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Shape uniformity is one of the key factors for determining the performance of planar solid oxide fuel cells. Three parameters must be considered to acquire a full picture of shape uniformity: the extent of warpage, surface roughness and thickness variations. The present study examines the thickness variations of yttria-stabilized zirconia electrolytes after sintering. An optical technique has been successfully developed to determine the thickness variations, which are closely related to microstructure uniformity. A warm isostatic pressing lamination technique can be used to reduce thickness variations.