Patent Publication Number: US-2023152688-A1

Title: Layer forming system including cover with support pads, a positioning system with the cover and support pads, and a method of loading a plate

Description:
BACKGROUND 
     Field of Art 
     The present disclosure relates to substrate processing, and more particularly, to planarization or imprinting of surfaces in semiconductor fabrication. 
     Description of the Related Art 
     Planarization and imprinting techniques are useful in fabricating semiconductor devices. For example, the process for creating a semiconductor device includes repeatedly adding and removing material to and from a substrate. This process can produce a layered substrate with an irregular height variation (i.e., topography), and as more layers are added, the substrate height variation can increase. The height variation has a negative impact on the ability to add further layers to the layered substrate. Separately, semiconductor substrates (e.g., silicon wafers) themselves are not always perfectly flat and may include an initial surface height variation (i.e., topography). One method of addressing this issue is to planarize the substrate between layering steps. Various lithographic patterning methods benefit from patterning on a planar surface. In ArFi laser-based lithography, planarization reduces the impact of depth of focus (DOF) limitations, and improves critical dimension (CD), and critical dimension uniformity. In extreme ultraviolet lithography (EUV), planarization improves feature placement and reduces the impact of DOF limitations. In nanoimprint lithography (NIL) planarization improves feature filling and CD control after pattern transfer. 
     A planarization technique sometimes referred to as inkjet-based adaptive planarization (IAP) involves dispensing a variable drop pattern of polymerizable material between the substrate and a superstrate, where the drop pattern varies depending on the substrate topography. A superstrate is then brought into contact with the polymerizable material after which the material is polymerized on the substrate, and the superstrate removed. Improvements in planarization techniques, including IAP techniques, are desired for improving, e.g., whole wafer processing and semiconductor device fabrication. 
     One step in a planarization/imprint method uses a positioning system to load a superstrate/template onto a superstrate/template chuck at a planarizing/imprinting station. Another step in a planarization/imprint method includes using a positioning system to move a substrate from a formable material dispensing station to the planarizing/imprinting station after the formable material has been dispensed on the substrate. During the moving from the dispensing station to the planarization/imprint station, the formable material may evaporate. This evaporation leads to an undesirable amount deviation from a target residual layer thickness (RLT). Thus, there is a need for a planarization/imprint system and method that reduces and/or eliminates evaporation of formable material when moving the substrate from a dispensing station to a planarizing/imprinting station. There is also a need for a planarization/imprint system and method that reduces the number of positioning systems needed to provide for the reduced and/or eliminated evaporation while also providing for the loading of the superstrate/template at the planarizing/imprinting station. 
     SUMMARY 
     In an embodiment, a system for forming a layer on a substrate comprises a dispensing station configured to dispense formable material on the substrate, a shaping station configured to contact the dispensed formable material on the substrate with a plate, and a positioning system. The positioning system includes a hand configured to hold the substrate, a cover having an underside surface facing the hand and a topside surface opposite the underside surface, the cover being configured such that the underside surface covers the substrate and the dispensed formable material when the cover is positioned over the hand, and a plurality of support pads positioned on the topside surface of the cover, the plurality of support pads being configured to support the plate. 
     In an embodiment, a positioning system comprises a hand configured to hold a substrate, a cover having an underside surface facing the hand and a topside surface opposite the underside surface, the cover being configured such that the underside surface covers the substrate when the cover is positioned over the hand, and a plurality of support pads positioned on the topside surface of the cover, the plurality of support pads being configured to support a plate. 
     In an embodiment, a method of loading a plate on a plate chuck at a shaping station using a positioning system comprises loading a plate onto a plurality of support pads of a cover such that the cover carries the plate, using the positioning system to move the cover and the plate to the shaping station while the plate is supported by the plurality of support pads and while the plate is carried by the cover, and coupling the plate with a superstrate chuck at the shaping station. The positioning system includes a hand configured to hold the substrate, the cover having an underside surface facing the hand and a topside surface opposite the underside surface, the cover being configured such that the underside surface covers the substrate when the cover is positioned over the hand, and the plurality of support pads positioned on the topside surface of the cover. 
     These and other objects, features, and advantages of the present disclosure will become apparent upon reading the following detailed description of exemplary embodiments of the present disclosure, when taken in conjunction with the appended drawings, and provided claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       So that features and advantages of the present disclosure can be understood in detail, a more particular description of embodiments of the disclosure may be had by reference to the embodiments illustrated in the appended drawings. It is to be noted, however, that the appended drawings only illustrate typical embodiments of the disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. 
         FIG.  1    is a schematic diagram illustrating an example planarization system in accordance with an aspect of the present disclosure. 
         FIG.  2 A  illustrates a schematic cross section of an example positioning system in accordance with an aspect of the present disclosure. 
         FIG.  2 B  illustrates a schematic cross section of another example positioning system in accordance with another aspect of the present disclosure. 
         FIG.  2 C  illustrates a schematic perspective view of an example cover in accordance with an aspect of the present disclosure. 
         FIG.  3 A  shows a flow chart of an example superstrate/template loading method in accordance with aspect of the present disclosure. 
         FIG.  3 B  shows a flow chart of an example planarization method in accordance with aspect of the present disclosure. 
         FIGS.  4 A to  4 F  show a series of schematic cross sections of a portion of the loading method of  FIG.  3 A . 
         FIGS.  5 A to  5 N  show a series of schematic cross sections of a portion of the planarization method of  FIG.  3 B  including the steps of transferring a substrate having dispensed drops from a dispensing station to a planarization station. 
         FIGS.  6 A to  6 C  illustrate a schematic cross section of an example planarization process in accordance aspect of the present disclosure. 
     
    
    
     While the subject disclosure will now be described in detail with reference to the figures, it is done so in connection with the illustrative exemplary embodiments. It is intended that changes and modifications can be made to the described exemplary embodiments without departing from the true scope and spirit of the subject disclosure as defined by the appended claims. 
     DETAILED DESCRIPTION 
     Planarization System 
       FIG.  1    illustrates an example system for shaping a surface in accordance with an aspect of the present disclosure. The system for shaping a surface may be, for example, a planarization system or an imprint system. The example embodiment described herein is a planarization system  100 . However, the concepts are also applicable to an imprint system. Thus, while the terminology throughout this disclosure is primarily focused on planarization, it should be understood that the disclosure is also applicable to the corresponding terminology of an imprint context. 
     The shaping system, e.g., the planarization system  100 , is used to planarize a film on a substrate  102 . In the case of the shaping system being an imprint system, the imprint system is used to form a pattern on the film on the substrate. The substrate  102  may be coupled to a substrate chuck  104 . The substrate chuck  104  may be but is not limited to a vacuum chuck, pin-type chuck, groove-type chuck, electrostatic chuck, electromagnetic chuck, and/or the like. 
     The substrate  102  and the substrate chuck  104  may be supported by a substrate positioning stage  106 . The substrate positioning stage  106  may provide translational and/or rotational motion along one or more of the x-, y-, z-, θ-, Ψ, and φ-axes. The substrate positioning stage  106 , the substrate  102 , and the substrate chuck  104  may also be positioned on a base (not shown). Separate from the stage  106 , a positioning system  110 ,  150 , discussed below with respect to  FIGS.  2 A and  2 B , may be used to provide the translational and/or rotational motion. 
     As shown in  FIG.  1   , in an example embodiment, the planarization system  100  may include three separate stations: a dispensing station  103 , a shaping station (e.g., a planarizing station  105 ), and a curing station  107 . The three stations may be located at different locations. A positioning system  110 ,  150  may be capable transferring the substrate  102  to each of the three stations. In some instances, a stage  106  may participate in the movement of the substrate  102 . In the example embodiments discussed below in more detail with respect to  FIGS.  5 A to  5 N , the planarizing station  105  is located at a first location and the dispensing station  103  is located at a second location that is different from the first location. In these example embodiments the substrate  102  is carried from the dispensing station  103  to the planarizing station  105  using the positioning system, for example the positioning system  110  of  FIG.  2 A  or the positioning system  150  of  FIG.  2 B . As discussed in more detail below, each of the stations may include a lift mechanism  114  that is configured to lift the substrate  102  from the substrate chuck  104  as part of the transferring process. In one example embodiment the lift mechanism  114  is a pin lift. More particularly, as shown in  FIG.  1   , each of the dispensing station  103 , the planarization station  105 , and the curing station  107 , may include a separate lift mechanism  114 , as well as a separate substrate chuck  104  and a separate positioning stage  106 . That is, the same reference number is used to designate the lift mechanism  114 , the substrate chuck  104 , and the positioning stage  106  in all of the stations because the structure of the lift mechanism  114 , substrate chuck  104 , and positioning stage  106  is identical at each station. However, it should be understood that each station has its own lift mechanism  114 , substrate chuck  104 , and positioning stage  106 . 
     The dispensing station  103  of the planarization system  100  may comprise a fluid dispenser  122 . The fluid dispenser  122  may be used to deposit droplets of liquid formable material  124  (e.g., a photocurable polymerizable material) onto the substrate  102  with the volume of deposited material varying over the area of the substrate  102  based on at least in part upon its topography profile. The formable material may be a photocurable composition comprising a photoinitiator and monomers. Exemplar monomers which may be in the photocurable composition include: acrylate monomers; vinyl monomers; styrenic monomers; etc. The formable material may have the composition described in U.S. Pat. App. Pub. No. 2020/0339828, which is hereby expressly incorporated by reference herein. As discussed in U.S. Pat. App. Pub. No. 2020/0339828, the formable material may be a photocurable composition comprising a polymerizable material and a photoinitiator, wherein at least 90 wt % of the polymerizable material may comprise acrylate monomers including an aromatic group. The photocurable composition can have a viscosity of not greater than 10, 15, 20, or 30 mPa·s, the total carbon content of the photocurable composition after curing can be at least 73%, and the Ohnishi number may be not greater than 3.0. At least 90 wt % of the polymerizable material can include monomers containing an aromatic group in their chemical structure. Some non-limiting examples of monomers comprising an aromatic group can be: benzyl acrylate (BA), benzyl methacrylate (BMA), 1-naphthyl methacrylate (1-NMA), bisphenol A dimethacrylate (BPADMA), 1-naphthyl acrylate (1-NA), 2-naphthyl acrylate (2-NA), 9,9-bis[4-(2-acryloyloxy ethoxy) phenyl]fluorine (A-BPEF), 9-fluorene methacrylate (9-FMA), 9-fluorene acrylate (9-FA), o-phenylbenzyl acrylate (o-PBA), bisphenol A diacrylate (BPADA), propenoic acid, 1,1′-[1,1′-binaphthalene]-2,2′-diyl ester (BNDA), styrene, divinyl benzene (DVB). Further details of the composition may be found in U.S. Pat. App. Pub. No. 2020/0339828. Some non-limiting examples of suitable monofunctional (meth)acrylates to be included in the polymerizable material are: isobornyl acrylate; 3,3,5-trimethylcyclohexyl acrylate; dicyclopentenyl acrylate; dicyclopentenyl acrylate; dicyclopentenyl oxyethyl acrylate; benzyl acrylate; naphthyl acrylate; 2-phenylethyl acrylate; 2-phenoxyethyl acrylate; phenyl acrylate; (2-ethyl-2-methyl-1,3-dioxolan-4-yl)methyl acrylate; o-phenyl benzyl acrylate; butyl acrylate; ethyl acrylate; methyl acrylate; n-hexyl acrylate; 2-ethyl hexyl acrylate; 4-tert-butylcyclohexyl acrylate; methoxy polyethylene glycol (350) monoacrylate; 2-methoxyethyl acrylate; lauryl acrylate; stearyl acrylate; 9-fluorene acrylate. Some non-limiting examples of suitable diacrylates to be included in the polymerizable material are: ethylene glycol diacrylate; diethylene glycol diacrylate; triethylene glycol diacrylate; tetraethylene glycol diacrylate; 1,2-propanediol diacrylate; dipropylene glycol diacrylate; tripropylene glycol diacrylate; polypropylene glycol diacrylate; 1,3-propanediol diacrylate; 1,4-butanediol diacrylate; 2-butene-1,4-diacrylate; 1,3-butylene glycol diacrylate; 3-methyl-1,3-butanediol diacrylate; 1,5-pentanediol diacrylate; 3-Methyl-1,5-pentanediol diacrylate; neopentyl glycol diacrylate; tricyclodecane dimethanol diacrylate; 1,6-hexanediol diacrylate; 1,9-nonanediol diacrylate; 1,10-decanediol diacrylate; 1,12-dodecanediol diacrylate; cyclohexane dimethanol diacrylate; bisphenol A diacrylate; ethoxylated bisphenol A diacrylate; m-xylylene diacrylate; 9,9-bis[4-(2-acryloyloxy ethoxy) phenyl]fluorine; 2,2′-diacrylate-1,1′-binaphthalene; dicyclopentanyl diacrylate; 1,2-adamantanediol diacrylate; 2,4-diethylpentane-1,5-diol diacrylate; poly(ethylene glycol) diacrylate; 1,6-hexanediol (EO)2 diacrylate; 1,6-hexanediol (EO)5 diacrylate; and alkoxylated aliphatic diacrylate esters. Some non-limiting examples of suitable multifunctional acrylates to be included in the polymerizable material are: trimethylolpropane triacrylate; propoxylated trimethylolpropane triacrylate (e.g., propoxylated (3) trimethylolpropane triacrylate, propoxylated (6) trimethylolpropane triacrylate); trimethylolpropane ethoxylate triacrylate (e.g., n˜1.3,3,5); di(trimethylolpropane) tetraacrylate; propoxylated glyceryl triacrylate (e.g., propoxylated (3) glyceryl triacrylate); 1,3,5-adamantanetriol triacrylate; tris (2-hydroxy ethyl) isocyanurate triacrylate; pentaerythritol triacrylate; Trisphenol PA triacrylate; pentaerythritol tetracrylate; ethoxylated pentaerythritol tetracrylate; dipentaerythritol pentaacrylate; tripentaerythritol octaacrylate; trimethylolpropane(PO)n triacrylate (n is 1, 2, 3 . . . ); trimethylolpropane(EO)n triacrylate (n is 1, 2, 3 . . . ). Examples of the vinyl benzene type of monomers include vinylbenzene (styrene), divinylbenzene (DVB), trivinylbenzene (TVB), 3,3′-divinylbiphenyl, 3,4′,5-trivinylbiphenyl, 3,3′,5,5′-tetravinylbiphenyl, 1,2-bis(3-vinylphenyl)ethane, bis(4-vinylphenyl) ether, bis(3-vinylphenyl) ether. Some non-limiting examples of suitable multifunctional monomers to be included in the polymerizable material are: molecules containing both acrylate functional groups and vinyl groups directly connected to aromatic rings. For example, 3-vinyl benzyl acrylate, 2-(4-vinyl)-phenyl, 1,3-propane diacrylate, 3,5-bivinyl benzyl acrylate, and 5-vinyl, 1,3-xylene diacrylate. Some non-limiting examples of maleimides and bismaleimides to be included in the polymerizable material are: N-benzylmaleimide; N-cyclohexylmaleimide; N-phenylmaleimide; and bis(3-ethyl-5-methyl-4-maleimidophenyl)methane. Some non-limiting examples of suitable benzoxazines to be included in the polymerizable material are: 6,6′-Methylenebis[3,4-dihydro-3-phenyl-2H-1,3-benzoxazine; and 3,3′-(Methylenedi-4,1-phenylene)bis[3,4-dihydro-2H-1,3-benzoxazine. 
     Different fluid dispensers  122  may use different technologies to dispense the formable material  124 . When the formable material  124  is jettable, ink jet type dispensers may be used to dispense the formable material. For example, thermal ink jetting, microelectromechanical systems (MEMS) based ink jetting, valve jet, and piezoelectric ink jetting are common techniques for dispensing jettable liquids. Because the substrate  102  is brought to the dispensing station  103 , and because the dispensing station  103  is a different location than the planarizing station  105 , the fluid dispensers  122  may be stationary. In another embodiment the fluid dispensers  122  may movable. 
     As shown in  FIG.  1   , the planarizing station  105  of the planarization system  100  may comprise a plate, e.g., a superstrate  108 , having a working surface  112  facing and spaced apart from the substrate  102 . The superstrate  108  may be formed from materials including, but not limited to, fused silica, quartz, silicon, organic polymers, siloxane polymers, borosilicate glass, fluorocarbon polymers, metal, hardened sapphire, and/or the like. In an embodiment the superstrate  108  is readily transparent to UV light radiation. The working surface  112  is generally of the same areal size as or slightly larger than the surface of the substrate  102 . In the case of the shaping station being an imprinting station, the plate may be a template with a patterned surface. 
     The planarizing station  105  may further include a plate chuck, e.g., a superstrate chuck  118 , and a planarization head  120 . The superstrate  108  may be coupled to or retained by the superstrate chuck  118 . The superstrate chuck  118  may be coupled to the planarization head  120 . The planarization head  120  may be movably coupled to a bridge. The planarization head  120  may include one or more actuators such as voice coil motors, piezoelectric motors, linear motor, nut and screw motor, etc., which are configured to move the superstrate chuck  118  relative to the substrate  102  in at least the z-axis direction, and potentially other directions (e.g., x-, y-, θ-, Ψ-, and φ-axis). In operation, either the planarization head  120 , the substrate positioning stage  106 , or both vary a distance between the superstrate  108  and the substrate  102  to define a desired space (a bounded physical extent in three dimensions) that is filled with the formable material  124 . For example, the planarization head  120  may be moved toward the substrate and may apply a force to the superstrate  108  such that the superstrate contacts and spreads droplets of the formable material  124  as further detailed herein. In the case the shaping station being an imprinting station, the plate chuck is a template chuck. 
     The planarizing station  105  may further comprise a camera  136  positioned to view the spread of formable material  124  as the superstrate  108  contacts the formable material  124  during the planarizing process. The camera  136  may include one or more of a CCD, a sensor array, a line camera, and a photodetector which are configured to gather light at a wavelength that shows a contrast between regions underneath the superstrate  108  and in contact with the formable material  124  and regions underneath the superstrate  108  but not in contact with the formable material  124 . The camera  136  may be configured to provide images of the spread of formable material  124  underneath the superstrate  108 , and/or the separation of the superstrate  108  from cured formable material  124 . The camera  136  may also be configured to measure interference fringes, which change as the formable material  124  spreads between the gap between the working surface  112  and the substrate surface. 
     As noted above, the curing station  107  may be located at a different location than the planarizing station  105 . In another embodiment the curing may be implemented at the planarizing station  105  such that there is not a separate curing station. In the case of there being a separate curing station  107 , following the forming of the formable material film  144  at the planarizing station  105 , the substrate  102  having a formable material film  144  and the superstrate  108  thereon, will travel to the curing station  107 . The curing station  107  includes a radiation source  126  that directs actinic energy, for example, UV light radiation, along an exposure path  128 . In an example embodiment the radiation source  126  comprises an array of light emitting diodes (LEDs)  127 . The array of LEDs  127  may be configured such that the emitted light is distributed at 80% or greater uniformity across the substrate  102 . The wavelength of the light emitted may be 300 to 400 nm. The substrate  102  and the superstrate  108 , with the formable material film  144  in between, may be positioned in superimposition with the exposure path  128 . The array of LEDs  127  transmits the actinic energy along the exposure path  128 . In this manner, the actinic energy is uniformly applied to the formable material film  144 . In the example embodiment where the curing occurs at the curing station  107 , the system does not include (is free from) additional optical components (e.g., dichroic mirrors, beam combiners, prisms, lenses, mirrors, etc.). However, in an embodiment where the curing is implemented at the same location as the planarizing station, such optical components may be included to direct the energy to the formable material. The curing station  107  may further include a separate camera  137  for data collection and monitoring with respect to the curing process. In an embodiment where the curing features are implemented at the same location as the planarizing station, the camera  136  may be used to monitor curing. 
     The planarization system  100  may be regulated, controlled, and/or directed by one or more processors  140  (controller) in communication with one or more components and/or subsystems such as the substrate chuck  104 , the substrate positioning stage  106 , the positioning system  110 ,  150 , the superstrate chuck  118 , the fluid dispenser  122 , the planarization head  120 , the camera  136 , the radiation source  126 , and/or the camera  137 . The processor  140  may operate based on instructions in a computer readable program stored in a non-transitory computer memory  142 . The processor  140  may be or include one or more of a CPU, MPU, GPU, ASIC, FPGA, DSP, and a general-purpose computer. The processor  140  may be a purpose-built controller or may be a general-purpose computing device that is adapted to be a controller. Examples of a non-transitory computer readable memory include but are not limited to RAM, ROM, CD, DVD, Blu-Ray, hard drive, networked attached storage (NAS), an intranet connected non-transitory computer readable storage device, and an internet connected non-transitory computer readable storage device. All of the method steps described herein may be executed by the processor  140 . 
       FIG.  2 A  shows a schematic cross section of a positioning system  110  in accordance with an example embodiment.  FIG.  2 B  shows a schematic cross section of a positioning system  150  in accordance with another example embodiment.  FIG.  2 C  shows a schematic perspective view of an example cover 
     As shown in  FIG.  2 A  the positioning system  110  includes a first articulating arm  137  coupled with a second articulating arm  139 . The positioning system  110  further includes a hand  141  coupled with the second articulating arm  139 . The hand  141  is also known as an end effector. The hand  141  is configured to carry and place the substrate  102  onto the substrate stage  106  at the various stations during the planarization process. The hand  141  may include one or more substrate support pads  143  for coming into contact with the underside of the substrate  102 . In an embodiment, the substrate support pads  143  may be connected to a vacuum source to provide a suction to actively hold the substrate  102  on the substrate support pads  143 . In an alternative embodiment, the substrate support pads  143  are not connected a vacuum source and the substrate  102  is passively held on the hand  141  by gravity. As shown in  FIG.  2 A  a cover  160  is coupled with the articulating arm  139 . The cover  160  is discussed in more detail below with respect to  FIG.  2 C . The cover  160  may be made out of material that blocks actinic radiation which would induce polymerization in the liquid formable material  124  and may be transparent to some bandwidth of visible light which does not induce polymerization in the liquid formable material  124  (for example, a clear plastic with a film that blocks UV, violet, and blue light). The cover  160  may be made out of material that is non-reactive to the liquid formable material  124 . For example, the cover  160  may be made of a metal, a plastic with a UV coating, a glass with a UV coating. Example materials that the cover may be made of include: aluminum; polyether ether ketone (PEEK); polyoxymethylene (also known as acetal); polytetrafluoroethylene (PTFE); a polyimide polymer (e.g., Vespel® manufactured by Dupont); alumina; or quartz. 
     A porous pad  162  may be provided within the cover  160 . The porous pad  162  may be sintered or perforated, for example. The porous pad  162  may have a volume fraction of at least 0.64. The pad is preferably open cell so that the voids create a network that can exchange with each other and the external environment. The porous pad  162  may have void size of 0.03 microns to 100 microns. The porous pad  162  may be made of metal such as stainless steel, titanium, nickel, ceramic such as alumina or silicon carbide, or a polymer material such as polyether ether ketone (PEEK), polyoxymethylene (also known as acetal), polytetrafluoroethylene (PTFE), or perfluoroalkoxy alkane (PFA). The sintered material may be coated with a material such as parylene to act as a barrier for metal ion transport or alter the wettability of the material. The porous pad  162  may have a generally circular shape similar in size to the substrate  102 . The porous pad  162  may be mounted to an inside surface of the cover  160 . The porous pad  162  may have a relatively large surface area while being relatively thin. The porous pad  162  may extend across substantially the entire inner diameter of the cover  160 . Thus, the porous pad  162  may have a have a diameter that is just smaller than the inner diameter of the cover  160 . That is, the diameter of the porous pad  162  may be as large as possible while still fitting within the cover  160 . For the example, the inner diameter of the cover  160  may be 0.5% to 5% larger than the diameter of the porous pad  162 . 
     A supply line  164  may be provided for supplying a fluid  172 , i.e., a liquid to the porous pad  162 . One end of the supply line  164  is contained within the cover  160  and terminating at the porous pad  162 , while the other end of the supply line  164  is located outside of the cover  160  in communication with a fluid source  165 . The fluid  172  can be provided by pump, by a differential pressure, or by syphon action due to the wicking of the porous pad. Preferably, the fluid is a liquid. The liquid is a more potent form than gas. With gas, there is a higher possibility of oversaturating the environment and inadvertently depositing material onto the substrate. In an example embodiment, when the fluid  172  is a liquid, the fluid  172  may be the formable material  124 . That this, the fluid  172  being supplied to the porous pad  162  may be the formable material  124  that was dispensed onto the substrate  102 . Accordingly, the composition of the fluid  172  may be the same as the composition of the formable material  124  described above. In another embodiment, the fluid may be a liquid having a different composition than the formable material  124 . The formable material  124  may be a composition comprising: a photoinitiator; a surfactant; and a monomer. For example, the liquid composition may be the monomers that are in the formable material  124 . The liquid composition may comprise those components of the formable material  124  that have a vapor pressure greater than a vapor pressure threshold. The vapor pressure threshold may be 0.133 Pascals (0.001 mmHg). For example, the composition may comprise: a first photoinitiator with a vapor pressure that is less than vapor pressure threshold; and a first monomer and a first surfactant both of which have a vapor pressure higher than the threshold, in which case the liquid composition is the first monomer and the first surfactant. For example, the composition may comprise: a second surfactant with a vapor pressure that is less than vapor pressure threshold; and a second monomer and a second photoinitiator both of which have a vapor pressure higher than the threshold, in which case the liquid composition is the second monomer and the second photoinitiator. In an embodiment, the formable material  124  may include solid components and liquid components. In which the solid components are solid when they are purely on their own and not in solution of the formable material  124 . In which the liquid components are liquid when they are purely on their own and not in solution of the formable material  124 . In an embodiment, the liquid composition include only the liquid components of the formable material  124  and does not include the solid components of the formable material  124 . The solid components of the formable material wouldn&#39;t evaporate appreciably and would potentially build up over time on the porous pad  162 . 
     In another embodiment, the fluid may be a gas. In the case that the fluid is a gas, the composition of the gas may be the volatile components of the formable material. When the fluid is gas, it is also possible to omit the porous pad entirely. The function of the porous pad to retain the fluid is not needed in the case of a gas. This is because the gas will the fill space above the substrate  102  to create the desired environment and does not need to be retained by a porous pad as a liquid would. The gas is a vapor produced by the liquid composition discussed above. 
     The positioning system  110  may translate and/or rotate along one or more of the x-, y-, z-axes; and three tilt axes as necessary via the first articulating arm  137  and the second articulating arm  139  to position the hand  141  and cover  160  to the desired location. That is, the positioning system  110 , controlled via the controller  140 , can pick up the substrate  102  with the hand  141  and position the substrate  102  the various stations, while also covering the substrate  102  with the cover  160 , as is described in more detail below with respect to  FIGS.  5 A to  5 N . 
     As shown in  FIG.  2 B  the positioning system  150  similarly includes a first articulating arm  137  coupled with a second articulating arm  139 . The positioning system  150  also similarly includes a hand  141  coupled with the second articulating arm  139  configured to carry and place the substrate  102  in the same manner as in the positioning system  110 . The positioning system  150  further includes the same cover  160 . The positioning system  150  differs from the positioning system  110  in that the positioning system  150  includes a third articulating arm  152 . As shown in  FIG.  2 B , in the positioning system  150 , the cover  160  is coupled with the third articulating arm  152 . Because the cover  160  in the positioning system  150  is coupled to a separate articulating arm than the hand  141 , the cover  160  can be moved and positioned independently from the hand  141 . In the case of the positioning system  110 , the cover  160  and the hand  141  are moved together because they are both coupled to the same articulating arm. 
     The cover  160  is the same in both positioning systems  110 ,  150 .  FIG.  2 C  shows a schematic perspective view the cover  160 . As shown in  FIG.  2 C  the cover  160  may include a generally cylindrical shape, i.e., having a circular cross section. The inside diameter of the cover  160  may be slightly larger than the diameter of the substrate  102 . For the example, the inner diameter of the cover  160  may be 0.5% to 5% larger than the diameter of the substrate  102 . The cover includes an enclosed top end  166 , an open bottom end  168 , and a wall  170  extending from the top end  166  to the bottom end  168 . The wall  170  is a continuous circumferential wall in the illustrated example embodiment. The wall  170 , along with the top end  166 , define an inner volume of space within the cover  160 . The cover  160  includes a plurality of support pads  174  for supporting a plate (e.g., a superstrate  108 ). The plurality of support pads  174  are coupled to the top of end  166  of the cover  160 . In other words, the plurality of support pads  174  are attached to and extend from the upper surface of the cover  160 . The plurality of support pads  174  may be made of polyether ether ketone (PEEK) or polyoxymethylene (also known as acetal, e.g., Delrin® manufactured by Dupont). 
     As discussed in more detail below with respect to  FIGS.  4 A to  4 F , the plurality of support pads  174  may be used to support the superstrate  108  as part of the process of loading the superstrate  108  onto the superstrate chuck  118  at the planarizing station  105 . Furthermore, as also discussed below in more detail with respect to  FIGS.  5 A to  5 N , as part of transferring the substrate  102  from the dispensing station (after dispensing) to the planarizing station  105 , the substrate  102  can be inserted upwardly through the open bottom end  168  into the cover  160 . In the case of imprinting, the plurality of supports pads may be used to support a template as part of the process of loading the template onto the template chuck at the imprinting station. 
     In another example embodiment, the cover may have a different shape other than cylindrical. For example, the cover may have a rectangular shape. In the case of the rectangular shape, the cover has a top end and four side walls. The rectangular shaped cover may have an open bottom end similar to the illustrated cover  160 . The rectangular shaped cover may also have an open side end and a closed bottom end. In the case of an open bottom end, the substrate  102  can be inserted upwardly into the cover and in the case of the open side end, the substrate can be inserted laterally into the cover, as noted below. In the case of a rectangular shaped cover, the pad within the cover may have a corresponding shape. That is, the pad may similarly have a rectangle shape with length and width dimensions that are within 0.5 to 5% of the inner length and width of the cover. The rectangular pad may have the same surface area to thickness ratio noted above in the circular embodiment. 
     In another example embodiment, the cover may be a hybrid shape including a cylindrical portion and a rectangular portion. For example, one half of the cover may have a cylindrical shape and one half may have a rectangular shape. In this case, the bottom end is enclosed and there is both a circumferential wall portion for one-half the length and opposing sidewalls for the over half of the length. The cover is open on one end on the rectangular shaped side. In this manner, the substrate  102  can be inserted laterally into the open rectangular shaped side. 
     While the cover  160  is shown in  FIGS.  2 A and  2 B  as being coupled with one of the articulating arms  139 ,  152 , the cover  160  may also be coupled to the hand  141 . In an embodiment, the cover  160  may be detachable/removable from the articulating arms  139 ,  152  or the hand  141 . In another embodiment, the cover may not be detachable/removable from the articulating arms  139 ,  152  or the hand  141 . 
     Planarization Method 
       FIG.  3 A  shows a flow chart of a superstrate/template loading method  300 , using the positioning system  110 ,  150 .  FIGS.  4 A to  4 F  show a series of schematic cross sections of a portion of the loading method of  FIG.  3 A . Because the loaded superstrate  108  may be used over many different planarizations, the loading method  300  of  FIG.  3 A  may be considered separate from the planarization method  310  of  FIG.  3 B . In other words, the planarization method  310  of  FIG.  3 B  may be performed many times after a single performance of the loading method  300 . However, in another embodiment, the loading of the superstrate may be considered a part of the overall planarization method, where the loading steps are performed periodically. 
     As shown in  FIG.  3 A , the loading method may be begin with step S 302  where the superstrate  108  (or template in the case of imprinting) is loaded onto the plurality of support pads  174  on the cover  160 . Step  302  corresponds to  FIGS.  4 A and  4 B . As shown in  FIG.  4 A , the superstrate  108  starts from an external position and is placed onto the plurality of support pads  174 , where the plurality of support pads  174  are on the top surface of the cover  160 . The superstrate  108  may be located at a separate station used to hold the superstrate  108  until the superstrate  108  is ready to be loaded onto the plurality of support pads  174 . In one example embodiment, the superstrate  108  may be placed at the separate station using another positioning system, where the other positioning system has similar arms and a hand/end effector to lift and orient (e.g., flip) the superstrate  108  at the separate station. For example, the other positioning system may orient the superstrate  108  such that the working surface  112  is facing downwardly. Then, when it is time to begin the loading method  300 , the other positioning system may then lift the superstrate  108  from the separate station and place the superstrate  108  onto the plurality of support pads  174  on the cover  160 , while maintaining the working surface  112  facing downward. 
       FIG.  4 B  shows the moment after the other positioning system has placed the superstrate  108  onto the plurality of support pads  174  on the cover  160  with the working surface  112  facing downward. While only two support pads of the plurality of support pads  174  are visible in the schematic cross section views, there may be four or more support pads as shown in the schematic perspective view of  FIG.  2 C . That is, there may be another pad behind each of the pads shown in the cross section view. As shown in  FIGS.  2 C and  4 B , the plurality of pads  174  are positioned adjacent the outer circumference edge of the cover  160 . With the plurality of supports pads  174  placed in this manner, as best shown in  FIG.  4 B , when the superstrate  108  is placed on the plurality of support pads  174 , only the outer circumferential edge  176  of the superstrate  108  comes into contact with the plurality of support pads  174 . The circumferential edge portion  176  of the superstrate is not used to contact formable material during the planarization method. That is, the circumferential edge  176  is not part of the working surface  112 . Thus, when placed onto the plurality of support pads  174 , the circumferential edge portion  176  of the superstrate  108  contacts the plurality of pads  174  and not the portion of the working surface  112  that will come into the contact with formable material  124 . In an embodiment, the circumferential edge portion  176  of the superstrate  108  may be chamfered or recessed relative to the working surface  112 . Accordingly, the plurality of support pads  174  may be shaped and sized to fit within the chamfer or recess. In an embodiment, the circumferential edge  176  may extend radially from the outermost edge by 1 to 3 mm. The working surface portion of the superstrate may have a diameter of 297 mm to 299 mm. Thus, in an embodiment, a ratio of the surface area of the working surface portion of the superstrate to the surface area of the circumferential edge  176  (i.e., the non-working surface portion of the superstrate) may be 25:1 to 100:1. 
     The plurality of support pads  174  may be passive or active. When passive, there is no active suction or other force imparted through the plurality of support pads  174  to hold the superstrate  108  in place on the plurality of support pads  174 . That is, only the weight of the superstrate  108  holds the superstrate  108  in place on the plurality of support pads  174  in the passive embodiment. In an active embodiment, the vacuum may be applied through the plurality of support pads  174 . Thus, in the active embodiment, a vacuum is applied through the plurality of support pads  174  to hold the superstrate  108  to the plurality of support pads  174  using a suction force. 
     The loading method  300  may then proceed to step S 304  where the superstrate  108  (or template in the case of imprinting) is carried to the planarizing station  105  (or imprinting station in the case of imprinting) while the superstrate  108  (or template in the case of imprinting) is supported by the plurality of support pads  174 . Step S 304  may be performed by using a positioning system such as the illustrated example positioning systems  110 ,  150 . That is, by actuating the articulating arms  137 ,  139 ,  152  and the hand  141 , the cover  160  may travel from the position where the superstrate  108  was loaded onto the plurality of support pads  174  of the cover  160  to the planarizing station  105 . During the travel, the superstrate  108  remains supported by the plurality of support pads  174 .  FIG.  4 C  shows a schematic cross section view of the planarizing station  105  as the superstrate  108  being carried by the cover  160  is brought into the planarizing station  105 . As shown in  FIG.  4 C , the superstrate  108  remain supported by the plurality of support pads  174  on the cover  160  as the superstrate  108  is brought underneath the superstrate chuck  118 . 
     After arriving at planarizing station  105  (or imprinting station in the case of imprinting), the loading method may proceed to step S 306  where the superstrate  108  (or template in the case of imprinting) is coupled with the superstrate chuck  118  (or template chuck in the case of imprinting).  FIG.  4 D  shows the moment after the superstrate  108  is coupled with the superstrate chuck  118 . Once the superstrate  108  is aligned just underneath the superstrate chuck  108 , a suction may be applied from the superstrate chuck  118  to the back surface (the surface opposite the working surface  112 ). This suction force couples the superstrate  108  with the superstrate chuck  118 . As shown in  FIG.  4 D , the coupling removes the superstrate  108  from the plurality of supports pads  174 . In the embodiment where the plurality of support pads  174  include a vacuum to hold the superstrate  108  to the plurality of support pads  174 , the vacuum to the plurality of support pads  174  is terminated during the coupling step S 306 . 
     After the superstrate  108  has been coupled with the superstrate chuck  118 , the loading method  300  may proceed to step S 308 , where the cover  160  is removed from the planarizing station  105  (or imprinting station in the case of imprinting). Step S 308  is performed in the reverse manner that the cover  160  was brought into the planarizing station  105 . That is, the articulating arms  137 ,  139 ,  152  and the hand  141  of the positioning system  110 ,  150  are actuated to move the cover  160  away from the planarizing station  105 . Once the cover  160  is removed from the positing system  160 , the planarization method  310  of  FIG.  3 B  can be performed, where the same positioning system  110 ,  150  can be used to carry the substrate  102 , as detailed below.  FIG.  4 E  shows the moment as the cover  160  is being removed from the planarizing station  105 .  FIG.  4 F  shows the moment after the cover  160  has been completely removed from the planarizing station  105 . As shown in  FIG.  4 F , the superstrate  108  remains coupled with the superstrate chuck  118  and the planarizing station  105  is ready for use. 
       FIG.  3 B  shows a flow chart of a planarization method  310  in accordance with an example embodiment.  FIGS.  5 A to  5 N  show schematic cross sections specifically regarding step S 312  and step S 314  of the planarization method, i.e., dispensing at the dispensing station  103  and transferring to the planarizing station  105 .  FIGS.  6 A to  6 C  show schematic cross sections specifically regarding step S 316  to step S 322 , i.e., from contacting the formable material at the planarizing station  105  through separating the superstrate from the cured layer. 
     The planarization method  310  may begin with step S 312 , where formable material  124  is dispensed onto the substrate  102  in the form of droplets. The positioning system  110 ,  150  may be operated to pick up a substrate  102  from a substrate holder (not shown) using the hand  141  and to mount the substrate  102  on the substrate chuck  104  at the dispensing station  103 . During this transfer, there is no need to cover the substrate  102  with the cover  160 . Once the substrate  102  is mounted to the substrate chuck  104  at the dispensing station  103 , the dispensing of the formable material  124  onto the substrate  102  may begin. As discussed above, the substrate  102  surface has some topography which may be known based on previous processing operations or may be measured using a profilometer, AFM, SEM, or an optical surface profiler based on optical interference effect like Zygo NewView™ 8200. The local volume density of the deposited formable material  124  is varied depending on the substrate topography. 
       FIG.  5 A  shows a schematic cross section of the substrate  102 , on the substrate chuck  104 , as the formable material  124  begins to be dispensed. As shown in  FIG.  5 A , drops of formable material  124  are being dispensed on the substrate  102 . As also shown in  FIG.  5 A , the lift mechanism  114  is in a fully retracted position. Thus, the substrate  102  is mounted to the substrate chuck  104 .  FIG.  5 B  shows the same view at a moment after the dispensing of the formable material  124  has been completed. That is,  FIG.  5 B  shows the moment after the completion of step S 312 . As shown in  FIG.  5 B , the dispenser  122  is no longer dispensing formable material and the substrate  102  has the formable material  124  deposited on top. Furthermore, the lift mechanism  114  remains in a fully retracted position such that the substrate  102  with formable material  124  is still mounted to the substrate chuck  104 . 
     The planarization method  310  may then proceed to step S 314  where the substrate  102  having the dispensed formable material  124  is transferred to the planarization station  105 . As noted above, because the formable material  124  is volatile, it is desirable to prevent or minimize evaporation of the formable material  124  during the transfer from the dispensing station  103  to the planarizing station  105 . The method of transfer that prevents or minimizes evaporation of the formable material is shows in  FIGS.  5 C to  5 L . 
       FIG.  5 C  shows a moment at the beginning of the transfer process. As shown in  FIG.  5 C , the lift mechanism  114  is actuated to first unmount the substrate  102  from the substrate chuck  104 . In the illustrated example embodiment, the lift mechanism  114  is one or more pin lifts. The lift mechanism  114  raises upwardly in the Z direction thereby pushing the substrate  102  upwardly in the Z direction.  FIG.  5 C  shows the moment when the lift mechanism  114  is in a fully extended position. In the fully extended position, the substrate is at a distance D from the upper end of the substrate chuck  104 . 
       FIG.  5 D  shows a moment as the positioning system  110 ,  150  brings the hand  141  and the cover  160  into position below and above the substrate  102 , respectively. As seen in  FIG.  5 D , the distance D is still being provided by holding the lift mechanism  114  in the extended position. The hand  141  is being moved within the space defined by distance D between the substrate  102  and the substrate chuck  104 . The cover  160  is similarly being brought into position just above the substrate  102  using the positioning system  110 ,  150 . In the case of the positioning system  110 , because the cover  160  and the hand  141  are coupled with the same articulating arm  139  (or in a case where the cover is coupled to the hand), both are moved into position simultaneously. However, in the case of the positioning system  150 , because the hand  141  is coupled with the articulating arm  139  while the cover  160  is coupled with the articulating arm  152 , the hand  141  and the cover  160  can be brought into position sequentially (in either order) or simultaneously. Therefore, while  FIG.  5 D  shows the hand  141  and the cover  160  moving into their respective positions simultaneously, it is also possible for the hand  141  and the cover  160  to be moved sequentially. 
       FIG.  5 E  shows a moment after the positioning system  110 ,  150  has completed moving the hand  141  and the cover  160  into the proper position at the dispensing station  103 . As shown in  FIG.  5 E , the hand  141  is completely underneath the substrate  102  and is ready to receive the substrate support pads  143 . At the same time the cover  160  is aligned above the superstrate  102  and dispensed formable material  124 . However, the cover  160  has not yet been moved down to cover the substrate  102  and formable material  124 . In other words, in the moment shown in  FIG.  5 E , the cover  160  is properly positioned along the X and Y dimension, but is not yet at the final position in the Z dimension. As noted above, while the movement of the hand  141  and the cover  160  is shown as moving simultaneously in the illustrated embodiment, the movement may also be sequential. 
       FIG.  5 F  shows a moment after the superstrate  102  has been lowered to mate with the hand  141  and the cover  160  has been lowered by positioning system  110 ,  150  to cover the substrate  102  and the formable material  124 . As shown in  FIG.  5 F , the lift mechanism  114  has been lowered downwardly in the Z direction to the fully retracted position. The retracting of the lift mechanism  114  brings down the substrate  102  in the Z direction until an underside surface mates with the suction type substrate support pads  143  of the hand  141 . Once mated, a vacuum (not shown) may be applied to substrate  102  via the suction type substrate support pads  143  to maintain the coupling between the hand  141  and the substrate  102 . After coupling with the hand  141 , the hand  141  is supporting the substrate  102 . Similarly, the positioning system  110 ,  150  lowers the cover  160  downwardly in the Z direction until the inner volume of the cover  160  encompasses the substrate  102  and the formable material  124 . More particularly, the cover  160  fully encompasses the formable material  124  and encompasses the top and sides of the substrate  102 . The cover  160  need not encompass the underside surface of the substrate  102 . The cover  160  may be sized relative to the substrate  102  such that in the position shown in  FIG.  5 F , a ratio of a diameter D 1  of the substrate  102  to a distance D 2  between the cover  160  and the substrate  102  (i.e., D1:D2) is 80:1 to 30:1. More specifically, the distance D 2  may be from the upper surface of the substrate  102  and the inner surface of the top end  166 . In another embodiment, the ratio D1:D2 may be 70:1 to 40:1 or 60:1 to 50:1. In an example embodiment, the diameter D 1  may be 300 mm and the distance D 2  may be 10 mm or less, more preferably 5 mm or less. The distance D 2  may be 1 mm to 10 mm, 2 mm to 8 mm, 3 mm to 7 mm, or 4 mm to 6 mm. 
     In the case of the positioning system  110 , because the arm  141  and the cover  160  are coupled to the same articulating arm  139  (or in a case where the cover is coupled to the hand), an additional lowering and lifting mechanism may be implemented to allow Z dimension movement of the cover  160  while the hand  141  remains stationary. For example, the lowering and lifting mechanism may include an actuator and two support shafts to allow for the relative Z dimension movement. In the case of the positioning system  150 , because the hand  141  and the cover  160  are coupled to different articulating arms, the hand  141  may be kept stationary via the articulating arm  139  while the cover may be lowered via the articulating arm  152 . 
     As noted above, in another embodiment the cover may have an enclosed bottom and an open side. In that case, instead of positioning the cover above the substrate and then lowering the cover, the cover may travel in the X dimension until the substrate enters into the cover via the open side. 
     After the cover  160  is located in the position to encompass the formable material  124 , the fluid  172  from the fluid source  165  may be activated to flow through the supply line  164 . The flowing of the fluid  172  from the fluid source  165  to the pad  162  via the supply line  164  is shown in  FIG.  5 F . Prior to the movement shown in  FIG.  5 F , the fluid  172  is not flowing through the supply line  164 . The providing of the fluid  172  to the pad  162  after the cover  160  encompasses the formable material  124  and the substrate  102  creates an environment around the substrate  102  that prevents or minimizes evaporation of the formable material  124 . In a first alternative embodiment, the pad  162  may need to be only occasionally charged with fluid  172  and sufficient fluid is supplied within the pores of the pad  162  to supply vapor to the volume between the substrate  102  and the cover  160 . In a second alternative embodiment, there is no supply line  164  and the pad  162  is charged with fluid  172  by an operator. In a third alternative embodiment, the supply line  164  is intermittently connected to the pad  162  so that the pad can be charged with fluid  172  when necessary. 
     In an example embodiment, as noted above, the fluid  172  may be the same as the formable material  124 . The evaporation of the formable material  124  is prevented or minimized by supplying the fluid  172  because the addition of the fluid  172  helps to saturate the vapor of the volatile components of the formable material  124  environment in the area surrounding the formable material  124 . That is, when there is an open air environment surrounding the formable material  124 , the formable material  124  will easily evaporate into the environment. However, when fluid  172  is provided to the pad  162 , fluid  172  evaporates into the surrounding, approaching its saturation or equilibrium vapor pressure. Therefore, the formable material  124  on the substrate will not easily evaporate because the surrounding environment is already at or near the saturation or equilibrium vapor pressure due to fluid  172 . 
       FIG.  5 G  shows a moment in the transferring process as the hand  141  (holding the substrate  102 ) and the cover  160  (covering the formable material  124  and the substrate  102 ) begin to be withdrawn from the dispensing station  103 . As shown in  FIG.  5 G , the hand  141  remains coupled with the underside of the substrate  102 , the cover  160  remains encompassing the formable material  124  and the substrate  102 , and the fluid  172  continues to be supplied to the pad  162 . The positioning system  110 ,  150  is controlled to move the hand  141  and the cover  160  simultaneously such that the cover  160  continues to encompass the formable material  124  and the substrate  102  while the substrate  102  is travelling. In the case of the positioning system  110  the simultaneous movement is achieved by actuating the second articulating arm  139 . In the case of the positioning system  150 , the simultaneous movement is achieved by coordinating the actuating of the second articulating arm  139  and the third articulating arm  152 . 
       FIG.  5 H  shows a moment in the transferring process when the substrate  102 , the hand  141 , and the cover  160  have completely exited the dispensing station  103 , but has not yet reached the planarizing station  105 . The moment shown in  FIG.  5 H  is essentially the same as in  FIG.  5 G , except for the location of the hand  141 , substrate  102 , and cover  160 . That is, as shown in  FIG.  5 H , the hand  141  remains coupled with the underside of the substrate  102 , the cover  160  continues to encompass the formable material  124  and the substrate  102 , the pad  162  continues to supply vapor to the volume between the substrate  102  and the cover  160 , and the fluid  172  may continue to be supplied to the pad  162 . 
       FIG.  5 I  shows a moment in the transferring process when the substrate  102 , the hand  141 , and the cover  160  are entering the planarizing station  105 . More specifically, the substrate  102 , the hand  141 , and the cover  160  are entering the space between the planarization head  120  (holding the superstrate  108  via the superstrate chuck  118 ) and the substrate chuck  104 . The moment shown in  FIG.  5 I  is essentially the same as in  FIG.  5 H , except for the location of the hand  141 , the substrate  102 , and the cover  160 . That is, as shown in  FIG.  5 I , the hand  141  remains coupled with the underside of the substrate  102 , the cover  160  continues to encompass the formable material  124  and the substrate  102 , the pad  162  continues to supply vapor to the volume between the substrate  102  and the cover  160 , and the fluid  172  may continue to be supplied to the pad  162 . The only difference being that the location of the substrate  102 , the hand  141 , and the cover  160  is at a point of entering the space between the planarization head  120  and the substrate chuck  104 . As seen in  FIG.  5 I , as the substrate  102 , the hand  141 , and the cover  160  enter the space between the planarization head  120  and the substrate chuck  104 , the lift mechanism  114  is the fully retracted position. The substrate  102 , the hand  141 , and the cover  160  continues to be moved via the positioning system  110 ,  150 . 
       FIG.  5 J  shows a moment in the transferring process when the substrate  102 , the hand  141 , and the cover  160  have fully entered into the planarizing station  105 . More specifically, the substrate  102 , the hand  141 , and the cover  160  are fully inserted into the space between the planarization head  120  (holding the superstrate  108  via the superstrate chuck  118 ) and the substrate chuck  104 . The moment shown in  FIG.  5 J  is essentially the same as in  FIG.  5 I , except for the location of the hand  141 , the substrate  102 , and the cover  160  has changed. That is, as shown in  FIG.  5 J , the hand  141  remains coupled with the underside of the substrate  102 , the cover  160  continues to encompass the formable material  124  and the substrate  102 , and the fluid  172  continues to be supplied to the pad  162 . The only difference being that the location of the substrate  102 , the hand  141 , and the cover  160  is now fully within the space between the planarization head  120  and the substrate chuck  104 . As seen in  FIG.  4 J , when the substrate  102 , the hand  141 , and the cover  160  fully enter the space between the planarization head  120  and the substrate chuck  104 , the lift mechanism  114  is still in the fully retracted position. The substrate  102 , the hand  141 , and the cover  160  is moved to the fully inserted position via the positioning system  110 ,  150 . 
       FIG.  5 K  shows a moment in the transferring process as the cover  160  and the hand  141  begin the process of being removed from the planarizing station  105 . As shown in  FIG.  5 K , the lift mechanisms  114  have been extended to contact the underside of the substrate  102 . At the same time, in a case that a vacuum is used to hold the substrate  102  to the hand  141  via the substrate support pads  143 , the vacuum may be terminated. Thus, the lift mechanism  114  lifts the substrate  102  off of the hand  141  upwardly in the Z dimension. Either simultaneously or before the lifting of the substrate  102  from the hand  141 , the cover  160  may also be moved upwardly in the Z dimension. The cover  160  should be lifted at the same time or prior to the lifting of the substrate  102  so that that substrate  102  with formable material  124  does not come into contact with the cover  160 . As also shown in  FIG.  5 K , the supply of the fluid  172  may have been terminated, i.e., there is no fluid  172  in the supply line  164 . The fluid  172  is no longer needed at the time that cover  160  is being removed because there is no longer an enclosed environment once the cover removal process has begun. 
     As above, moving the cover  160  in the Z dimension is achieved via the positioning system  110 ,  150 . Similar to the lowering process discussed above with respect to  FIG.  5 F , in the case of the positioning system  110 , because the arm  141  and the cover  160  are coupled to the same articulating arm  139  (or in a case where the cover is coupled to the hand), the additional lowering and lifting mechanism may be implemented to allow Z dimension movement of the cover  160  while the hand  141  remains stationary. In the case of the positioning system  150 , because the hand  141  and the cover  160  are coupled to different articulating arms, the hand  141  may be kept stationary via the articulating arm  139  while the cover may be raised via the articulating arm  152 . 
       FIG.  5 L  shows a moment as the positioning system  110 ,  150  removes the hand  141  and the cover  160  from the planarizing station  105 . As seen in  FIG.  5 L , the distance D is once again being provided by maintaining the lift mechanism  114  in the extended position. The hand  141  is being moved out of the space defined by distance D between the substrate  102  and the substrate chuck  104 . The cover  160  is similarly being removed from the position just above the substrate  102  using the positioning system  110 ,  150 . In the case of the positioning system  110 , because the cover  160  and the hand  141  are coupled with the same articulating arm  139 , both are removed simultaneously. However, in the case of the positioning system  150 , because the hand  141  is coupled with the articulating arm  139  while the cover  160  is coupled with the articulating arm  152 , the hand  141  and the cover  160  can be removed sequentially (in either order) or simultaneously. Therefore, while  FIG.  5 L  shows the hand  141  and the cover  160  being removed simultaneously, it is also possible for the hand  141  and the cover  160  to be removed sequentially. 
       FIG.  5 M  shows the moment in the transferring process after the hand  141  and the cover  160  have been completely removed from the planarization station  105 . As shown in  FIG.  5 M , at this moment the lift mechanism  114  is still fully extended such that the substrate  102  is not in coupled with the substrate chuck  104 . 
       FIG.  5 N  shows the final moment in the transferring process. As shown in  FIG.  5 M , at this moment the lift mechanism  114  has been fully retracted such that the substrate  102  has been lowered and is now coupled with the substrate chuck  104 . The formable material  124  on the surface of the substrate is now located beneath the planarization head  120 . More specifically, the substrate  102  with the formable material  124  is located underneath the superstrate  108  being held by the superstrate chuck  118 . Thus, the transfer of the substrate  102  with the formable material  124  from the dispensing station  103  to the planarizing station  105  is complete. As result of the implementation of the cover  160  evaporation of the formable material has been prevented or minimized during the transfer process. 
     After completion of the above-described process of transferring the substrate  102  with dispensed formable material  124  from the dispensing station  103  to the planarizing station  105 , the planarization method  310  may then proceed to steps S 316  and S 318 , where the substrate  102  having the formable material  124  is planarized using the planarizing station  105 .  FIG.  6 A  shows a schematic cross section at the planarizing station  105  at the moment just before the superstrate  108  comes into the contact with the formable material  124  on the substrate  102 . The planarization head  120  may be moved toward the substrate  102  and apply a force to the superstrate  108  such that the superstrate  108  contacts (S 316 ) and spreads (S 318 ) droplets of the formable material  124 . 
       FIG.  6 B  illustrates a post-contact step after the superstrate  108  has been brought into full contact with the formable material  124 . As the superstrate  108  contacts the formable material  124 , the droplets merge to form a formable material film  144  that fills the space between the superstrate  108  and the substrate  102 . Preferably, the filling process happens in a uniform manner without any air or gas bubbles being trapped between the superstrate  108  and the substrate  102  in order to minimize non-fill defects. At the moment shown in the  FIG.  6 B , the steps S 316  and S 318  have been completed. 
     The planarization method  310  may then proceed to step S 320 , where the spread formable material is cured. The curing may occur at a separate curing station  107  as illustrated in  FIG.  1    or may be cured at the same location as the planarizing station  105  in another embodiment. When the curing occurs at the curing station  107 , the superstrate  108  is released from the superstrate chuck  118  while the superstrate  108  is still in contact with the formable material film  144 . This action of releasing the superstrate  108  from the superstrate chuck  118  leaves the superstrate  108 /the film  144 /the substrate  102  free from the planarization head  120 . The releasing of the superstrate  108  from the superstrate chuck  118  may also be referred to as dechucking. Thus, as a result of releasing the superstrate  108  from the superstrate chuck  118 , the superstrate  108 /the formable material film  144 /the substrate  102  is moveable via the positioning system  110 ,  150  or the stage  106 . After reaching the curing station  107 , the formed film layer  144  is cured. The polymerization process or curing of the formable material  124  may be initiated with actinic radiation (e.g., UV light radiation). For example, radiation source  126  provides the actinic radiation causing formable material film  144  to cure, solidify, and/or cross-link, defining a cured layer  146  on the substrate  102 . More particularly, as shown in  FIG.  1   , the UV light radiation is emitted from the array of LEDs  127  that are directed toward the film  144 . Because the superstrate  108  is configured to be transparent with respect to the UV light radiation emitted from the array of LEDs  127 , the UV light radiation passes through the superstrate  108  and acts upon the formable material film  144  to cure the formable material film  144  resulting in the cured layer  146 . When the curing process is complete, the formable material film  144  has become a cured layer  146 . In an embodiment where the curing occurs at the same location as the planarizing station  105 , the light source may be provided above planarization head  120  and the light may be directed through the superstrate chuck  118  and the superstrate  108  to reach the film  144 . 
     The planarization method  310  may then proceed to step S 322 , where the superstrate  108  is separated from the cured layer  146 . In the case when the curing was performed at the separate curing station  107 , the superstrate  108 /the cured layer  146 /the substrate  102  may be brought back to the planarizing station  105 . To remove the superstrate  108  from the cured layer  146  the superstrate chuck  118  may be coupled once again to the superstrate  108  (i.e., rechucking the superstrate  108 ) via operation of the planarization head  120 , while the superstrate  108  is still in contact with the cured layer  146 . In the case that the curing occurs at the same location of the planarizing station  105 , the superstrate  108  remains coupled with the superstrate chuck  118  and there is no rechucking step. Once the superstrate  108  is coupled with the superstrate chuck  118 , the superstrate chuck  118  may begin to lift upwardly away from the substrate  102 , via operation of the planarization head  120 . Because the superstrate  108  is coupled with superstrate chuck  118 , the lifting force will cause the superstrate  108  to separate from the cured layer  146 . The separating force may be applied through several different methods. For example, the separating force may be applied by a pin pushing up on the superstrate  108 , by a vacuum pulling up on the upper surface  141  of the superstrate  108 , and/or by applying a high pressure jet of air at the intersection of the cured layer  146  and the superstrate  108 . 
       FIG.  6 C  shows a schematic cross section of the substrate  102  after the superstrate  108  has been removed from the cured layer  146 , i.e., after the completion of step S 312 . That is,  FIG.  6 C  shows the completed cured planarized layer  146  on the substrate  102 . The substrate  102  and the cured layer  146  may then be subjected to additional known steps and processes for device (article) fabrication, including, for example, patterning, curing, oxidation, layer formation, deposition, doping, planarization, etching, formable material removal, dicing, bonding, and packaging, and the like. The substrate  102  may be processed to produce a plurality of articles (devices). These additional steps may be performed by moving the substrate  102  having the exposed cured layer  146  to a distinct location. Once the substrate  102 , having the exposed cured layer  146 , is moved, the planarizing station  105  is ready to receive a new substrate with formable material and repeat the above process. 
     Further modifications and alternative embodiments of various aspects will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. It is to be understood that the forms shown and described herein are to be taken as examples of embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description.