A method for manufacturing metal-supported SOFCs with atmospheric plasma spraying (APS) is presented, making use of aqueous Suspension feedstock for the electrolyte layer and dry powder feedstock for the anode and cathode layers. The cathode layer was deposited first directly onto a metal Support, in older to minimize contact resistance, and to allow the introduction of added porosity. The electrolyte layers produced by Suspension plasma spraying(SPS) were characterized in terms of thickness, permeability, and microstructure, and the impact of substrate morphology on electrolyte properties was investigated. Fuel cells produced by APS were electrochemically tested at temperatures ranging from 650 to 750 degrees C. The Substrate morphology had little effect oil open circuit voltage, but substrates with finer porosity resulted in lower kinetic losses in the fuel cell polarization. (C) 2009 Elsevier B.V. All rights reserved.