Advanced fabrication strategies for Durable, High-Efficiency, and scalable solid oxide fuel cells

Authors

• Abid Ullah
• Shahbaz Ahmad, University of Sharjah
• Tahir Ali, University of Peshawar
• Ayesha Samreen, University of Peshawar
• Saim Saher, Universiti Malaya
• Muhammad Zulqarnain Arif, Tickle College of Engineering
• Arunachala M. Kannan, Ira A. Fulton Schools of Engineering

Document Type

Review

Publication Date

3-1-2026

Abstract

Solid oxide fuel cells offer high efficiency, fuel flexibility, and strong sustainability potential, yet their commercialization is still constrained by fabrication complexity, cost, and durability challenges. This review provides a comparative assessment of both conventional and emerging SOFC fabrication techniques for electrolytes, electrodes, and interconnects, with emphasis on how processing affects microstructure and overall electrochemical performance. Key methods such as tape casting, screen printing, vapor phase deposition, plasma spraying, electrophoretic deposition, electroless plating, inkjet printing, and advanced additive manufacturing are evaluated in terms of scalability and industrial relevance. The role of artificial intelligence in optimizing fabrication parameters is also highlighted as an increasingly important direction. By integrating high precision yet cost intensive processes with scalable and economically practical routes like tape casting and screen printing, this review outlines a forward-looking pathway toward high performance, durable, and commercially viable SOFC technologies.

Publication Title

Fuel

ISSN

00162361

DOI

10.1016/j.fuel.2025.137515

Recommended Citation

Ullah, Abid; Ahmad, Shahbaz; Ali, Tahir; Samreen, Ayesha; Saher, Saim; Arif, Muhammad Zulqarnain; and Kannan, Arunachala M., "Advanced fabrication strategies for Durable, High-Efficiency, and scalable solid oxide fuel cells" (2026). Research Publications (2026 to 2030). 189.
https://knova.um.edu.my/research_publications_2026_2030/189

Volume

407