We report a cost-effective processing method for fabricating intermediate temperature solid oxide fuel cells (SOFCs) with Ni-samaria doped ceria (SDC) anode. First, SDC and NiO powders were mechanically treated to make their composite powder. Then, the composite powder was applied into a ceramic tape casting method to form a thick layer for the anode supporting. Finally, an anode supported single cell with a configuration of Ni-SDC/SDC/La0.6Sr0.4CO0.2Fe0.8O3-delta (LSCF) was prepared. Because of the usage of the composite powder, homogenous distribution and connection of each Ni and SDC were achieved. Peak power densities of 460, 750 and 910mW cm(-2) were obtained on the single cell at 550, 600 and 650 degrees C, respectively. (c) 2006 Elsevier B.V. All rights reserved.