Due to the poor redox cycling resistance of the second generation of mu-SOFCs, a new generation of SOFC has been recently developed using a porous electrolyte-supported structure to overcome this problem. In this research, the porous structure was successfully fabricated with slip casting using calcined YSZ (ZrO(2) + 8 mol% Y(2)O(3)) with or without graphite as a pore former. Calcination of YSZ powder at 1300-1500 degrees C prior to making the slip leads to growth of YSZ crystals and particle size which results in a decrease in surface area and powder sinterability. This was found to be an important criterion in developing the porous structure as, due to the high sinterability of non-calcined YSZ. even the addition of graphite is inadequate to generate sufficient open porosity. A dense YSZ electrolyte layer was immediately coated on the porous structure using YSZ calcined at 1300 degrees C with a sequential slip casting method. Sample thickness was found to be a function of both graphite content as well as YSZ calcination temperature. Physical properties of the porous YSZ supports and SEM analysis of the support and coated electrolyte are presented. Crown Copyright (C) 2010 Published by Elsevier B.V. All rights reserved.