A
solid oxide fuel
cell device that includes an elongate substrate having a first end and an opposing second end with a length therebetween, a
cold zone along a first portion of the length adjacent the first end, and a hot
reaction zone along a second portion of the length adjacent the second end. The hot
reaction zone is configured to be heated to an operating
reaction temperature, and the
cold zone is configured to remain at a low temperature below the operating
reaction temperature. A fuel inlet and air inlet are each positioned in the
cold zone and coupled to respective elongate fuel and oxidizer passages that extend through the hot
reaction zone within the elongate substrate in parallel and opposing relation to respective fuel and air outlets adjacent the first end. An
anode and a
cathode are each positioned adjacent a respective fuel and oxidizer passage in the hot reaction zone within the elongate substrate and each is electrically coupled to a respective first and second exterior contact surface on the elongate substrate in the cold zone. A
solid electrolyte is positioned between the
anode and
cathode, and negative and positive electrical connections are made to the respective first and second exterior contact surfaces. A fuel
cell system is also provided incorporating a plurality of the fuel devices with their hot reaction zones positioned in a
hot zone chamber and their cold zones extending outside the
hot zone chamber. A heat source is coupled to the
hot zone chamber to heat the reaction zones to the operating
reaction temperature. Fuel and air supplies are coupled outside the hot zone chamber to the cold zones for supplying fuel and air flows into the respective fuel and oxidizer passages. A method of making a
solid oxide fuel
cell device is also provided in which fluid
anode and
cathode materials are flowed into passages followed by liquid removal to thereby form anodes and cathodes in the passages.