US Patent 9536793 Self-aligned gate-first VFETs using a gate spacer recess

Methods for self-aligned gate-first VFETs using gate-spacer recess and the resulting devices are disclosed. Embodiments include providing a substrate including adjacent transistor regions; forming adjacent and spaced fin-structures each including hardmask over a fin and over a different transistor region; forming a gate-dielectric and metal-spacer consecutively on each side of each fin-structure; forming a liner on all exposed surfaces of the hardmask, gate-dielectrics, and metal-spacers and the substrate; forming an ILD filling spaces between the fin-structures and coplanar with an upper surface of the liner; removing the liner over the fin-structures; removing the hardmask and recessing the liner, the gate-dielectrics and metal-spacers of each fin-structure creating cavities in the ILD; forming a low-k spacer on sidewalls of and over the metal-spacers and liners in each cavity; forming a top S/D structure over the gate-dielectric and fin in each cavity; and forming a top S/D contact over each top S/D structure.