A simple and cost-effective method, starting with electrophoretic deposition (EPD) on a carbon sheet, has been developed for preparation of a NiO-YSZ anode and thin, gas-tight YSZ electrolyte layer on it for use in solid oxide fuel cells (SOFCs). The innovative feature of this approach enables the deposition of anode materials as well as the YSZ electrolyte, which were subsequently co-fired in air at high temperatures to remove the carbon and form an anode-supported dense YSZ electrolyte. A functional SOFC constructed by brush painting a layer of mixed cathode consisting of La0.8Sr0.2MnO3 (LSM) and YSZ on the electrolyte layer followed by firing at 1250 degrees C, displayed a peak power density of 434 mW cm(-2) at 800 degrees C when tested with H-2 as fuel and ambient air as oxidant. (c) 2006 Elsevier B.V. All rights reserved.