Solid oxide fuel cells with 3d inkjet-printed microstructures and method for fabricating the same

A solid oxide fuel cell, comprising:

• an anode layer comprising yttria-stabilized zirconia (YSZ) and NiO;
• an electrolyte layer comprising YSZ deposited upon the anode layer;
• a plurality of microstructures comprising a microstructure material and deposited upon the electrolyte layer, each microstructure composed of a plurality of layers of microstructure ink that have been applied by an inkjet printing system and sintered, the microstructure ink comprising YSZ;
• and
• a cathode layer deposited upon the electrolyte layer and the plurality of microstructures, the cathode layer comprising lanthanum strontium manganite (LSM) and YSZ;
• wherein each microstructure of the plurality of microstructures is shaped like a conical frustum having a first base and a second base, wherein the first base is substantially parallel to the second base, and wherein the microstructure is coupled to the electrolyte layer through the second base, and
• wherein a ratio between an area of the first base and an area of the second base is less than 0.5.