Tubular solid oxide fuel cell (SOFC) systems have many desirable characteristics over their planar counter-parts. Anode-supported tubes provide an excellent platform for individual cells. They allow for a thin electrolyte layer to be applied to the outside of the tube, which helps to minimize polarization losses. This paper describes the fabrication of nickel-zirconia (Ni-YSZ)-based anode tubes via extrusion of a plastic mass through a die of the required dimensions. The anode tubes were then dried and fired. Tests were performed on the tubes to determine the effects of firing temperature on porosity to allow for a pinhole-free electrolyte coating to be applied. Thin layer coating techniques, including vacuum-assisted dip coating and painting, were compared. Ni-YSZ anode-supported tubular SOFCs with a gas-tight thin YSZ electrolyte layer were then realized. Microstructure of the anode support, electrolyte and cathode thin films was also examined. (C) 2004 Published by Elsevier B.V.