Membrane electrode assembly in solid oxide fuel cells

A method of making a membrane-electrode assembly, comprising:

• a. providing a mechanical support structure having opposite first and second mechanical support structure layer surfaces, wherein said mechanical support structure is arranged in a first three-dimensional pattern, wherein said first three-dimensional pattern having a first set of features extending inward from said first mechanical support structure layer surface, and a second set of features extending inward from said second mechanical support structure layer surface opposite to said first mechanical support structure layer surface of said first three-dimensional pattern;
• b. depositing an electrolyte layer of substantially constant thickness to said mechanical support structure first layer surface and conforming with said mechanical support structure first three-dimensional pattern, wherein said electrolyte layer has opposite first and second electrolyte layer surfaces, wherein said electrolyte layer is arranged in a second three-dimensional pattern, wherein said second three-dimensional pattern has a first set of electrolyte features extending inward from said first electrolyte layer surface, and a second set of electrolyte features extending inward from said second electrolyte layer surface opposite to said first layer surface of said second three-dimensional pattern;
• c. depositing a first electrode layer adjacent and conforming to said first electrolyte layer surface;
• d. removing said first set of mechanical support structure features and a portion of said second mechanical support structure features, wherein a remaining portion of said second mechanical support structure features and said first set of electrolyte features are exposed to form a third three-dimensional pattern made from said first electrolyte features and said mechanical support structure;
• and
• e. depositing a second electrode layer adjacent and conformal within said second electrolyte layer surface and with said remaining second mechanical support features.