Etching is one of the critical steps in the fabrication of microelectr
onics devices. A time-optimal control problem with a dual-term termina
l cost including both bottom linewidth and side-wall curvature is form
ulated to implement an optimal open-width design principle. A singular
-are solution does not exist and the control action is bang-bang. The
optimal switching time is analytically calculated. The feasibility and
effectiveness of this technique are illustrated by simulation studies
. This design and control philosophy can easily be applied to other mi
croelectronics manufacturing processes.