Patent Publication Number: US-2019177835-A1

Title: Textured processing chamber components and methods of manufacturing same

Description:
FIELD 
     Embodiments of the present disclosure relate to chamber components for equipment used in the manufacturing of semiconductor devices. 
     BACKGROUND 
     The manufacture of the sub-half micron and smaller features in the semiconductor industry rely upon a variety of processing equipment, such as physical vapor deposition chambers (PVD) and the like. The deposition chambers use RF coils to maintain a plasma in the processing chamber. Existing chamber components utilized in PVD chambers may have a high temperature differential which causes high film stress for materials that may adhere to the components during the operation of the PVD chamber. The inventors have observed higher film stress may result in flaking of the deposited material during operation of the PVD chamber after the film has reached a critical thickness. The flaking of the deposited material results in increased contamination (e.g., particles) of the interior of the PVD chamber which contributes to substrate defects, low yield, damage to the chamber component part(s), and shorter component part life spans. Thus, the high risk of contamination undesirably demands increased frequency for cleaning, maintenance, and refurbishment of the PVD chamber. 
     The inventors have also observed that chamber components with features such as coil spacers are difficult to manufacture using state-of-the-art metallic additive manufacturing technology such as 3-D printing because pores or cracks may form in the components during manufacturing. Pores in the components such as in component part features are problematic in reducing or diminishing the structural integrity of the feature which may lead to a shorter life span of the component part or feature. 
     Therefore, the inventors have provided improved processing chamber components that help reduce or prevent contamination of processing chambers and methods of manufacturing such processing chamber components. 
     SUMMARY 
     Processing chamber components and methods of manufacture of same are provided herein. In some embodiments, a component part body includes a component part body having a base plane and at least one textured surface region, wherein the at least one textured surface region comprises a plurality of independent surface features having a first side having at least a 45 degree angle with respect to the base plane. In at least some embodiments, the textured surface includes a plurality of independent surface features which are pore free. 
     In some embodiments, a coil spacer for a processing chamber includes: a top portion; a bottom portion; an opening disposed in the top portion and extending towards the bottom portion; an exterior surface; an interior surface disposed adjacent the opening; and a cup region disposed between the top portion and bottom portion, wherein the cup region has an exterior portion; wherein a textured surface is disposed upon the exterior portion of the cup region, and wherein the at least one textured surface region includes a plurality of independent surface features having a first side having at least a 45 degree angle with respect to the bottom portion. 
     In some embodiments, a method of reducing or eliminating pores in a three dimensional printed chamber component includes: (a) depositing the metal powder in an amount sufficient to form a layer having a thickness of 20-40 micrometers; (b) melting the metal powder to form a layer; and (c) repeating (a) and (b) until chamber component is fabricated substantially free of pores. 
     Other and further embodiments of the present disclosure are described below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present disclosure, briefly summarized above and discussed in greater detail below, can be understood by reference to the illustrative embodiments of the disclosure depicted in the appended drawings. However, the appended drawings illustrate only typical embodiments of the disclosure and are therefore not to be considered limiting of scope, for the disclosure may admit to other equally effective embodiments. 
         FIG. 1A  depicts a schematic cross-sectional view of a process chamber having components in accordance with some embodiments of the present disclosure. 
         FIG. 1B  depicts a cross sectional view of a coil spacer in accordance with some embodiments of the present disclosure. 
         FIG. 2  depicts an isometric cross-sectional view of a coil spacer in accordance with some embodiments of the present disclosure. 
         FIG. 3  depicts an isometric cross-sectional view of a coil spacer in accordance with some embodiments of the present disclosure. 
         FIG. 4  depicts an isometric cross-sectional view of a coil spacer in accordance with some embodiments of the present disclosure. 
         FIG. 5  is a schematic side view of a coil spacer in accordance with some embodiments of the present disclosure. 
         FIG. 6  is a partial schematic side view of the coil spacer showing features in accordance with the present disclosure. 
         FIG. 7  is a flow chart of a manufacturing process in accordance with some embodiments of the present disclosure. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The figures are not drawn to scale and may be simplified for clarity. Elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. 
     DETAILED DESCRIPTION 
     The present disclosure relates to a chamber component for a processing chamber, the chamber component, including: a component part body having a base plane and at least one textured surface region, wherein the at least one textured surface region includes a plurality of independent surface features having a first side having at least a 45 degree angle with respect to the base plane. Advantages of the present disclosure may include one or more of the following. A chamber component which can be manufactured within very tight tolerances, for example having good thickness uniformity and control. Reproducible and robust geometric features may be formed in the chamber component in portions not accessible using traditional manufacturing methods. Additive manufacturing enables complex shapes and geometries that are difficult to replicate with traditional methods of manufacturing. Additionally, the 3D printed chamber component may be manufactured faster and cheaper than other similarly shaped conventional chamber components. Moreover, the component parts may be free of pores that reduce the structural integrity of the component part and shorten the life span of the component part. 
     Referring now to  FIG. 1A ,  FIG. 1A  illustrates processing chamber  101  as an exemplary physical vapor deposition (PVD) chamber having components in accordance with the present disclosure as described below. Examples of suitable PVD chambers include the SIP ENCORE® PVD processing chambers, commercially available from Applied Materials, Inc., of Santa Clara, Calif. Processing chambers available from other manufactures may also be adapted to include the embodiments described herein. In one embodiment, the processing chamber  101  is capable of depositing, for example, titanium, aluminum oxide, aluminum, aluminum nitride, copper, tantalum, tantalum nitride, titanium nitride, tungsten, or tungsten nitride on a substrate  118 . 
     The processing chamber  101  has an inductive coil  170 , according to one embodiment. The processing chamber  101  has a body  105  that includes sidewalls  102 , a bottom  103 , and a lid  104  that encloses an interior volume  106 . A substrate support, such as a pedestal  108 , is disposed in the interior volume  106  of the processing chamber  101 . A substrate transfer port  109  is formed in the sidewalls  102  for transferring substrates into and out of the interior volume  106 . 
     A gas source  113  is coupled to the processing chamber  101  to supply process gases into the interior volume  106 . In one embodiment, process gases may include inert gases, non-reactive gases, and reactive gases, if necessary. Examples of process gases that may be provided by the gas source  113  include, but not limited to, argon gas (Ar), helium (He), neon gas (Ne), nitrogen gas (N 2 ), oxygen gas (O 2 ), and H 2 O among others. 
     A pumping device  112  is coupled to the processing chamber  101  in communication with the interior volume  106  to control the pressure of the interior volume  106 . In one embodiment, the pressure of the processing chamber  101  may be maintained at about 1 Torr or less. In another embodiment, the pressure within the processing chamber  101  may be maintained at about 500 milliTorr or less. In yet another embodiment, the pressure within the processing chamber  101  may be maintained at about 1 milliTorr and about 300 milliTorr. 
     The lid  104  may support a sputtering source, such as a target  114 . The target  114  generally provides a source of material which will be deposited in the substrate  118 . The target  114  may be fabricated from a material containing titanium (Ti) metal, tantalum metal (Ta), tungsten (W) metal, cobalt (Co), nickel (Ni), copper (Cu), aluminum (Al), alloys thereof, combinations thereof, or the like. In an exemplary embodiment depicted herein, the target  114  may be fabricated by titanium (Ti) metal, tantalum metal (Ta) or aluminum (Al). 
     The target  114  may be coupled to a DC source power assembly  116 . A magnetron  119  may be coupled adjacent to the target  114 . Examples of the magnetron  119  assembly include an electromagnetic linear magnetron, a serpentine magnetron, a spiral magnetron, a double-digitated magnetron, a rectangularized spiral magnetron, among others. Alternately, powerful magnets may be placed adjacent to the target  114 . The magnets may rare earth magnets such as neodymium or other suitable materials for creating a strong magnetic field. The magnetron  119  may confine the plasma as well as distributing the concentration of plasma along the target  114 . 
     A controller  131  is coupled to the processing chamber  101 . The controller  131  includes a central processing unit (CPU)  160 , a memory  168 , and support circuits  162 . The controller  131  is utilized to control the process sequence, regulating the gas flows from the gas source  113  into the processing chamber  101  and controlling ion bombardment of the target  114 . The CPU  160  may be of any form of a general purpose computer processor that can be used in an industrial setting. The software routines can be stored in the memory  168 , such as random access memory, read only memory, floppy or hard disk drive, or other form of digital storage. The support circuits  162  are conventionally coupled to the CPU  160  and may comprise cache, clock circuits, input/output subsystems, power supplies, and the like. The software routines, when executed by the CPU  160 , transform the CPU  160  into a computer (controller)  131  that controls the processing chamber  101  such that the processes are performed in accordance with the present disclosure. The software routines may also be stored and/or executed by a second controller (not shown) that is located remotely from the processing chamber  101 . 
     An additional RF power source  181  may also coupled to the processing chamber  101  through the pedestal  108  to provide a bias power between the target  114  and the pedestal  108 , as needed. In one embodiment, the RF power source  181  may provide power to the pedestal  108  to bias the substrate  118  at a frequency between about 1 MHz and about 100 MHz, such as about 13.56 MHz. 
     The pedestal  108  may be moveable between a raised position and a lowered position, as shown by arrow  182 . In the lowered position, a top surface  111  of the pedestal  108  may be aligned with or just below the substrate transfer port  109  to facilitate entry and removal of the substrate  118  from the processing chamber  101 . The top surface  111  may have an edge deposition ring  136  sized to receive the substrate  118  thereon while protecting the pedestal  108  from plasma and deposited material. The pedestal  108  may be moved to the raised position closer to the target  114  for processing the substrate  118  in the processing chamber  101 . A cover ring  126  may engage the edge deposition ring  136  when the pedestal  108  is in the raised position. The cover ring  126  may prevent deposition material from bridging between the substrate  118  and the pedestal  108 . When the pedestal  108  is in the lowered position, the cover ring  126  is suspended above the pedestal  108  and substrate  118  positioned thereon to allow for substrate transfer. 
     During substrate transfer, a robot blade (not shown) having the substrate  118  thereon is extended through the substrate transfer port  109 . Lift pins (not shown) extend through the top surface  111  of the pedestal  108  to lift the substrate  118  from the top surface  111  of the pedestal  108 , thus allowing space for the robot blade to pass between the substrate  118  and pedestal  108 . The robot may then carry the substrate  118  out of the processing chamber  101  through the substrate transfer port  109 . Raising and lowering of the pedestal  108  and/or the lift pins may be controlled by the controller  131 . 
     During sputter deposition, the temperature of the substrate  118  may be controlled by utilizing a thermal controller  138  disposed in the pedestal  108 . The substrate  118  may be heated to a desired temperature for processing. After processing, the substrate  118  may be rapidly cooled utilizing the thermal controller  138  disposed in the pedestal  108 . The thermal controller  138  controls the temperature of the substrate  118 , and may be utilized to change the temperature of the substrate  118  from a first temperature to a second temperature in a matter of seconds to about a minute. 
     An inner shield  150  may be positioned in the interior volume  106  between the target  114  and the pedestal  108 . The inner shield  150  may be formed of aluminum or stainless steel among other materials. In one embodiment, the inner shield  150  is formed from stainless steel. An outer shield  195  may be formed between the inner shield  150  and the sidewall  102 . The outer shield  195  may be formed from aluminum or stainless steel among other materials. The outer shield  195  may extend past the inner shield  150  and is configured to support the cover ring  126  when the pedestal  108  is in the lowered position. 
     In one embodiment, the inner shield  150  includes a radial flange  123  that includes an inner diameter that is greater than an outer diameter of the inner shield  150 . The radial flange  123  extends from the inner shield  150  at an angle greater than about ninety degrees relative to the inside diameter surface of the inner shield  150 . The radial flange  123  may be a circular ridge extending from the surface of the inner shield  150  and is generally adapted to mate with a recess formed in the cover ring  126  disposed on the pedestal  108 . The recess may be a circular groove formed in the cover ring  126  which centers the cover ring  126  with respect to the longitudinal axis of the pedestal  108 . 
     The inductive coil  170  of the processing chamber  101  may be just inside the inner shield  150  and positioned above the pedestal  108 . The inductive coil  170  may be positioned nearer to the pedestal  108  than the target  114 . The inductive coil  170  may be formed from a material similar in composition to the target  114 , such as tantalum, to act as a secondary sputtering target. The inductive coil  142  is supported from the inner shield  150  by a plurality of chamber components such as chamber component  100  which may comprise or consist of coil spacers  110  ( FIG. 2 ). The coil spacers  110  may electrically isolate the inductive coil  170  from the inner shield  150  and other chamber components. 
     The inductive coil  170  may be coupled to a power source  151 . The power source  151  may have electrical leads which penetrate the sidewall  102  of the processing chamber  101 , the outer shield  195 , the inner shield  150  and the coil spacers  110 . The electrical leads connect to a tab  165  on the inductive coil  170  for providing power to the inductive coil  170 . The tab  165  may have a plurality of insulated electrical connections for providing power to the inductive coil  170 . Additionally, the tabs  165  may be configured to interface with the coil spacers  110  and support the inductive coil  170 . The power source  151  applies current to the inductive coil  170  to induce an RF field within the processing chamber  101  and couple power to the plasma for increasing the plasma density, i.e., concentration of reactive ions. 
       FIG. 1B  depicts a cross-sectional view of a chamber component  100  in accordance with the present disclosure. The chamber component  100  may include a coil spacer  110 . In embodiments, the chamber component  100  includes only a coil spacer  110 . The chamber component  100  may optionally include at least one tab receptor  130 . A fastener  135  may be utilized to hold the tab receptor  130  and coil spacer  110  together to form chamber component  100 . 
     The coil spacer  110  has a top portion  140  and a bottom portion  145 . The bottom portion  145  may be disposed proximate the inner shield  150 . The coil spacer  110 , tab receptor  130  and fastener  135  may attach together to secure the coil spacer  110  to the inner shield  150 . In one embodiment, the bottom portion  145  of the coil spacer  110  is disposed proximate an opening  155 . In embodiments, the inner shield  150  may have a feature (not shown) which inter-fits with a complimentary feature of the coil spacer  110  to locate and/or secure the coil spacer  110  to the inner shield  150 . For example, the coil spacer  110  may have threads, ferrule, taper or other structure suitable for attaching the coil spacer  110  to the inner shield  150 . 
     The tab receptor  130  may serve as a backing or structural member for attaching the coil spacer  110  to the inner shield  150 . Additionally, the tab receptor  130  or fastener  135  may interface with the tab  165  of the inductive coil  170 . The tab receptor  130  may have receiving features  175  for forming a joint or connection with respective complimentary tab features  180  on the tab  165 . In one embodiment, the tab features  185 ,  180  engage to form a structural connection between the tab  165  and the coil spacer  110  for supporting the inductive coil  170 . The tab features  185 ,  180  may be finger joints, tapered joint, or other suitable structure for forming a union between tab  165  and the coil spacer  110  suitable for supporting the inductive coil  170 . In some embodiments, the tab features  185  may form part of an electrical connection. 
     One or more of the coil spacers  110  may have an electrical pathway (not shown in  FIG. 1B ) extending there through. The electrical pathway may provide an electrical connection between the tab  165  on the inductive coil  170  and a power source (not shown) for energizing the inductive coil  170 . Alternately, the coil spacers  110  may not provide an electrical pathway and the power for energizing the inductive coil  170  is provided in another manner without passing through one of the coil spacers  110 . The electrical pathway may be a conductive path for transmitting an electrical signal. Alternately, the electrical pathway may be a void or space which provides accessibility of electrical connections between the power source (not shown) and the tab  165  of the inductive coil  170 . 
     The coil spacer  110  may be formed from a metal, such as stainless steel. In embodiments, stainless steel powder having a size of 35-45 micrometers is a suitable precursor material as described further below. The coil spacer  110  may electrically isolate the inductive coil  170  from the inner shield  150 . The coil spacer  110  may have an opening  190 . The opening  190  may be configured to accept the tab  165 . The opening  190  may be disposed in the top portion  140  and extend towards the bottom portion  145 . In one embodiment, the opening  190  has a circular profile and is configured to accept tab  165  having a round shape. In another embodiment, the opening  190  is shaped to receive a tab  165  having a complimentary inter-fitting shape. 
     In embodiments, coil spacer  110  includes a base plane  198  in alignment with axis  197  and bottom portion  145 . Base plane  198  generally extends across bottom portion  145 .  FIG. 1B  also shows an outer shield  195  adjacent chamber component  100 . While not connected with chamber component  100 , outer shield  195  is shown aligned in parallel with axis  197 , bottom portion  145 , and base plane  198 . 
     In embodiments, the coil spacer  110  may have surfaces and a plurality of independent surface features in accordance with the present disclosure (as depicted in greater detail in  FIGS. 2-6 ) configured to promote adhesion and minimize flaking of deposited material during operation of a processing chamber. For example, although not visible in  FIG. 1 , coil spacer  110  may include at least one textured surface region, wherein the at least one textured surface region includes a plurality of independent surface features having a first side having at least a 45 degree angle with respect to the base plane.  FIGS. 2-6  illustrate various embodiments of chamber components for a processing chamber such as coil spacers  200 ,  300 ,  400 , and  500  configured to inhibit flaking of deposited material.  FIG. 2  depicts a cross-sectional view of one embodiment of a chamber component illustrated as a coil spacer  200 .  FIG. 3  depicts a cross-sectional view of one embodiment of a chamber component illustrated as a coil spacer  300 .  FIG. 4  depicts a cross-sectional view of yet another embodiment of a chamber component illustrated as a coil spacer  400 .  FIG. 5  a schematic side view of a coil spacer  500  in accordance with some additional embodiments of the present disclosure.  FIG. 6  is a partial schematic side view of the coil spacer  500  in accordance with embodiments of the present disclosure. 
     As shown in  FIGS. 2-6 , the coil spacers  200 ,  300 ,  400 , and  500  have a body  210 . The body  210  may be of unitary construction, such as that from 3D printing, and have an interior surface  205  and an exterior surface  207 . The interior surface  205  is disposed adjacent the opening  290 . The interior surface  205  and exterior surface  207  may be spaced apart to form an outer lip  212  at the top portion  240  the coil spacers  200 ,  300 ,  400 . The outer lip  212  may be configured to rigidly support the inductive coil  170  (shown in  FIG. 1A ) with minimal stress. The outer lip  212  may be sized to promote heat dissipation. For example, a larger, e.g., thicker, outer lip  212  has more mass and dissipates heat better than a thinner lip. The outer lip  212  may have a thickness  215  ( FIG. 2 ) between about 2 mm and about 8 mm, such as about 5 mm, for better thermal performance. Although the coil spacers  200 ,  300 ,  400 , and  500  may operate in the processing chamber under similar conditions and at similar temperatures, the maximum operating temperature of each coil spacer  200 ,  300 ,  400 , and  500  is influenced properties and geometry of the coil spacers  200 ,  300 ,  400 , and  500  such as shape and thickness of the outer lip  212  or the inclusion of features such as protrusions disposed atop the outer lip. The coil spacer of one embodiment may have maximum temperatures exceeding that of the coil spacer from other embodiments when used in the same processes chamber under the same temperature process. 
     The coil spacers  200 ,  300 ,  400 , and  500  may have substantially the same surface area on the exterior surface  207 . For example, the exterior surface  207  may have a surface area of between about 9.0 square inches (in 2 ) to about 9.5 in 2 . In one embodiment, the coil spacers  200 ,  300 ,  400 , and  500  have a surface area on the exterior surface of about 4.2388 in 2 . Other parameters such as volume and weight may be substantially different for the coil spacers  200 ,  300 ,  400 , and  500  and will be discussed individually with each embodiment of the coil spacers  200 ,  300 ,  400 , and  500  below. 
     Although the coil spacers  200  is shown symmetrical about a central axis, or centerline  245 , coil spacers  200 ,  300 ,  400 , and  500  may be irregular in shape or asymmetrical. The opening  290  of the coil spacers  200 ,  300 ,  400 , and  500  extend through the top portion  240  of the coil spacers. In one embodiment, the opening  290  may be described by a cylindrical projection (only shown by dashed lines  276  in  FIG. 2 ) about the centerline  245 . The opening  290  extends through the coil spacers  200 ,  300 ,  400 , and  500  from an outer lip  212  proximate the top portion  240  and disposed between the exterior surface  207  and the interior surface  205  to an inner lip  271 . The inner lip  271  extends toward the centerline  245  to a bottom opening  246  in the coil spacers  200  as shown in  FIG. 2 . The bottom opening  246  may be configured to interface with the inner shield  150  ( FIG. 1B ) of a processing chamber such as a PVD processing chamber. The bottom opening  246  may also be configured to provide electrical or other connections between the processing chamber (not shown) and an inductive coil  170  ( FIG. 1B ). For example, the inductive coil  170  ( FIG. 1B ) may have power leads which pass through the bottom opening  246  to the RF power source (not shown) for energizing the inductive coil. 
     The exterior surface  207  of a component part body  293  may have at least one textured surface region  295  (see, e.g.,  FIG. 2 ), wherein the at least one textured surface region  295  includes a plurality of independent surface features  291 . In embodiments, independent surface features  291 ,  591  protrude axially from the component part body  293  (see, e.g.,  FIGS. 2, 5, and 6 ) and are equally spaced around periphery of the component part body  293 . In embodiments, the component part body  293  includes at least two textured surface regions  295 . Surface features  291 ,  591  formed independently on component part body such as  293  promote adhesion to the coil spacers  200 ,  300 ,  400 , and  500 . Similarly, the interior surface  205  may have surface features  291  formed thereon. The surface features  291  formed on the surfaces  205 ,  207  may be substantially similar. The surface features  291  formed on the surface  205 ,  207  may be repetitive predetermined pattern of projections that creates an engineered surface structure that interrupts the macro-level surface contour of the surface  205 ,  207  to promote film adhesion of deposited materials. Alternately, the geometry of the surface features  291  may differ on different the surfaces  205 ,  207  and/or across one or more of the surfaces  205 ,  207 . In one embodiment, as described further below, the cup region  260  disposed between the top portion  240  and bottom portion  145 , wherein the cup region  260  has an exterior surface  207  including at least one textured surface region  295 . The at least one textured surface region  295  includes a plurality of independent surface features having a first side having at least a 45 degree angle with respect to the bottom portion  145 . In embodiments, the surface features  291  may be formed in localized patterns such that the pattern of surface features  291  may be different on the outer lip  212  and cup region  260 . The surface features  291 ,  591  may provide a macro-textured area which promotes adhesion of deposition materials. During plasma processing, deposition materials may readily adhere to the surface features  291 ,  591  formed on the exterior surface  207 . The deposition materials may readily adhere to the surface features  291  formed on the interior surface  205  of the coil spacer  200  as well. The surface features  291 ,  591  may additionally be configured to increase the surface area of the coil spacers  200 ,  300 ,  400 , and  500 . The increased surface area helps increase the film adhesion during processing. Thus, the surface features  291 ,  591  promote adhesion and mitigate flaking off of the adhered material and possibly contaminating the processing chamber. 
     As described further below, the surface features  291 ,  591  may be protrusions formed during the 3D printing process. The surface features  291 ,  591  may be a texture such as a pattern of small cylindrical protrusions or the like, or other suitable textures for enhancing film adhesion. In embodiments, the independent surface features  291 ,  591  may be printed on the exterior surface of the coil spacer  200 ,  300 ,  400 , and  500  as well. 
     Turning back to  FIG. 2 , the coil spacer  200  has a void  254  extending beyond the opening  290 . The void  254  is interior and extends from the dashed lines  276  to a lower portion  273  of the interior surface  205 . The void  254  is bounded by a bottom surface  252  coil spacer  200  which extends from a protrusion  280  proximate the inner lip  271  to the lower portion  273  of the interior surface  205 . The protrusion  280  has a top surface  282 , an inner surface  281  and an outer surface  283 . The outer surface  283  is proximate the bottom surface  252 . The inner surface  281  may be significantly aligned with the inner surface  272  such that inner surfaces  272 ,  281  are aligned with the cylindrical projection illustrated by dashed lines  276 . The top surface  282 , inner surface  281  and outer surface  283  may have surface features  291  formed thereon to promote adhesion of deposited films. 
     The body  210  of the coil spacer  200  has a wall  287 . The wall  287  has a thickness defined by the distance between the interior surface  205  and the exterior surface  207  of the wall  287 . In one embodiment, the thickness of the wall  287  is substantially uniform. That is, a thickness  215  of the outer lip  212  is substantially the same throughout the profile of the wall  287  of the coil spacer  200 . In another embodiment, the wall  287  has a thickness which is not uniform. For example, the thickness  215  of the outer lip  212  may be greater than a thickness  225  at the cup region  260  of the wall  287 . 
     In one embodiment, the body  210  of the coil spacer  200  may be formed from stainless steel or other suitable material. The coil spacer  200  may be configured to promote thermal uniformity and thus reduce stress in material adhered to the coil spacer  200 , which desirably mitigates flaking of the adhered material. The thermal mass and heat dissipating properties of the coil spacer  200  may reduce the thermal gradients between the top portion  240  and the bottom portion  145  of the coil spacer  200 . Some embodiments of  FIG. 2  include a plurality of independent surface features  291  having a first side having at least a 45 degree angle with respect to a base plane, for example as shown in  FIGS. 5 and 6  below. In  FIG. 2 , the base plane is shown as axis X′  208  and axis Z′  209 . 
     Turning to  FIG. 3 , the coil spacer  300  has a cavity  345  extending beyond the opening  290 . The cavity  345  may have top surface  361 , a bottom surface  362  and an inner wall  363 . The top surface  361  and the bottom surface  362  may have a depth  347  defined by the distance of the top and bottom surfaces  361 ,  362  from the inner wall  363  to the opening  290 . The inner wall  363  may have a height  346  defined by the distance between the top surface  361  and the bottom surface  362 . The top surface  361  and bottom surface  362  along with the inner wall  363  substantially describe the extent of the cavity  345 . In one embodiment, the cavity  345  has a substantially rectangular side profile. In another embodiment, the cavity  345  may have a triangular side profile wherein the top surface  361  and the bottom surface  362  intersect and there is no inner wall  363 . 
     The component part body of the coil spacer  300  may be formed from stainless steel or other suitable material. The coil spacer  300  may be formed by additive manufacturing with surface features  291  formed thereon to promote adhesion of deposited material. Some embodiments of  FIG. 3  include a plurality of independent surface features  291  having a first side having at least a 45 degree angle with respect to a base plane, for example as shown in  FIGS. 5 and 6  below. 
     Turning to  FIG. 4 , the coil spacer  400  has fins  450 . Troughs  451  are defined between the fins  450 . The fins  450  may have a width  452  which may be tuned to achieve a desired rate of heat transfer. The troughs  451  may have a width  454  determined by the number of fins  450  and the width  452  of the fins. In one embodiment, the coil spacer  400  may have 8 equally spaced fins  450 . Alternately, the coil spacer  400  may have between about 4 and 18 equally spaced fins  450 , such as 12 fins or 8 fins. The coil spacer  400  may additionally have a flange wall thickness  410  near the inductive coil (not shown) of between about 2 mm to about 8 mm, such as about 5 mm. The fins  450  and flange wall thickness  410  help reduce the temperature differential across the coil spacer  400 . The fins  450  for the coil spacer  400  conduct heat away faster, thus allowing the coil spacer  400  to be maintained at lower temperature compared to the coil spacer  300  without fins. The width  452  of the fins  450  plays a role in reducing the temperature of the coil spacer  400 . For example, a cup having 8 fins  450  having the width  452  of about 2 mm may have temperature slightly higher than a cup having 8 fins  450  having the width  452  of about 3 mm. Thus, increasing the width  452  of the fins  450  may reduce the temperature experienced by the coil spacer  400  during operation of the processing chamber. As shown in  FIG. 4 , the coil spacer may include an interior surface having a plurality of fins  450 , e.g. heat transfer fins, and an exterior surface  207  on which the at least one textured surface region is formed. 
     The coil spacer  400  may be formed by printing, such as 3D printing, from a stainless steel or other suitable material. The stainless steel material for the coil spacer  400  permits the coil spacer  400  to experience temperatures well in excess of the maximum temperature the coil spacer  400  experiences during operation. The coil spacer  400  may have two or more fasteners to hold the coil spacer  400  in place on the inner shield. The number of fasteners may be increased to improve thermal conductivity between the coil spacer  400  and inner shield. 
     In one embodiment, the coil spacer  400  has 8 fins and a flange wall thickness  410  of about 5 mm. The coil spacer  400  may be formed by additive manufacturing with the surface features  291  formed on the surfaces, including the fins  450 , troughs  451 , and void  455  to promote adhesion of deposited material. The coil spacer  400  may be configured to promote thermal uniformity and thus reduce stress and mitigate flaking of adhered material. 
     Some embodiments of  FIG. 4  include a plurality of independent surface features  291  having a first side having at least a 45 degree angle with respect to a base plane, for example as shown in  FIGS. 5 and 6  below as with respect to independent surface features  591 . 
     Referring now to  FIG. 5 , a cross-sectional view of a coil spacer  500  in accordance with some embodiments of the present disclosure is shown. Component part body  505  is shown having a base plane  510  and at least one textured surface region  520 . However, in embodiments, the component part body  505  may include at least two textured surface regions (not shown in  FIG. 5 ). The at least one textured surface region  520  includes a plurality of independent surface features  591  having a first side  530  having at least a 45 degree angle with respect to the base plane  510 . In embodiments, the plurality of independent surface features  591  protrude axially from the component part body  505  and are equally spaced around periphery of the component part body  505 . In embodiments, the independent surface features  591  are equally sized and equally spaced cylindrical protrusions. 
     In embodiments, the plurality of independent surface features  591  include protrusions  592  having a predetermined diameter. Non-limiting suitable diameters of protrusions in accordance with the present disclosure include protrusions  592  having a diameter of about 1.1 to about 1.8 millimeters, or about 1.40 millimeters, or 1.40 millimeters. In embodiments, an independent surface feature  591  is the same structure as a protrusion  592 . 
     In embodiments, the plurality of independent surface features  591  include protrusions  592  having a predetermined height. Non-limiting suitable heights of protrusions  592  in accordance with the present disclosure include protrusions  592  having a height of about 0.70 to 1.30 millimeters, or about 1.00 millimeters, or 1.00 millimeters. 
     In embodiments, the plurality of independent surface features  591  include protrusions  592  having a predetermined spacing on the component part body  505 . Non-limiting suitable spacing of protrusions  592  in accordance with the present disclosure include protrusions  592  having a spacing of about 0.70 to about 1.30 millimeters, or about 1.00 millimeters, or 1.00 millimeters. Spacing may be measured for example by measuring from the edge of a first protrusion  592  to the edge of a second protrusion  592  immediately adjacent the first protrusion. In embodiments, each feature has a center, and each center is about 1.3 to about 2.5 millimeters from any adjacent feature, or in some embodiments, about 2.2 millimeters. 
     Still referring to  FIG. 5 , protrusions  592  include cylindrical shaped protrusions having a substantially flat top surface. In embodiments, the plurality of independent surface features  591  have an upper fillet radius of about 0.25 millimeters. In embodiments, the plurality of independent surface features  591  have a bottom fillet radius of about 0.10 millimeters. In embodiments, the plurality of independent surface features  591  include a predetermined repetitive pattern of cylindrical protrusions  592 . In embodiments, the at least one textured surface region  520  includes a predetermined repetitive pattern of spaces between the plurality of independent surface features  591 . 
     The coil spacer  500  may be formed by printing, such as 3D printing, from a stainless steel or other suitable material. The stainless steel material for the coil spacer  500  permits the coil spacer  500  to experience temperatures well in excess of the maximum temperature the coil spacer  500  experiences during operation. 
     Following completion of the additive processes of the method of the present disclosure, the method produces a coil spacer  110 ,  200 ,  300 ,  400 , or  500  including a plurality of independent surface features such as  291  and  591  that are free of pores and inclusions. The plurality of independent surface features such as  291  and  591  are substantially homogenous and include a substantially unitary crystal structure among the materials used to produce the plurality of independent surface features. In embodiments, the plurality of independent surface features are substantially free of pores and inclusions among each adjacent deposited layer. In embodiments, the plurality of independent surface features are substantially pore free, such as below about 1%, about 0.5% or below about 0.5% upon inspection at the completion of the additive process. In embodiments, inspection is performed by forming a cross sectional cut along the surface of the component or coil spacer (at least 3 to 5 millimeters from the surface thereof and visually inspecting the cross section with the use of an optical microscope). 
       FIG. 6  is a partial schematic side view of a coil spacer  500  as disclosed in  FIG. 5 , more clearly showing the plurality of features in accordance with some embodiments of the present disclosure. Here, body  210  is shown having a base plane  510  and at least one textured surface region. The at least one textured surface region includes a plurality of independent surface features  591  having a first side  530  having at least a 45 degree angle with respect to the base plane  510 . In embodiments, the plurality of independent surface features  591  protrude axially from the body  210  and are equally spaced around periphery of the body  210 . 
     A cup region  260  is shown disposed between the top portion  140  and bottom portion  145 , wherein the cup region  260  has an exterior surface  207 . At least one textured surface region is disposed upon at least portions of the exterior surface  207  of the cup region  260  (e.g., an exterior portion  602  of the cup region  260 ). The at least one textured surface region may be any region as discussed above with respect to any other embodiments disclosed herein. The at least one textured surface region includes a plurality of independent surface features  591  having a first side  530  having at least a 45 degree angle with respect to the base plane  510 . Base plane  510  generally extends as a plane across bottom portion  145 . Dotted lines  604  show the angle of first side  530  in relation to the base plane  510 . In embodiments, the angle of first side  530  in relation to the base plane  510  is greater than or equal to 45 degrees, such as between about 85 degrees and 45 degrees, or between about 75 degrees and 45 degrees, or between about 65 degrees and 45 degrees, or between about 55 degrees and 45 degrees, or between about 50 degrees and 45 degrees, or about 45 degrees, or 45 degrees. In embodiments, the downskin (e.g., the downwardly facing surfaces of the independent surface features  591 ) of the first side  530  is formed to be substantially pore free or having a porosity of less than 1% or less than 0.5% as described above. 
     Additive Manufacturing 
     3D printing is a technique of manufacturing three dimensional components by laying down successive thin layers of material. 3D Printing is also used in the semiconductor industry for manufacturing semiconductor processing chamber components (such as coil spacers) for plasma deposition chambers that can provide improved adhesion of deposition material on the surface of the chamber component. In a 3D printing processes of the present disclosure, a thin layer of precursor, e.g., a metal powder or other feed stock material is progressively deposited and fused to form a full 3-dimensional component of the chamber. In embodiments, a precursor material is preselected to reduce or eliminate porosity of the chamber component. In embodiments, the chamber component precursor material is stainless steel metal powder. In embodiments, the stainless steel metal powder has a powder size characterized as 35-45 micrometers. 
     In some embodiments, suitable techniques for 3D printing the coil spacers  110 ,  200 ,  300 ,  400 , and  500  include 3D printing using selective laser sintering. A laser or other suitable power such as around a 244 W source sinters powdered material, such as 35 to 40 micrometer stainless steel powder, by aiming the laser automatically at points in the powder defined by a 3D model. The laser binds the material together to create a solid structure such as a one-piece structure. When a layer is finished, the build platform moves downward and a new layer of material is sintered to form the next cross section (or layer) of the coil spacers  110 ,  200 ,  300 ,  400 , and  500 . Repeating the aforementioned process builds up the coil spacers  110 ,  200 ,  300 ,  400 , and  500  one layer at a time. In embodiments, where a porosity of the coil spacer, feature, or first surface of the feature are substantially pore-free (e.g. porosity &lt;1% or &lt;0.5%) the first several layers may be sacrificial up to about 500 micrometers. When layered to 500 micrometers, about 40 micrometer layers are successively added to reduce the porosity of the component. The inventors have discovered that by preselecting the size of the powder, and providing a predetermined thickness of the layers, above the first 500 micrometers of layering, a laser may be applied at around 244 W to reduce or eliminate pore formation in the coil spacer, feature, or surface edge of the feature. Printing processes may exclude the use of additional supports that may contribute to problematic roughness in the downskin. In embodiments, a high speed steel hard recoater blade is selected to ensure the homogenous size of the precursor powder such as 35-45 micrometer stainless steel powder. 
     Referring now to  FIG. 7 , a schematic view of a manufacturing process  700  in accordance with one manufacturing embodiment is shown. In embodiments, a method of reducing or eliminating pores in a three dimensional printed chamber component includes at  705  optionally preselecting a stainless steel powder having a size in the amount of 35 to 45 micrometer. In embodiments, process  700  optionally starts at  710  with depositing a metal powder to form a first layer of a three dimensional component. Next at  715 , process  700  includes melting the metal powder to form a first layer. At  717 ,  710  and  715  are repeated until the first layer has a thickness of about 500 micrometers. After reaching a thickness of about 500 micrometers, the process  700  continues with  720  by depositing the metal powder in an amount sufficient to form an additional layer having a thickness of 20-40 micrometers. At  725 , process  700  continues by melting the metal powder to form the additional layer. At  730 , the process continues by repeating  720  and  725  until chamber component is fabricated substantially free of pores. 
     In embodiments, a component, a coil spacer, a feature, and/or the outer down skin portion of the feature are 3D printed to be substantially free of pores such that a porosity less than or equal to 1% or 0.5% may be advantageously provided. In embodiments, the methods of the present disclosure include using a precursor such as a metal powder or stainless steel powder having a particle size distribution in the amount of 35-45 micrometers. In embodiments, the particle size distribution is such that the majority of particles have a diameter in the amount of about 35-45 micrometers. In embodiments, the stainless steel powder has a spherical nature. In embodiments, stainless steel powder is substantially pure such as having a purity of 99.9%. 
     While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof.