A polyvinyl alcohol assisted combustion synthesis method was used to prepare Ce0.8Sm0.2O2-delta (SDC) powders for an intermediate temperature solid oxide fuel cell (IT-SOFC). The XRD results showed that this combustion synthesis route could yield phase-pure SDC powders at a relatively low calcination temperature. A thin SDC electrolyte film with thickness control was produced by a dry pressing method at a lower sintering temperature of 1250 degrees C. With Sm0.5Sr0.5Co3-SDC as the composite cathode, a single, cell based on this thin SDC electrolyte was tested from 550 to 650 degrees C. The maximum power density of 936 mW cm(-2) was achieved at 650 degrees C using humidified hydrogen as the fuel and stationary air as the oxidant. (c) 2006 Elsevier B.V. All rights reserved.