Preliminary Characterization and Analysis of the Designs and Research-manufacturing Approaches


This report summarizes the results of Phase I of a study entitled, Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells. The work was carried out by a group called the Multilayer Fuel Cell Alliance (MLFCA) led by NexTech Materials and including Adaptive Materials, Advanced Materials Technologies (AMT), Cobb & Co., Edison Materials Technology Center, Iowa State University, Gas Technology Institute (GTI), Northwestern University, Oak Ridge National Laboratory (ORNL), Ohio State University, University of Missouri-Rolla (UMR), and Wright-Patterson Air Force Base. The objective of the program is to develop advanced manufacturing technologies for making solid oxide fuel cell components that are more economical and reliable for a variety of applications. In the Phase I effort, five approaches were considered: two based on NexTech's planar approach using anode and cathode supported variations, one based on UMR's ultra-thin electrolyte approach, and two based on AMI's co-extrusion technology. Based on a detailed manufacturing cost analysis, all of the approaches are projected to result in a significantly reduced production cost. Projected costs range from $139/kW to $179/kW for planar designs. Development risks were assessed for each approach and it was determined that the NexTech and UMR approaches carried the least risk for successful development. Using advanced manufacturing methods and a proprietary high power density design, the team estimated that production costs could be reduced to $94/kW.


Materials Science and Engineering


United States. Department of Energy

Keywords and Phrases

30 Direct Energy Conversion; Air; Anodes; Cathodes; Ceramics; Design; Electrolytes; Fuel Cells; Manufacturing; Power Density; Production; Soild Oxide Fuel Cells

Document Type

Technical Report

Document Version


File Type





© 2000 Nextech Materials, All rights reserved.

Publication Date

01 Oct 2000