Faculty Advisor or Committee Member

Isa Bar-On, Advisor

Faculty Advisor or Committee Member

Marina R. Pascucci, Committee Member

Faculty Advisor or Committee Member

Robert N. Katz, Committee Member

Faculty Advisor or Committee Member

Richard D. Sisson, Jr., Department Head




"Planar Solid Oxide Fuel Cell manufacturing can be considered in the pilot plant stage with efforts driving towards large volume manufacturing. The science of the solid oxide fuel cell is advancing rapidly to expand the knowledge base and use of material combinations and layer forming methods for the unit cell. Few of the many processing methods, over 15, reported in literature for layer formation are used today in high volume manufacturing. It is difficult to establish future market demand and cost levels needed to plan a course of action today. The need to select amongst different designs, materials and processes will require a tool to aid in these decisions. A modeling tool is presented to robustly compare the various process combinations and manufacturing variable to make solid oxide fuel cells in order to identify key trends prior to making strategic investment decisions. The ability to accurately forecast investment requirements and manufacturing cost for a given high volume manufacturing (HVM) process based on expected volume is critical for strategic decisions, product placement and investor communications. This paper describes the use of an updated process based cost model that permits the comparison of manufacturing cost data for various process combinations, production volumes, and electrolyte layer thickness tolerances. The effect of process yield is addressed. Processing methods discussed include tape casting, screen printing and sputtering."


Worcester Polytechnic Institute

Degree Name



Materials Science & Engineering

Project Type


Date Accepted





solid oxide fuel cell, sofc, mulit-layer ceramics, PBCM, fuel cell, cost model, process based cost model, Fuel cells, Manufacture, Costs, Cost, Mathematical models, Ceramic materials