Fabricating a large-area unit cell is very important for the development of solid oxide fuel cell (SOFC) stack. In this study, details of sintering process of half cell with NiO-yttria stabilized zirconia (YSZ) anode-supported YSZ thin electrolyte film fabricated by co-tape casting have been discussed. The results demonstrates that the shrinkages and shrinking rates mismatches between the electrolyte and the anode can be controlled by the organic additive content in the anode slurry composition and heating rate. Low heating rate suppresses the cracks formation in the electrolyte films. A warp-free unit cell with size of 100 x 100 mm(2) and dense electrolyte has been successfully fabricated. A power of 22.2 W, with a power density of 0.27 W cm (2) has been achieved at 0.7 V and 750 degrees C in O-2/humidified H-2 atmosphere. The area specific resistance of the cell is 1.20 Omega cm(2) at 0.7 V and 750 degrees C. Copyright (C) 2012, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.