A Process Based Cost Model for Multi-Layer Ceramic Manufacturing of Solid Oxide Fuel Cells

Planar Solid Oxide Fuel Cell (SOFC) 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, > 15, reported in literature for layer formation are used today in high volume manufacturing. For this reason it is difficult to establish future market demand and cost levels needed to plan a course of action. The need to select amongst different designs, materials and processes will require a robust tool to identify key trends in the various process combinations and manufacturing variables 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 values. The effects of process yield and