The use and enhancement of a semi-automated wafer characterization tool, a dual channel capacitive sensor module, is demonstrated by implementing a new measurement algorithm for metallization process control. This tool is capable of measuring the deposited metal film thickness induced bow and warpage in a full wafer surface scan. The nondestructive solution can measure Cu metal film thickness with a total measurement uncertainty of 0.18 μm (). The stress conversion map can be obtained based on the modified Stoney’s formula and the capacitance-displacement technique. A wafer thinning process was also performed to characterize the warpage/bow of 8-in. wafers, which continues to increase as wafer thicknesses are reduced from 725 to 300 μm. There was a linear relationship between the wafer warpage and bow and the square of the inverse of the thickness. Metrology results from actual 3-D interconnect processing wafers are presented.