Screen-printing technology was developed to fabricate gas-tight yttria-stabilized zirconia (YSZ) electrolyte films on porous NiO-YSZ anode substrates for use in solid oxide fuel cells (SOFCs). Several key process parameters such as the starting YSZ powder, printing ink composition, printing time and sintering temperature were studied and reported in detail. SEM results revealed that the selected process parameters exerted obvious influences on the microstructure of the screen-printed YSZ films. Open-circuit voltages (OCVs) were used to evaluate the usage feasibility of screen-printed YSZ films in SOFCs. Cell performance test results showed that the above-mentioned parameters had crucial effects on the OCVs and power density of the prepared cells. Based on appropriate parameters, an OCV value of 1.081 V and a power density of 0.96 Wcm(-2) were obtained at 800 degrees C using hydrogen as fuel and ambient air as oxidant. (c) 2006 Elsevier B.V. All rights reserved.