A variable-temperature ion-exchange process was developed to produce strengthened glasses with decreased strength variability. By introducing a high-temperature step into the normal ion-exchange process, the strength variability was greatly decreased (similar to60%) with only about 10% loss in the average strength. The surface damage resistance was also studied using indentation strength tests, and, again, there was a significant improvement compared with the traditional ion-exchange (isothermal) process. Stress profiles in isothermal and variable-temperature ion-exchanged glasses were measured using an optical method. The strength and strength variability of ion-exchanged glass predicted from the measured stress profiles agreed with the experimental strength data.