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The metal‐supported solid oxide fuel cell (MS‐SOFC) consisting of a porous Ni‐Mo as metal‐support, a La0.75Sr0.25Cr0.5Mn0.5O3–δ (LSCM) as diffusion barrier layer, a nano‐structured Ce0.55La0.45O3–δ (LDC)‐Ni as anode layer, a LDC as anode interlayer, a La0.8Sr0.2Ga0.8Mg0.2O3–δ (LSGM) as electrolyte, a Sm0.15Ce0.85O3–δ (SDC) as cathode interlayer, a 50 wt.% SDC–50 wt.% Sm0.5Sr0.5CoO3–δ (SSC) as composite cathode interlayer and a 25 wt.% SDC–75 wt.% SSC as cathode current collector are prepared by atmospheric plasma spraying (APS). The 25 cm2 cell delivers maximum power densities of 962 and 1,119 mW cm−2 at 700 and 750 °C. The durability, thermal cycling and redox cycling tests of this cell show the cell have good durability, thermal cycle stability and redox stability. The assembled single cell stack of 100 cm2 cell shows electric output powers of 39 W (481 mW cm−2) and 27.4 W (338 mW cm−2) at 750 °C and 700 °C. The long‐term stability test of this single cell stack shows a degradation rate of about 0.77% k−1 h−1 over 1,770 h at 400 mA cm−2 and 700 °C. Furthermore, a 25‐cell MS‐SOFC stack is assembled to evaluate the power performance and it shows a stack power of 829.8 W at 19.85 V and 740 °C.

We report a freestanding micro solid oxide fuel cell with both the anode and cathode deposited using electrostatic spray deposition (ESD) technique. The cell is consisted of dense yittria‐stabilized zirconia (YSZ) electrolyte (100 nm thick), porous lanthanum strontium manganite (LSM)–YSZ cathode (∼3 μm thick), and porous NiO‐YSZ anode (∼3 μm thick). LSM‐YSZ and NiO‐YSZ composite powders were initially prepared by glycine nitrate process and super‐critical fluid processes, respectively, and both cathode and anode layers were deposited by the ESD. The resulting freestanding micro cell exhibited an open circuit voltage close to the theoretical value of 1.09 V, and a maximum power density of 41.3 mWcm–2 at 640 °C.