (FEA) have been employed in the past (e.g., [20] and [21]). Measurements of the device response often include transmit and receive frequency response measurements in a water or oil tank and also the device input electrical impedance (e.g., [5] and [10]). Laser interferometry has also 1057-7157/$26.00 © 2010 IEEE

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Page 1: New Modeling and Characterization of CMOS-Fabricated Capacitive … · 2018. 7. 27. · modeling. A method for improved computation of the electrostatic coupling and environmental

104 JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, VOL. 20, NO. 1, FEBRUARY 2011

Modeling and Characterization of CMOS-FabricatedCapacitive Micromachined Ultrasound Transducers

Christopher B. Doody, Member, IEEE, Member, ASME, Xiaoyang Cheng, Member, IEEE,Collin A. Rich, Member, IEEE, David F. Lemmerhirt, Member, IEEE, and

Robert D. White, Member, IEEE, Member, ASME

Abstract—This paper describes the fabrication, characteriza-tion, and modeling of complementary metal–oxide–semiconductor(CMOS)-compatible capacitive micromachined ultrasound trans-ducers (CMUTs). The transducers are fabricated using the inter-connect and dielectric layers from a standard CMOS fabricationprocess. Unlike previous efforts toward integrating CMUTs withCMOS electronics, this process adds no microelectromechanicalsystems-related steps to the CMOS process and requires no criticallithography steps after the CMOS process is complete. Efficientcomputational models of the transducers were produced throughthe combined use of finite-element analysis and lumped-elementmodeling. A method for improved computation of the electrostaticcoupling and environmental loading is presented without the needfor multiple finite-element computations. Through the use of laserDoppler velocimetry, transient impulse response and steady-statefrequency sweep tests were performed. These measurements arecompared to the results predicted by the models. The performancecharacteristics were compared experimentally through changes inthe applied bias voltage, device diameter, and medium properties(air, vacuum, oil, and water). Sparse clusters of up to 33 elementswere tested in transmit mode in a water tank, achieving a centerfrequency of 3.5 MHz, a fractional bandwidth of 32%–44%, andpressure amplitudes of 181–184 dB re 1 µParms at 15 mm fromthe transducer on axis. [2009-0230]

Index Terms—Acoustic models, acoustic transducers, capacitivemicromachined ultrasound transducers (CMUTs), finite-elementanalysis (FEA), lumped-element modeling, ultrasound.

I. INTRODUCTION

D IAGNOSTIC medical ultrasound requires arrays of ul-trasound transducers to transmit acoustic energy into the

body and to receive echo information for imaging. Piezoelec-tric crystals or piezocomposites are utilized for most existingcommercial ultrasound technology [1], [2]. Due to the factthat piezoelectric transducers have an acoustic impedance ofthe same order of magnitude as that of many stiff solids,

Manuscript received September 21, 2009; revised October 12, 2010;accepted October 23, 2010. Date of publication December 20, 2010; date ofcurrent version February 2, 2011. This work was supported in part by theNational Science Foundation under Grant IIP-0450493 and in part by theMichigan Economic Development Corporation. Subject Editor D. L. DeVoe.

C. B. Doody was with Tufts University, Medford, MA 02155 USA.He is now with STD Med, Inc., Stoughton, MA 02072 USA (e-mail:[email protected]).

X. Cheng, C. A. Rich, and D. F. Lemmerhirt are with Sonetics Ultra-sound, Ann Arbor, MI 48103 USA (e-mail: [email protected];[email protected]; [email protected]).

R. D. White is with the Mechanical Engineering Department, Tufts Univer-sity, Medford, MA 02155 USA (e-mail: [email protected]).

Color versions of one or more of the figures in this paper are available onlineat http://ieeexplore.ieee.org.

Digital Object Identifier 10.1109/JMEMS.2010.2093559

piezoelectric transducers are an ideal choice for performingultrasonic investigations directly on solids for applications suchas nondestructive evaluation. However, when the objective isto excite and detect ultrasound in human or animal tissue,which has acoustic properties more similar to water than rigidsolids, the impedance mismatch between piezoelectrics andtissue results in energy loss [3], [4].

In the case of tissue- or fluid-coupled applications, matchinglayers are usually placed between the piezoelectric transducerand the medium [3]. However, this solution introduces its ownset of problems. Often, materials with the necessary charac-teristic impedance are hard to find or nonexistent, resulting inthe common use of nonoptimal matching layers. In addition,high-frequency transducers require impractically thin matchinglayers for optimal effect [5].

Recently, capacitive micromachined ultrasound transducers(CMUTs) have been developed as an alternative to piezoelec-tric transducers [5]–[14]. CMUTs have become a competingmicroelectromechanical systems (MEMS) technology due totheir ability to overcome some of the drawbacks of piezoelectrictransducers. Because the structure of a CMUT consists of aflexible thin-film membrane, the device structure is inherentlybetter acoustically matched to tissue compared to rigid piezo-electric crystals. Also, CMUTs exhibit some attractive featuressuch as the possibility of integrating signal processing, signalrouting, and power electronics on a chip with the transducersand the possibility of increased bandwidth, which impacts axialresolution [15].

The design of capacitive acoustic transducers for transmitand receive operations in air can be traced back at least to theearly part of the 20th century (e.g., [16] and [17]). The earliestexample of the use of an electrostatic transducer in submergedoperation is by Cantrell et al. in the late 1970s [18], [19].Modern micromachining methods were first applied to elec-trostatic in-air microphone design by Hohm and Hess in 1989,soon followed by the demonstration of surface-micromachinedCMUTs in air by Haller and Khuri-Yakub in 1994 [6], [8] andfor submerged operation by Ladabaum et al. and Soh et al. in1996 [5], [9].

Researchers have described a variety of CMUT designs andcomputational models. Both lumped-element modeling andfinite-element analysis (FEA) have been employed in the past(e.g., [20] and [21]). Measurements of the device response ofteninclude transmit and receive frequency response measurementsin a water or oil tank and also the device input electricalimpedance (e.g., [5] and [10]). Laser interferometry has also

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DOODY et al.: MODELING AND CHARACTERIZATION OF CMOS-FABRICATED CMUTS 105

been used in the past to characterize CMUT dynamics [22].These techniques have been applied to a variety of transducerstructures, typically achieved using a surface-micromachinedMEMS process (e.g., [5]) or a wafer-bonding process (e.g., [23]and [24]).

This paper extends the computational and experimentaltechniques to CMUT devices fabricated using the layers ofa standard n-well complementary metal–oxide–semiconductor(CMOS) circuit fabrication process. This approach offerscost and reliability advantages since an existing commercialintegrated-circuit foundry process is used rather than a customMEMS process. Using a CMOS process also allows seamlessintegration of front-end readout circuits immediately adjacentto the CMUT devices on the same chip. This approach makesfeasible large-scale fully populated 2-D ultrasound arrays, sinceon-chip multiplexers and low-noise amplifiers help overcomethe practical challenges of carrying and conditioning outputsignals from thousands of transducer elements.

This paper presents modeling and characterization workthat supports the development of CMOS-fabricated CMUTelements for large-scale planar ultrasound arrays. The exper-imental operation of transducer elements and sparse arraysis also presented, demonstrating that CMOS layers can besuccessfully used to produce high-performance CMUT trans-ducers. This lays the groundwork for the production of denselypacked CMUT-in-CMOS systems in the future. Because ele-ment mechanics and readout electronics are tightly integratedin these arrays, the modeling efforts have been tailored tosupport a system-level design approach. After introducing thedesign and fabrication process for the elements, the hybridfinite-element/lumped-element modeling scheme is presented.This scheme is employed to predict the behavior of variouselement designs. Laser Doppler velocimetry (LDV), alongwith water-tank measurements, is used to evaluate the elementperformance, and these results are compared to the modelingpredictions.

II. DESIGN AND FABRICATION

A. CMUT-in-CMOS Integration Approach

A CMUT device consists of a diaphragm backed with a vac-uum cavity and supported by a rigid substrate. Upper and lowerconductive electrodes are incorporated into the diaphragm andthe substrate, providing the means to electrostatically drivethe diaphragm and measure its deflection in response to im-pinging acoustic pressure. CMUT elements are most typicallyfabricated using a surface-micromachined fabrication processto create a dielectric or polysilicon membrane by removingan underlying region of sacrificial material [6], [8], [10], [12],[23]. More recently, wafer-bonding processes have been usedto create CMUTs with single-crystal silicon membranes [23],[24], including, in recent years, the demonstration of a methodof trench isolation that reduces acoustic coupling betweenelements [25], [26].

To realize the distinct benefits of integrating CMUTs withCMOS circuits, several integration approaches have been used.One method uses flip-chip bonding to attach a readout circuitchip to a CMUT array. Through-wafer vias [27] or trench-

Fig. 1. (Top) Top view of CMUT side by side with CMOS circuits.(Bottom) Cross-sectional view.

isolated through-wafer interconnects [25], [26] are used to carrysignals from the device side of the wafer to bonding pads on theback side of the wafer. For reduced complexity, another methoduses low-temperature deposition and patterning techniques tocreate CMUT devices on top of CMOS readout circuits [28],[29]. A third approach, with some similarities to the processpresented here, creates CMUT structures using the layers ofthe CMOS fabrication process itself, with minor MEMS-relatedalterations to the standard integrated-circuit process flow [7].

The devices presented in this paper are realized using an ap-proach designated as CMUT-in-CMOS. The CMUT-in-CMOSprocess creates the transducer structures using electronic deviceand interconnect layers which are integral to the CMOS fabrica-tion process. Unlike previous efforts toward integrating CMUTswith electronics, this process adds no MEMS-related steps tothe CMOS process and requires no critical lithography stepsafter the CMOS process is complete. Fig. 1 shows a top viewand a cross-sectional illustration indicating the shared CMOSand CMUT layers.

B. Fabrication Process

The CMUT-in-CMOS process begins with a standardfoundry CMOS fabrication run, which creates the primarystructural layers for the CMUT as well as CMOS transistorson the same chip. For the devices presented here, a 1.5-μm n-well CMOS process with two metal and two polysilicon layerswas used (ABN mixed-mode CMOS from On Semiconductor,Phoenix, AZ; accessed through the MOSIS Service, Marina DelRay, CA). As shown in Figs. 1 and 2, the CMUT devices areformed by defining sacrificial layers, electrodes, and passiva-tion layers within the interconnect metallization and dielectricpassivation layers of the CMOS process. In this case, the upperCMOS metallization layer (M2) was used for the top CMUT

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106 JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, VOL. 20, NO. 1, FEBRUARY 2011

Fig. 2. Illustration of CMUT-in-CMOS fabrication process flow. (a) Silicon die with layers patterned in CMOS foundry process. (b) Photoresist is manuallyapplied (or screen printed) around perimeter to protect bonding pads. (c) CMUT gap is formed by sacrificial wet etching of lower metal layer. (d) Photoresist isstripped; chip is soaked in acetone/methanol and allowed to air dry. (e) Dielectric is deposited to seal the CMUT cavity, and bonding pads are shadow masked toprevent coverage. (f) Completed device is ready for packaging.

TABLE IMATERIAL PROPERTIES AND LAYER THICKNESSES USED IN THE COMPUTATIONAL MODEL

electrode, the lower metal layer (M1) formed the sacrificiallayer for the gap, and a polysilicon layer (poly 1) was patternedfor the bottom electrode. The silicon dioxide layers over poly 1and between M1 and M2 provided isolation between the elec-trodes, and the CMUT membrane was formed by the intermetaldielectric combined with the overglass layer. Typical propertiesfor these layers are given in Table I [32]–[36].

The geometry of the CMUT structure requires violation ofseveral noncritical design rules. Most notably, the overglassopenings in the etch-port regions around the CMUT perimeterare smaller than what is recommended. Typical integrated-circuit designs would have overglass openings larger than50 μm × 50 μm, since these are used primarily for electricalaccess to the bonding pads around the chip perimeter and,occasionally, for probe points within its central region. Forthe CMUT etch ports, 10 μm × 10 μm openings were usedto avoid consuming an excessive area. Also, typical CMUTdesigns require curved geometry on the metal and polysiliconlayers. These design rule exceptions do not compromise theintegrity of the CMOS process, and CMUT chips have beensuccessfully fabricated on shared multiproject wafers without anegative impact.

After the completion of the foundry CMOS process, severalstraightforward release and sealing steps are performed at thedie level. This fabrication sequence is shown in Fig. 2. First,

a protective photoresist layer is applied to the bonding padsaround the perimeter of the chip. This resist can be manuallyapplied or screen printed. Dimensions and alignment to theunderlying features are noncritical, so photolithography is notrequired. The chip is then immersed in an aggressive aluminumetch solution such as Transene Aluminum Etchant Type A at70 ◦C to remove the sacrificial material defining the CMUTgaps. Rinsing is performed in deionized water, acetone, andmethanol, and the chip is allowed to dry at room temperatureor in a 100 ◦C oven. Since the device gap is relatively large(0.6 μm), problems with stiction between the membrane and thesubstrate do not occur. The final fabrication step is the vacuumdeposition of the sealing material, typically plasma-enhancedchemical vapor deposition (PECVD) dielectrics and/orParylene C. This step seals the CMUT cavities by blockingthe etch ports and provides surface protection for the chip.For PECVD, shadow masking is used to prevent the perimeterbonding pads from being covered with the dielectric. ForParylene-C coating, the chip can be mounted and wire bondedprior to sealing, so that Parylene can be blanket deposited overthe entire device without masking.

Several criteria are used to select the appropriate sealingmaterial and deposition procedure. The deposition temperaturemust be below 450 ◦C to avoid damaging the CMOS layers.Mechanical properties such as Young’s modulus and residual

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DOODY et al.: MODELING AND CHARACTERIZATION OF CMOS-FABRICATED CMUTS 107

Fig. 3. (Lower) FIB image of CMUT-in-CMOS device cross section. TheCMUT gap and lower polysilicon electrode are visible at the left, and the gatesand source/drain contacts for the CMOS transistors can be seen at the right.(Upper) Top view of CMUT and on-chip circuits, showing region where FIBcut was made. Cut is approximately 100 µm long.

stress impact the rigidity of the membrane as well as its initialdeflection. The sticking coefficient of the material should alsobe considered, since this determines the thickness needed toclose off the etch-port openings and impacts how much de-position will occur within the gap. Parylene C is an attractivesealing material, due to its very low Young’s modulus androom-temperature deposition, and it has been used with somesuccess. However, because it has a very low sticking coefficient,Parylene is deposited within the gap, and experiments haverevealed deleterious parasitic charging effects which interferewith dc biasing the CMUT during receive operation. Therefore,additional experiments were performed with PECVD silicondioxide, silicon nitride, and silicon oxynitride, deposited at380 ◦C–400 ◦C. Favorable results without substantial chargingeffects were obtained with these PECVD materials. The resultsgiven in this paper use 3 μm of PECVD oxynitride, whichhas been tuned to provide lower residual stress compared toPECVD nitride or oxide [36].

The CMUT-in-CMOS approach has been successfullydemonstrated, both for the devices presented here and forlarger imaging arrays with on-chip receive circuitry [37]. Fig. 3shows a focused ion beam (FIB) image of a released andsealed device, together with a cross-sectional view showingCMUT features (gap and lower electrode) alongside CMOScircuit components (polysilicon gates and metal source/draincontacts). The fabrication process provides advantages in termsof simplicity, cost, yield, and repeatability. All of the criticallithography steps and thin-film deposition steps for the CMUTstructures occur during the CMOS foundry process, which isa tightly controlled high-volume manufacturing process thatbenefits from the semiconductor industry’s huge investment ininfrastructure and engineering for integrated-circuit production.The steps after the foundry CMOS process are straightforwardand low cost (wet etching without critical timing and blanketdeposition of low-temperature dielectrics, which can occur inrelatively affordable PECVD and Parylene C deposition cham-bers). As compared to other CMUT fabrication approaches,

the CMUT-in-CMOS process is likely to produce higher yieldchips at a lower cost, since few custom low-volume processsteps are needed. It should be noted, however, that the funda-mental sensitivity of the CMUT-in-CMOS transducer structuresthemselves may be limited compared to custom approaches,since the layer thicknesses (notably the sacrificial layer and thediaphragm thickness) are predetermined by the CMOS processselected. On the other hand, because CMOS circuitry can beintegrated so tightly with the CMUTs at no additional cost orfabrication effort, there is room for significant circuit-basedsignal-to-noise improvements (e.g., low-noise amplifiers, time-gain control circuits, and, perhaps, analog-to-digital converterscan be included on a chip, minimizing parasitics and system-level noise contributions). The modeling work presented inthis paper contributes to ongoing efforts to evaluate the overallbenefits and limitations of the CMUT-in-CMOS approach, pro-viding an important computational tool to explore transducer/circuit/system design and performance tradeoffs.

C. Device Design

The CMUT-in-CMOS integration approach requires the de-sign of the CMUT structure to be constrained to the layersavailable within the integrated-circuit manufacturing process.The CMUT membrane diameter and thickness are designedto achieve a desired resonant frequency, which is targeted tomeet the demands of a particular imaging application (e.g.,higher frequencies yield better lateral and axial resolution,while lower frequencies allow greater penetration depth). TheCMUTs presented here are designed for the 1–5-MHz rangetypically used for abdominal ultrasound imaging.

The center frequency of a circular membrane scales with boththe thickness and diameter of the membrane. Since the lateraldimensions of the CMUT are defined photolithographically,a range of diameters is achievable. The membrane thicknessis constrained by the layer thicknesses available within thefabrication technology. Thinner membranes provide increasedmechanical sensitivity due to the increased volume compliance,resulting in larger capacitance changes for a given appliedpressure. Thicker membranes decrease the volume compli-ance, allowing higher applied bias voltages prior to pull-in orcollapse.

The layer combinations available within the chosen CMOSprocess dictate that the CMUT membrane will be at least2.0 μm thick, with a more typical thickness of 3.0–7.0 μm,depending on the thickness of the post-CMOS sealing layer.To obtain a center frequency between 1.0 and 5.0 MHz forabdominal imaging, with a structure constructed mainly ofsilicon dioxide and aluminum and mass loaded by a waterlikefluid environment, a CMUT diameter of 100 μm was chosen.Devices with diameters between 30 and 100 μm were designedfor evaluation of the frequency response. Models that may beused to make these design choices are described in detail laterin this paper.

Fig. 4 shows a photograph of a 100-μm-diameter CMUTprior to release etching. As shown, the device is designed withetch ports offset from the central membrane region. This designfeature encourages etch-port sealing with minimal deposition of

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108 JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, VOL. 20, NO. 1, FEBRUARY 2011

Fig. 4. Photograph of a 100-µm-diameter CMUT showing etch ports offsetfrom device membrane.

the sealing material within the gap. Design variations with etchports within the membrane region have also been evaluated.

III. MATHEMATICAL MODELING

A. Lumped-Element Modeling

Lumped-element acoustic models were used in order tocreate a dynamic computational model of the transducers.Two coupled electrical-mechanical acoustic models of a singleCMUT element are shown in Fig. 5. The left-hand model repre-sents the element in “transmit” mode. In “transmit” mode, thedriving RF voltage Vac is applied to the element’s diaphragm.The output of the model is the diaphragm’s volume velocityUdia. The right-hand model represents the element in “receive”mode. In receive mode, an external acoustic pressure Pin isapplied to the diaphragm face. The result is a volume velocitywhich is converted to a current by the ideal transformer, feedingfrom there to the receive electronics.

The lumped-element acoustic model incorporates environ-mental loading, diaphragm mass, diaphragm acoustic com-pliance, the negative electrostatic spring, and backing cavitycompliance. Some of these elements were calculated analyt-ically using standard expressions [30], [31]. Other elementswere determined numerically using finite-element methods asdescribed hereinafter.

Environmental mass loading Zenv was computed using aformulation similar to the four components for a rigid baf-fled piston radiating into an infinite half-space suggested byBeranek [30]

Zenv = [MA1s(RA1 +RA2 +RA1RA2CA1s)]· [CA1MA1RA1s

2 + (MA1 + CA1RA1RA2)s+RA1 +RA2]

−1 (1)RA1 = 0.243ρc/(πa2) (2)RA2 = ρc/(πa2) (3)MA1 = 0.643ρ/(πa) (4)CA1 = 5.52(πa3)/(ρc2) (5)

where ρ and c are the density for the environment and the speedof sound, respectively, and s is the Laplace transform variable.In the CMUT, the diaphragm moves as a bending structure,

not as a rigid piston. Therefore, the expressions previously pre-sented have the same scaling with the characteristic impedanceof the medium (ρc), and the diaphragm radius, as Beranek’sresult, but the coefficients in front of each term are modified.The coefficients were determined by computing, using FEA,the acoustic field transmitted into an infinite acoustic half-spaceby an axisymmetric baffled structure oscillating in a simplysupported static bending modeshape

ψ(r) = 1 − 23 + υ

5 + υ

( ra

)2

+1 + υ

5 + υ

( ra

)4

. (6)

The simply supported static bending modeshape is selectedbased on electrostatic finite-element models, shown later inthis paper, which show this shape to be a good match to theelectrostatically excited shape of the transducer deflection. Avalue of 0.2 is used for ν, as the bending structure is predom-inantly silicon dioxide and PECVD oxynitride. The acousticimpedance Zenv is the ratio of the volume velocity of thetransducer to the effective pressure at the surface. In orderto conserve transmitted power, the effective pressure is thesurface integral of the surface velocity times the local pressure,normalized by the total volume velocity

Peff =1Udia

∫A

uPdA. (7)

A series of computations was run at various frequencies.A convergence study was conducted to ensure convergenceof the computation. The coefficient for MA1 determines thelow-frequency imaginary asymptote. The coefficient for RA2

determines the high-frequency real asymptote. RA1 is thendetermined in combination with RA2 and MA1 to match thelow-frequency real asymptote. Finally, the coefficient for CA1,which has an impact only in the transition region at high ka,was determined in order to minimize the mean square errorbetween the FEA and analytical computations over the rangeof frequencies between ka = 0.1 and ka = 3.0. A comparisonbetween the finite-element result and the analytical approxima-tion previously given is shown in Fig. 6. The approximation isgood for ka < 2.

The final pure acoustic element in the model comes from thesmall cavity behind the membrane. The cavity is filled with theresidual rarefied gas that is left during the low-pressure sealingand passivation process (PECVD or Parylene coating). Thiscavity acts as a small mechanical spring as it is compressedby the motion of the diaphragm. For CMUTs with a relativelylow vacuum within the backing cavity, this gas may not con-tribute much stiffness but may be easily included. The cavitycompliance can be calculated by [31]

Ccav = Vcav/(ρcavc2) (8)

where Vcav is the volume of the cavity, c is the speed of soundin the cavity (for air, this is not strongly affected by pressure),and ρcav is the density of the rarefied air in the cavity, whichmay be approximated by the ideal gas law

ρcav = ρ0Pcav

P0(9)

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DOODY et al.: MODELING AND CHARACTERIZATION OF CMOS-FABRICATED CMUTS 109

Fig. 5. Lumped-element model of the transducer in (left) transmit mode and (right) receive mode.

Fig. 6. Comparison of finite-element and analytical approximation to theenvironmental loading presented in nondimensional form.

where the density in the cavity is the density of air at at-mospheric pressure ρ0 multiplied by the ratio of the cavitypressure to atmospheric pressure. For the devices modeled inthis paper, Pcav is 300 mT, which is the pressure during thePECVD.

B. Electromechanical Coupling

Electromechanical coupling can be computed by consid-ering the capacitor formed between the aluminum and thedoped polysilicon electrodes, along with the two interveningdielectrics and the vacuum gap (see Figs. 1 and 7). In order forenergy to be conserved in the coupling, the acoustic power flow-ing into one port of the transformer must equal the electricalpower flowing out of the second port. By carefully consideringthis conservation, we can determine the electromechanical cou-pling, including incomplete electrode coverage and a variableheight vacuum gap. Consider first the height of the vacuumgap, which, for this axisymmetric design, is a function of radialposition

g1 = d1 − xΨ(r) (10)

where d1 is the undeflected height of the vacuum gap, Ψ(r) isthe radial shape of the static deflection, and x is the magnitudeof the static deflection. Note that, at this point, Ψ(r) is anunknown function, and x is an unknown magnitude that will

depend on the applied dc bias. Consider now an incrementaldeflection from this equilibrium position described by an in-finitesimal change in x, which is δx. During this deflection,we consider the voltage and electrostatic pressure to be heldconstant. The incremental change in the energy stored in thecapacitor must equal the acoustic energy delivered

δEacoustic =PelectδQ

δEelect =12V 2δC (11)

where C is the capacitance between the electrodes, V is theapplied voltage, Pelect is the resulting electrostatic pressure,and δQ is the volume displacement. We now make use ofthe equivalent capacitance for the series capacitance acrossmultiple dielectric layers

C =∫A1

(d1 − xΨ(r)

ε1+d2

ε2+d3

ε3

)−1

dA (12)

where ε1 is the dielectric constant for the vacuum gap, d2,d3, ε2, and ε3 are the thicknesses and dielectric constants forthe other dielectric layers, and the integral is over the area ofthe smaller electrode. The incremental change in capacitanceis then

δC =∂C

∂xδx

=∫A1

−(d1 − xΨ(r)

ε1+d2

ε2+d3

ε3

)−2 (−Ψ(r)ε1

)dA.

(13)

The increment in volume displacement used in (11) comesdirectly from the area integral of displacement

δQ =∫A2

δxΨ(r)dA (14)

where, here, the integral is over the entire deflecting diaphragmarea A2. If the two energy increments from (11) are equated,

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110 JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, VOL. 20, NO. 1, FEBRUARY 2011

Fig. 7. Axisymmetric cross section of the transducer.

we can solve for the equivalent electrostatic pressure

Pelect =1

2ε1V 2 ·

∫A1

Ψ(r)(

d1−xΨ(r)ε1

+ d2ε2

+ d3ε3

)−2

dA∫A2

Ψ(r)dA.

(15)

In the case of a dc bias summed with a pure tone ac voltage

V =Vbias + Vac cos(ωt)

V 2 =V 2bias +

12V 2

ac . . .

+ 2VacVbias cos(ωt) +12V 2

ac cos(2ωt). (16)

If we are concerned only with the linear response (theresponse at the drive frequency ω), then the linear couplingconstant for the ideal transformer is

N =Pelect

Vac

=(Vbias

ε1

)·∫

A1Ψ(r)

(d1−xΨ(r)

ε1+ d2

ε2+ d3

ε3

)−2

dA∫A2

Ψ(r)dA. (17)

Note that N has units of Pa/V or, equivalently, A/(m/s) (inSI units). It is a bidirectional coupling constant for the idealtransformer. d1 − xΨ(r) is the vacuum gap computed with thedc bias applied. For a dc bias well below the pull-in voltage,xΨ(r) is much smaller than d1, and we can approximate N as

N ≈(Vbias

ε1

)·(d1

ε1+d2

ε2+d3

ε3

)−2∫

A1Ψ(r)dA∫

A2Ψ(r)dA

. (18)

Note that, for incomplete electrode coverage, the ratio ofthe area integrals of the static deflection modeshapes in (18)must still be computed even for low dc biases. For larger biasvoltages, xΨ(r) cannot be neglected with respect to d1 andmust be determined by a static structural analysis, as describedhereinafter in the discussion of finite-element computations.

The electrostatic spring compliance Celect can also be de-termined from a similar analysis. Returning to (15), the lin-ear electrostatic spring compliance comes from the change in

electrostatic pressure δP due to a small change in volumedisplacement δQ with only a dc bias applied

Celect = −(∂Pelect

∂Q

)−1

= −(∂Pelect

∂x

∂x

∂Q

)−1

=( −ε21V 2

bias

(∫A2

Ψ(r)dA)2

∫A1

Ψ2(r)(

d1−xΨ(r)ε1

+ d2ε2

+ d3ε3

)−3

dA.

(19)

It is important to note that Celect should have a negativevalue. Once again, we need to determine Ψ(r) and x beforeCelect can be computed. At bias voltages well below the pull-involtage of the transducer, the change in the vacuum gap can beneglected, and we can approximate Celect as

Celect ≈( −ε21V 2

bias

) (d1

ε1+d2

ε2+d3

ε3

)3

(∫A2

Ψ(r)dA)2

∫A1

Ψ2(r)dA.

(20)

C. Pure AC Drive

Although all of the results presented in this paper use adc bias plus pure tone ac to drive the CMUT, a brief noteregarding the pure ac drive is needed. Returning to the voltageexpression shown in (16), if the dc bias is zero, there are noterms remaining at ω. Thus, with the pure ac drive, we expectinstead to see a mechanical response primarily at twice the drivefrequency 2ω. The model as presented can be used for this casewith a few simple modifications. Referring to (16), we see that,in (17)–(20), Vbias should be replaced with Vac/4. Finally, whencomputing xΨ(r) using static FEA, the static driving voltage isV 2

ac/2 rather than V 2bias. The model in Fig. 5 can now be applied,

with the driving voltage of magnitude Vac at a frequency of2ω. The results on the acoustic side (volume velocities andpressures) will correctly capture the response.

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DOODY et al.: MODELING AND CHARACTERIZATION OF CMOS-FABRICATED CMUTS 111

D. FEA

Due to the complex cross-sectional geometry of the trans-ducer designs, FEA was used to determine the diaphragmcomplianceCdia, effective diaphragm massMdia, and the staticdeflection in response to the applied dc bias xΨ(r), which, inturn, affects the electromechanical coupling coefficient N andthe electrostatic spring Celect as previously described.

COMSOL Multiphysics was used to model the complexgeometry of each transducer as an axisymmetric cross section.Linear elastic materials were used. Triangular Lagrange ele-ments with quadratic-shaped functions were employed to meshthe structure. A convergence study was conducted to ensure thatthe solution was fully converged. Six thousand two hundredelements were sufficient for convergence to better than 0.5%.The element mesh was dense within the thin bending layersand coarse in the region of the bulk silicon far from the activeportions of the model. Within the thin layers, the element size ison the order of 0.5 μm, with at least two elements through thethickness of each layer. The element size becomes coarser grad-ually through the silicon base toward the bottom of the model,reaching a maximum element size of approximately 5 μm.

A layout of the transducer’s cross section, along with theboundary conditions used in the simulation, is shown in Fig. 7.The transducer is composed of a bulk silicon base, severalthin-film dielectric and metal layers, and a passivation layer.There is an “air gap” (filled with rarefied gas) in between themoving diaphragm and the base layers. In the FEA model, thisis treated as a vacuum gap for the purposes of the computation.Two conductive layers (aluminum and doped polysilicon) formthe variable parallel-plate capacitor for electrical-mechanicalcoupling.

The thicknesses for each of the layers in the CMOS processare taken from the careful work of Marshall and Vernier [32].The elastic modulus and density for each of the CMOS layersare taken from the work of Marshall et al. [33]. The Poissonratio of the layers is taken from textbook values for the variousmaterials [34]. The PECVD oxynitride sealing layer is the layerfor which we have the least characterization data. Here, wetake the density and Poisson ratio from textbooks [34], [35]and the elastic modulus from the average values determined byThurn et al. in their study of the unannealed mechanicalproperties of PECVD oxynitride films [36]. The values aresummarized in Table I. It should be noted that the modulus ofthe PECVD films can vary widely; this is expected to be thesingle most variable parameter in the process. Variations in thismodulus will change the value of the diaphragm complianceCdia, resulting mainly in shifts of the resonant frequency.Cdia, representing the in vacuo diaphragm acoustic compli-

ance, was calculated by applying a unit uniform pressure loadto the top surface and computing the resulting static deflection.The acoustic compliance is the surface integral of the displace-ment divided by the magnitude of the applied pressure.

An in vacuo eigenfrequency analysis was then performed onthe same model in order to determine the diaphragm effectivemass Mdia according to

1√Mdia · Cdia

= f1 · 2π (21)

TABLE IIRESULTS OF THE FINITE-ELEMENT COMPUTATION FOR A 100- AND AN

80-µm-DIAMETER CMUT

where f1 is the first eigenfrequency in hertz determinedfrom FEA.

For comparison to laser vibrometry (LDV) measurements, itis convenient to know the relationship between the centerpointdisplacement (which is measured) and the volume velocity(which we compute). We therefore also extract from FEAthe ratio of the static centerpoint displacement to the staticvolume displacement uctr. From this, we can easily computecenterpoint displacement u from volume velocity Udia

u =uctrUdia

jω. (22)

The results of the FEA computations are shown in Table II.Finally, we need to determine the modeshape and static de-flection due to the applied dc bias xΨ(r) in order to computethe two electromechanical coupling parameters previously de-scribed. An iterative analysis is performed, where the pressureapplied to the top electrode is a function of position anddeflection

P (r) =1

2ε1V 2

bias ·(d1 − x(r)

ε1+d2

ε2+d3

ε3

)−2

. (23)

The deflection x(r) is a result of the linear static analysis,requiring an iterative procedure to be applied in COMSOL tofind the converged solution. Once the solution converges for agiven Vbias, x(r) = xΨ(r) is known, and we can numericallycompute the area integrals in (17) and (19).

Alternatively, the computation can be conducted analyticallyassuming that Ψ(r) is the axisymmetric static bending mode-shape given before in (6). An iterative procedure is then used tocompute x. The volume displacement is determined by apply-ing the effective electrostatic pressure to a series combinationof the static diaphragm compliance Cdia and the electrostaticspring Celect. The deflection amplitude x is the volume dis-placement divided by the area integral of the modeshape

x =1∫

A1ψ(r)dA

(1

Cdia+

1Celect

)−1 (NVbias

2+ Patm

).

(24)

The computation begins assuming that x is zero and theniterates on the computation until x converges. The results ob-tained by this iterative analytical procedure are very similar tothe results obtained by FEA, as shown in Figs. 8 and 9. It is forthis reason that we use the simply supported modeshape. Sincethe iterative analytical computation is less computationallyexpensive than the FEA run, we prefer this method and use theanalytical method with the modeshape shown in (6) to producethe results shown in the rest of this paper.

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Fig. 8. Comparison of FEA and analytical results for the coupling constant Nas a function of applied bias voltage.

Fig. 9. Comparison of FEA and analytical results for the electrostatic springmagnitude −Celect as a function of applied bias voltage.

With these parameters in hand, the dynamic model shown inFig. 5 can be applied to compute the membrane volume velocityor the centerpoint displacement in response to a given dc biasplus RF drive. A sample frequency response plot is shown inFig. 10 for a 100-μm-diameter CMUT in transmit mode. In air,the primary resonance for this particular device is predicted tobe 4.6 MHz, with a very narrow fractional bandwidth of 0.06%.In a water environment, the model predicts a 3.0-MHz centerfrequency, with a fractional bandwidth of 22% for the samedevice. The computed fractional bandwidths are based on thevolume velocity, as this is the most relevant parameter to sourcestrength.

E. Array Computations

In the results shown hereinafter, both single elements and ar-rays of elements are discussed. For array testing, the transmittedpressure response is measured on axis. In order to compare theresults with model predictions, a simple model of array transmitresponse is required.

Fig. 10. Modeled transmit frequency response for a single element in air andwater environments.

At low frequencies (ka� 1), we can treat the element as abaffled simple source, and assuming that we are in the far fieldand there are no reflections

Pm =jρf

Rme−jkRmUm (25)

where ρ is the density of the environment, f is the frequencyof the drive in hertz, Rm is the distance from the mth to thefield point, and k is the wavenumber in the environment. Aswith all previous quantities, the pressure is harmonic at the drivefrequency, and we are considering steady-state pressures only.At the frequency of operation (3 MHz in water), for these sizeelements (50-μm radius), directivity from the finite size of theelement results in at most 3% deviation from omnidirectionalradiation. This expectation is based on standard baffled pistondirectionality expressions as supported by finite-element cal-culations for a simply supported oscillation shape. In addition,water-tank measurements are taken at distances of more than100 diameters, placing the field point well into the far field.Thus, the monopole radiation assumption is justified. The fullfar-field pressure can be computed by summing the monopolefields from each element

P (x, y, z) = jρf ·N∑

m=1

1Rm

· Ume−jkRm . (26)

In this computation, coupling between the elements in thearray is neglected. This coupling can come from multiplesources, including acoustic coupling through the environment,structural vibrations in the substrate, and electrical couplingbetween elements. Acoustic coupling in the environment can beincluded in the calculation and does have an impact on the com-puted pressure field. However, the uncoupled model presentedhere matches the experimental results more closely in terms ofbandwidth and absolute pressure than a model that includesfull acoustic coupling between the elements, suggesting thatacoustic coupling is not the dominant coupling mechanism. Theother sources of coupling (structural and electrical) are not well

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DOODY et al.: MODELING AND CHARACTERIZATION OF CMOS-FABRICATED CMUTS 113

known for this design and, hence, could only be included in anad hoc fashion, which will not be done.

IV. EXPERIMENTAL RESULTS

A. Laser Vibrometry Results

LDV was used to characterize individual element vibration.This was accomplished using a Polytec fiber-optic single-pointvibrometer type OFV-551, with an OFV 3001 controller in-corporating the OVD-30 high-frequency displacement decoder(Polytec GmbH, Waldbronn, Germany). The decoder has a50-kHz–20-MHz bandwidth and has been calibrated by Polytecwithin the last two years. An Agilent 33220A signal generatoris used to provide the excitation voltages (Agilent, Santa Clara,CA). A National Instruments high-speed digitizer board typePCI-5124 with a 200-MHz sample rate and 12 b of accuracywas used to capture data in the Labview programming envi-ronment (National Instruments, Austin, TX). Frequency sweeptests were performed on CMUT elements of two differentdiameters (80 and 100 μm) in three environments (vacuum, air,and oil), with a varying dc bias. The data were analyzed usingFourier techniques in software to extract the peak responseat the drive frequency and determine the relative phase andmagnitude as compared to the excitation signal.

The peak displacement results are reported normalized to theproduct of the dc bias and the peak ac voltage (in nm/V2).Velocity can be computed from displacement simply by mul-tiplying by jω. Fractional bandwidths and peak frequenciesare always computed based on velocity, not displacement,as velocity is the most relevant quantity to transmitted pres-sure. The test results show a peak frequency between 3 and7.6 MHz, depending on the experimental case in question, witha low-frequency gain on the order of 10−3 to 10−2 nm/V2.The fractional bandwidth varies from 0.3% to 23% for singleelements, depending mainly on the environment.

The centerpoint displacement calculated from the modelwas compared to the frequency sweep data obtained fromthe CMUT elements. A frequency plot comparison for a100-μm-diameter element tested in air with a 9-Vdc bias and2-Vpp ac drive is shown in Fig. 11. The computational modelpredicted a peak frequency of 4.6 MHz, which is similar tothe 5.1-MHz resonant frequency measured experimentally. Theslightly higher resonant frequency seen experimentally could bedue to material property variations, particularly in the PECVDoxynitride sealing layer, or slightly tensile residual stresses.The measured fractional bandwidth is 0.6%, which is somewhatwider than the predicted 0.06%, suggesting that some unmod-eled damping mechanisms are present. Adding as little as 0.5%material damping to the computational model will bring thein-air bandwidth into agreement with the measured result. Themodel and experimental results agree very well as to the low-frequency amplitude, suggesting that the electrostatic couplingfor this case is well captured.

Comparisons between frequency sweeps with different dcbiases were also performed on the same 100-μm-diameterelement in air. The experimental and computational results for40- and 80-Vdc biases are shown in Figs. 12 and 13. As the dc

Fig. 11. Frequency response comparison between a computational result andexperimental data.

Fig. 12. Experimental frequency response comparison for different dc biases.

bias increases, the resonant frequency decreases slightly, andthe peak displacement increases. The reduction in the resonantfrequency is due to the increase in the magnitude of the negativeelectrostatic spring Celect with bias. The increase in magnitudeis due to an increase in the coupling constant N which is dueto a decrease in the effective gap height d1. While the modeldoes show both effects, the change in both the peak frequencyand the magnitude of the response is greater in the experimentalcase.

The effect of transducer diameter on the resonant frequencywas also tested. A frequency sweep, shown in Fig. 14 for twodifferent biases, was performed on an 80-μm-diameter CMUT.The 80-μm device was from the same chip as the 100-μmdevice previously shown; thus, all layer thicknesses and ma-terials remained the same. The 80-μm-diameter element showsa higher primary resonance occurring at 7.6 MHz, as well as asmaller fractional bandwidth of 0.24%. This is consistent withthe model results, which predict a 6.91-MHz center frequencyand 0.04% fractional bandwidth. As with the larger CMUT, themodel is predicting a slightly lower resonant frequency thanwhat is measured and a narrower fractional bandwidth. Once

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114 JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, VOL. 20, NO. 1, FEBRUARY 2011

Fig. 13. Computational frequency response comparison for different dcbiases.

Fig. 14. Experimental frequency response for an 80-µm-diameter element fordifferent dc biases.

again, this indicates that the PECVD oxynitride modulus maybe somewhat higher than what is expected, or some tensilestresses may be present. Again, unmodeled material dampingappears to be present.

Frequency sweeps of the transducer were also performed invacuum. A vacuum chamber was built for testing the transducerat 1.08 torr while maintaining optical access to the diaphragm.A plot comparing the response at atmospheric and low pressureis shown in Fig. 15. In vacuum, the transducer shows an identi-cal result to air, with a peak frequency of 5.8 MHz and a frac-tional bandwidth of 0.6%. This suggests that the environmentis not providing significant damping or mass loading to thedevice in either air or vacuum; the dynamics are dominated bythe structure itself. This is consistent with the modeling results,which show no change in the resonant frequency when movingto a vacuum environment. The modeled fractional bandwidthdecreases slightly in vacuum, as losses to the environment arethe only damping mechanism in the model. If material dampingwas included at 0.5% as suggested earlier, the material dampingwould dominate, and the model would show no change in the

Fig. 15. Frequency response comparison for air versus vacuum.

Fig. 16. Transient impulse response of a single 100-µm-diameter element inoil (LDV measurement).

fractional bandwidth when moving from air to vacuum, whichis consistent with the experimental results.

Finally, the transducer was tested in an oil environment. Adrop of 200-cSt silicone oil with a density of 1000 kg/m3 wasapplied to the CMUT surface for this test. The speed of soundin silicone oil, which is 1500 m/s, is similar to that in water, butoil is nonconductive, reducing the possibility of short circuitswithin the test fixture. Both water and oil have similar acousticproperties to tissue and can therefore be used for testing. In oil,the signal-to-noise ratio is lower compared to that in air, and thepeak is much suppressed due to damping. We therefore found itmore effective to measure a transient impulse response, ratherthan an ac frequency sweep, to determine the peak frequencyand bandwidth.

A 100-ns-wide 10-V pulse was delivered to the transducer,with an 80-Vdc bias applied. The resulting centerpoint dis-placement was recorded using LDV. The tests were conductedon the same 100-μm-diameter single element that was testedpreviously. The result is shown in Fig. 16. By selecting peaksfrom the impulse response, the damped natural frequency wasdetermined to be 3.0 ± 0.12 MHz (N = 3). Using the logdecrement method, the fractional bandwidth is approximately

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DOODY et al.: MODELING AND CHARACTERIZATION OF CMOS-FABRICATED CMUTS 115

Fig. 17. Two-dimensional laser vibrometry scan of a 100-µm element operat-ing in air while driven with a 9-Vdc bias and a 2-Vppk ac drive at 5 MHz. Thecross sections along the two diagonals are shown in Fig. 18.

Fig. 18. Measurements of the vibration modeshape of a 100-µm transduceralong two different radial cross sections. The location of the two sections isshown in Fig. 17.

23% ± 4% (N = 3). This is remarkably close to the predictedwater-loaded response of the transducer at 2.99 MHz and 21%fractional bandwidth. We expect the model to be a betterpredictor of bandwidth in water compared to air because theunknown material damping parameters have less influence inthe water-loaded case.

Single-point laser vibrometry data have been presented sofar in this paper. In all cases, the point of maximum velocityon the surface of the CMUT was measured. Since the trans-mitted pressure and receive sensitivity for the elements areboth directly related to the volume velocity, rather than thesingle-point velocity, it is important to verify that the ratiobetween the volume velocity of the transducer and the single-point velocity of the transducer is close to the FEA predictedvalue of 3.08 108 m/m3. In order to verify this, a 2-D scan ofthe 100-μm-diameter element was taken in air while drivingthe element at its resonant frequency of 5 MHz. The magnitudeof the observed displacement is shown in Fig. 17. The maxi-

Fig. 19. Configuration of CMUT elements for array testing.

Fig. 20. Computational and experimental results for the on-axis frequencyresponse measured in water at 15 mm from the transducer face with 100-Vdc

bias plus 100-Vpeak−to−peak ac drive. Data for a single element and threearray configurations are shown. See Fig. 19 for the array layout.

mum displacement magnitude for this drive case is 70.1 nm.The total volume displacement was computed by numericallyintegrating the 2-D scan using a trapezoidal integration ruleover the 40 point by 40 point scan and results in a totalvolume displacement for this drive case of 2.29 × 10−16 m3.The ratio is 3.06 108 m/m3, which is remarkably close tothe FEA predicted value. This justifies the use of the single-point frequency response curves used throughout this paper andindicates that the fractional bandwidth and peak frequenciesextracted from these single-point measurements are similar tothose seen in the transmitted pressure field.

In addition, the 2-D scan of the surface vibration allowsexperimental comparison with the simply supported staticdeflection shape which was used in some of the analyticalcalculations as justified by the aforementioned FEA results.Although the surface vibration pattern is more complicated thanthe axisymmetric model, the simply supported shape, shown inFig. 18, is comparable to the shape observed experimentally.Thus, it appears to be a reasonable choice for limiting the

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116 JOURNAL OF MICROELECTROMECHANICAL SYSTEMS, VOL. 20, NO. 1, FEBRUARY 2011

TABLE IIIMODEL PREDICTIONS COMPARED TO EXPERIMENTAL RESULTS

complexity of the computations while preserving a realisticmodel.

B. Water-Tank Testing

Water-tank testing has been carried out for arrays of100-μm-diameter elements. Data were collected using afactory-calibrated 400-μm-diameter hydrophone (Model HGL-0400, Onda Corporation, Sunnyvale, CA) suspended 15 mmin front of the surface of the transmitting array on the ar-ray centerline. The hydrophone connects to the oscilloscopethrough a preamplifier with a calibrated frequency response of1–20 MHz. The wire bonds and electrical connections to theCMUT array are potted in epoxy to protect them from the waterenvironment. The PECVD oxynitride passivation and sealinglayer protects the surface of the CMUT array sufficiently withno additional matching or encapsulation layers. The elementor array is biased at 100 Vdc and driven with a 100-V peak-to-peak ac burst of 15 cycles at the frequency of interest. Thefirst arrival acoustic response of the hydrophone is recorded,and the peak-to-peak transmitted pressure is extracted from thetime domain signal. The excitation frequency is swept to buildup the frequency response curve.

The CMUTs are laid out on an interleaved hexagonal gridwith edges of 250 μm, as shown in Fig. 19. The array layoutis sparse in this test setup to allow room for routing lines andcircuits. The sparse layout is expected to reduce the systembandwidth and total pressure output. Much higher array densi-ties are achievable by stacking the CMUTs on the top of theelectronic components of the system, which will be done infuture work. A single element and three array configurations,shown in the figure, have been tested in transmit mode in thewater tank. The results are shown in Fig. 20 and are summarizedalong with the other testing and modeling results in Table III.For a single element, the peak frequency is 3.3 MHz witha fractional bandwidth of 28%. The model predicts a peakfrequency of 3 MHz and a bandwidth of 22%, which is similarto the measured result, considering that no parameters of themodel have been tuned in any way.

As the size of the array increases to 7, 19, or 33 elements,the bandwidth increases to 32% and then 44%, and the peakfrequency shifts up slightly to 3.5 MHz. This effect is not

captured in the uncoupled array model, which does not predictany change in the peak frequency or bandwidth for the on-axisfrequency response as the number of elements increases. Thesource of the increase in bandwidth as the array grows in size isnot known. Unmodeled coupling is one possible cause.

The arrays produce on-axis pressures of 181 to 184 dB re1 μParms at the test location. This is identical to the pres-sure predicted by the model at this test location for Array B.However, for Array C and Array D, the measured pressure issomewhat lower than that predicted by the linear model. Thecause of this discrepancy is not known, although unmodeledcoupling between elements is suspected.

V. CONCLUSION

A CMUT-in-CMOS device has been described and demon-strated. The transducer elements are fabricated using inter-connect and dielectric layers in an n-well CMOS fabricationprocess. Unlike previous efforts toward integrating CMUTswith CMOS, this process adds no MEMS-related steps to theCMOS process and requires no critical lithography steps afterthe CMOS process is complete. Only minimal postprocessingis required.

In order to model this device, a method of combining FEAand lumped-element modeling for CMUT elements has beendescribed. An efficient computational strategy has been de-scribed, which accounts for the effects of incomplete electrodecoverage, nonlinear bias-dependent electrostatic coupling, andenvironmental loading. Only three finite-element runs are re-quired to determine all the parameters necessary for the com-putation. The results have shown that the devices respond witha spatial motion that is very similar to the axisymmetric simplysupported static bending modeshape. Advantage can be takenfrom this fact to reduce the computational burden, particu-larly in regard to computation of the electrostatic couplingparameters.

Computational predictions have been compared to the ex-perimental results obtained via laser vibrometry and water-tank testing. The modeling method is shown to be accurate,predicting the resonant frequency of the transducer designs inoil, in water, in air, and in vacuum within 10% of the experi-mental values, as well as providing predictions of the fractional

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DOODY et al.: MODELING AND CHARACTERIZATION OF CMOS-FABRICATED CMUTS 117

bandwidth that lie within experimental uncertainty for sub-merged testing of single elements. For in-air and in vacuotesting, the model slightly underpredicts the bandwidth dueto unmodeled material damping effects which are significantin these regimes. The model predictions are achieved usingpreviously published material property values with no modi-fication or tuning, thus opening a path for future computationaloptimization work of both individual elements and arrays.

Arrays of 7 to 33 CMUT-in-CMOS elements achieve a centerfrequency of 3.5 MHz and a fractional bandwidth of 32%–44%when operated in a water tank. The on-axis peak transmittedpressure for the arrays at 15 mm from the transducer face is181–184 dB re 1 μParms. This paper has focused primarilyon the design, fabrication, and modeling of single CMUT-in-CMOS elements. The arrays described in this paper weredesigned to allow routing lines and circuits to lie betweentransducer elements, resulting in a sparse fill factor. This isexpected to result in a lower fractional bandwidth and a lowertransmit pressure than those that can be achieved by denselypacked arrays. Dense arrays will be produce in the future byusing additional metallization layers in the process to fabricatethe transducers and stacking them on the top of the CMOSelectronics. This paper has laid the groundwork for the higherdensity chips by showing the feasibility of using CMOS layersto achieve transducers and developing and validating the neededmodeling tools.

ACKNOWLEDGMENT

The authors would like to thank J. Hoffman for his assistancein the Tufts machine shop, V. Miraglia of Tufts Bray Labo-ratories, M. Doire of Tufts Advanced Technology Laboratory,and L. Polidora and D. Della Pasqua of the Department ofMechanical Engineering, Tufts University.

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Christopher B. Doody (S’07–M’09) receivedthe B.S. degree in mechanical engineering fromWorcester Polytechnic Institute, Worcester, MA, in2007, and the M.S. degree in mechanical engineer-ing from Tufts University, Medford, MA, in 2009.His M.S. thesis focused on the characterization andmodeling of capacitive micromachined ultrasoundtransducers for medical ultrasound purposes throughthe use of a hybrid finite-element/lumped-elementmodeling scheme.

From 2007 to 2009, he was a Research Assistantat Tufts University. Since 2009, he has been with STD Med, Inc., Stoughton,MA, where he is currently a Mechanical Design Engineer. His research interestsinclude the design, development, and manufacturing of medical devices invarious fields.

Mr. Doody is a member of the American Society of Mechanical Engineers.

Xiaoyang Cheng (S’06–M’09) received the B.S. de-gree in mechanical engineering from Huazhong Uni-versity of Science and Technology, Wuhan, China,the M.S. degree from South China University ofTechnology, Guangzhou, China, and the Ph.D. de-gree in electrical engineering from The University ofNew Mexico, Albuquerque, in 2008. His Ph.D. dis-sertation focused on the development of minimallyinvasive microelectromechanical systems (MEMS)ultrasound transducers [capacitive micromachinedultrasound transducers (CMUTs)] for biomedical

applications.Since 2008, he has been with Sonetics Ultrasound, Inc., Ann Arbor, MI,

where he is currently a Senior Electronics Engineer working on the devel-opment of CMUT arrays for medical diagnosis. His research interests in-clude capacitive sensing, MEMS interface circuit design, and CMOS–MEMSintegration.

Collin A. Rich (S’95–M’00) received the B.S.E.E.degree from the University of Illinois, Urbana-Champaign, in 1994, and the M.S. and Ph.D. degreesin electrical engineering from the University ofMichigan, Ann Arbor, in 1997 and 2000, respec-tively. His doctoral work focused on thermopneu-matically actuated silicon microvalves for microflowcontrol using MEMS fabrication techniques.

His subsequent industrial career has focused onnew life-science products using both MEMS andnon-MEMS technologies. He was with Integrated

Sensing Systems, Inc., Ypsilanti, MI, where he developed patented MEMS-based implantable pressure-sensing devices. He subsequently cofoundedSonetics Ultrasound, Inc., Ann Arbor, the focus of which is MEMS-based2-D transducer arrays for true 3-D/4-D volumetric ultrasound and wherehe is currently Chief Technology Officer. In addition, he cofounded AccuriCytometers, Inc., Ann Arbor, which is leading the development of a market-transforming patented flow cytometer instrument that now enjoys worldwidedistribution. He has coauthored several technical publications and is the holderof 14 issued patents as well as multiple pending applications.

David F. Lemmerhirt (S’98–M’05) was born inAurora, IL, in 1975. He received the B.S.E.E. degreefrom the University of Illinois, Urbana-Champaign,in 1997, and the M.S. and Ph.D. degrees in electricalengineering from the University of Michigan, AnnArbor, in 1999 and 2005, respectively.

In 1996, he was a Technical Associate at LucentTechnologies (Bell Labs), Naperville, IL. In 1998,he became a Member of Technical Staff with IntelCorporation, Hillsboro, OR. Since 2004, he has beenwith Sonetics Ultrasound, Inc., Ann Arbor, where he

is currently a Senior Research and Development Engineer. He is the authorof multiple technical publications and is the holder of two issued patentsand five pending applications. His past research activities include compoundsemiconductor devices, micromachined sensors and actuators, and multisensormicrosystems. He is currently engaged in the development of CMOS-basedmicroelectromechanical systems ultrasound transducer arrays for medical mon-itoring and imaging.

Dr. Lemmerhirt was a recipient of the College of Engineering DistinguishedAchievement Award and the Outstanding Service Award from the NationalScience Foundation Engineering Research Center for Wireless IntegratedMicroSystems at the University of Michigan.

Robert D. White (S’00–M’05) received the B.S. andM.S. degrees in mechanical engineering from theMassachusetts Institute of Technology, Cambridge,in 1999, and the Ph.D. degree in mechanical engi-neering from the University of Michigan, Ann Arbor,in 2005.

From 1999 to 2000, he was a MEMS TestEngineer at The Charles Stark Draper Laborato-ries, Cambridge, where he worked on microelectro-mechanical systems gyroscopes and accelerometers.Since 2005, he has been an Assistant Professor of

mechanical engineering at Tufts University, Medford, MA, where he hasdirected the Tufts Micro and Nano Fabrication Facility since 2007. He teachesin the areas of microsystems, acoustics, dynamics, and controls. He is the authorof multiple technical publications and patents. His primary research interestsinclude the design, fabrication, modeling, and testing of acoustic microsystems,with additional work in inner ear mechanics, acoustics and vibrations, andmechatronics.

Prof. White was a recipient of the Charles Stark Draper Laboratory Fellow-ship in 1998, the National Science Foundation Graduate Research Fellowshipin 2001, and the Rackham Predoctoral Fellowship in 2004. He is a member ofthe Acoustical Society of America, American Society of Mechanical Engineers,and American Institute of Aeronautics and Astronautics.