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Research Project Information

Research Project Summary Information

A Feasibility Study of 3 Dimensional Printing of Micro-Tubular Solid Oxide Fuel Cells "Single Step"(28241)

Watt Fuel Cell Corporation


A large problem with the fuel cell industry is the cost of goods sold (COGS) of its products; therefore, the industry has not been able to effectively penetrate significantly into any markets without the use of government subsidies. WATT Fuel Cell Corporation recognizes that reducing the cost of its production of fuel cells is critical to reach commercial energy markets, and to meet market expectations as a viable energy solution. Processes to make micro-tubular Solid Oxide Fuel Cells (SOFC) have been developed in the past 20 years and are well known but are not cost effective, as costs range from nearly $12 to $100 per watt for the system installation. Furthermore, some fuel cell technologies require hydrogen as the fuel, which requires additional fuel infrastructure modifications.

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Project Description

The objective of this project is to test the feasibility of a new manufacturing process for SOFC called Single Step Process (SSP). The new manufacturing process is to create multi-layered, tubular structures during a single spray forming operation with automated, user-defined controls.


The result will enable WATT to build its pilot manufacturing process, which is to be completed after this project. If successful, the SSP will realize significant energy savings through the reduction of the number of times the SOFC will be put into the kiln. The total time for production and the utilization of materials are also improved if more processing steps are removed and included in the SSP. Furthermore, the efficiency of cell production is also expected to increase using the SSP.

Project Results


Watt Fuel Cell Corporation
27 Seaview Boulevard
Port Washington, NY 11050

Principle Investigator

Benjamin Emley

Universities Involved


Project Type:

Research Study

Technologies Types:

Energy Power Supply
Fuel Cell

NYSERDA Contact Information

Davetta Thacher


R&D - Mfg Tech & On-Site Pwr

Contract Details

Start Date: 10/17/2012
Project Status: Active
Contract Number: 28241

Last Updated: 3/18/2014