Low-cost, colloidal deposition methods have been utilized to produce novel solid oxide fuel cell (SOFC) structures on metal alloy support electrodes. Yttria-stabilized zirconia (YSZ) films were deposited on iron-chrome supports on top of a thin Ni/YSZ catalytic layer, and sintered at 1350degreesC, in a reducing atmosphere. Dense, 20 mum YSZ electrolyte films were obtained on highly porous stainless steel substrates. Metal-supported fuel cells were tested at 800 and 900degreesC, achieving power densities of over 200 mW/cm(2) at 900degreesC using platinum paste cathodes. The cells have shown excellent resistance to thermal cycling, and open up a low-cost path to SOFC commercialization. (C) 2003 The Electrochemical Society.