The present invention provides a method for conveniently manufacturing a
solid oxide fuel
cell (SOFC) at a cost that is less than five-hundred dollars per kilowatt of
electricity. The method comprises forming an
electrode layer and depositing an
electrolyte material on the surface of the
electrode. The formed structure is an
electrode-
electrolyte bi-layer. A second electrode is deposited onto this bi-layer to form a multilayer fuel
cell structure comprising an
electrolyte positioned between two electrodes. This multilayer structure is then heated and fired in a single
thermal cycle to remove any binder materials and sinter, respectively, the fuel
cell. This
thermal cycle can be performed in a furnace having one or more chambers. The chamber(s) preferably contains a variable or
multiple frequency microwave source for heating the cell and removing binder materials in the electrolyte and electrode structures. The chamber(s) also preferably include a
convection and / or
radiation source for
sintering the fuel cell. In addition, the method of the invention harmonizes and minimizes the deviation among the thermophysical properties of the electrolyte and electrode structures. This
harmonization reduces and minimizes the
temperature gradient within the cell such that the structure can be uniformly heated and fired during the
thermal cycle. The multilayer structure is also unlikely to distort and fracture by minimizing the
temperature gradient in the cell. An SOFC can also be manufactured by the
present method in an
order of magnitude less time than standard processes.