Advanced Layer Fabrication Technologies in Solid Oxide Fuel Cells: From Traditional Methods to Additive and Thin-Film Strategies

This review examines modern approaches to layer formation in solid oxide fuel cells (SOFCs), focusing on traditional, thin-film, and additive manufacturing methods. A systematic comparison of technologies, including slip casting, screen printing, CVD, PLD, ALD, HiPIMS, inkjet, aerosol, and microextrusion printing, is provided. It is shown that traditional methods remain technologically robust but are limited in their capabilities for miniaturization and interfacial architecture design. Modern thin-film and additive approaches provide high spatial accuracy, improved ion-electron characteristics, and flexibility in the design of multilayer structures; however, they require addressing issues related to scalability, ink stability, interfacial compatibility, and reproducibility. Particular attention is paid to interfacial engineering methods, such as functionally graded layers, nanostructured infiltration, and temperature-controlled 3D printing. Key challenges are discussed, including thermal instability of materials, the limited gas impermeability of ultra-thin electrolytes, and degradation during long-term operation. Development prospects lie in the integration of hybrid methods, the digitalization of deposition processes, and the implementation of intelligent control of printing parameters. The presented analysis forms the basis for further research into the scalable and highly efficient production of next-generation SOFCs designed for low-temperature operation and long-term operation in future energy systems.