In this study, solid oxide fuel cells (SOFCs) consisting of a NiO-YSZ anode, a NiO/YSZ-YSZ functional layer, YSZ electrolyte and a (La0.8Sr0.2)MnO3 + yttria-stabilized zirconia (LSM-YSZ) cathode were fabricated by tape-casting, lamination, and a co-firing process. NiO/YSZ-YSZ nano-composite powder was synthesized for the anode functional layer via the Pechini process in order to improve cell performance. After optimization of the slurries for the anode functional anode, electrolyte and cathode, all components were casted so as to fabricate the monolithic laminate. The co-firing temperature was optimized to minimize second phase formation between the (La0.8Sr0.2)MnO3 (LSM) and yttria-stabilized zirconia (YSZ) and to increase the sinterability of the YSZ electrolyte. The YSZ electrolyte was fully sintered with the addition of 0.5 wt% CuO, and the second phases of La2Zr2O7 and SrZrO3 did not form at 1350 degrees C. Ni-YSZ anode-supported unit cells were fabricated by co-firing at 1250-1400 degrees C. The unit cells co-fired at 1250 degrees C, 1300 degrees C, 1325 degrees C, 1350 degrees C and 1400 degrees C had maximum power densities of 0.18, 0.18, 0.30, 0.46 and 0.036 W/cm(2), respectively, in humidified hydrogen (similar to 3% H2O) and air at 800 degrees C. Copyright (C) 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.