Although copper damascene interconnects offer many advantages over conventional subtractive etched Al alloys, the challenges and costs associated with converting to copper have combined to extend the useful life of Al alloy etching into the deep submicron regime. As a result, metal masking and etching are facing new challenges. Deep ultraviolet (DW) photolithography has replaced the conventional i-line technique for patterning fine metal pitches, but some DUV photoresists are less able to withstand the aggressive plasma environment than their i-line counterparts. Reflectivity increases at DUV wavelength, so dielectric antireflective films are added on top of the metal stack. The mask-open process, where the dielectric film is plasma etched prior to etching the metal stack, alters the photoresist further and influences the subsequent metal etch. Aspect ratio dependent etch effects increase when etching narrow spaces resulting from tightened metal Ditches, and gas additives may be required to protect the metal sidewalls. These effects are characterized and the challenges of deep submicron metal etch process development are discussed. The option of true hardmasked etching of the metal stack is also investigated.