anode as the support structure for the cell, with an electrolyte thin film deposited on it. [6][7][8] The deposited thin film electrolyte layer should be dense and pore free to prevent gas from leaking through it; also to prevent the shorting of the cell. It is also preferred that highly porous electrodes be used, in order to further increase the gas transport rate.SOFCs which utilize the anode or cathode (composed of oxide materials) as the support for the cell do show several weaknesses, as compared to traditional high operating temperature SOFCs. These include: weak structure, brittleness, internal differences in thermal expansion (during the reduction process of the oxide anode), high fabrication temperatures, low cell output power density, and high fabrication cost. [9,10] In addition to the mentioned shortcomings, the issue of preventing fuel leaks is the most challenging for the reported thin electrolyte SOFCs.In the present work, the fuel cell's operating temperature (<450 °C), physical structure, and output power density were all enhanced, while the fabrication costs were lowered remarkably. This was achieved by the fabrication of a low-cost 3D porous nickel anode which possesses a very flat surface with nanopores onto which a dense continuous thin film electrolyte layer can be deposited to form the TFSOFC, the schematic of which is shown in Figure 1. The fabricated porous nickel anode can be machined, soldered or welded, and does not require a reduction process.A 3D porous nickel anode with a flat nanoporous surface was fabricated using the process shown in Figure 2a, by thoroughly mixing commercial nickel powder (particle size between 1 and 3 µm) with an ammonium bicarbonate (particle size of from 100 to 500 nm) proppant. The mixing of the two components must be thorough; therefore, it is typically performed by mechanical mixing and ball milling procedures. The resulting mixture (nickel powder and proppant) is then pressed into a parallel faced ≈1 mm thick square tablet at 5000 psi (see Figure 2b). The tablets can be pressed into any shape required for an anode, and fuel channels can be included in the processing as shown in insert of Figure 2b. The tablet of pressed nickel powder/proppant is then loaded into a high temperature tubular furnace and sintered at 800 °C for 2 h in an ambient hydrogen/argon atmosphere (1:9%).The surface of the sintered nickel sample is microscopically rough and contains average pores sizes of several hundred nm. Such a surface, despite having the required pore structure, is much too rough to be effectively coated with a uniformly thin A simple fabrication process for a 3D porous nickel anode for a thin film solid oxide fuel cell (SOFC) is developed. The 3D porous nickel anode is fabricated using a metal/proppant mixing method followed by pressing and heat treatment. The anode bulk possesses a high porosity which is required for efficient delivery of fuel to the cell. Following fabrication, the anode's surface is processed by means of mechanical, chemical, and ion etching to...