Cost effective high volume manufacture (HVM) is a major challenge to the success of solid oxide fuel cells (SOFCs). More than fifteen processing methods have been reported in the literature many of which could be used in various combinations to create the desired product characteristics. Modeling tools are needed to aid in the selection of the appropriate process combination prior to making expensive investment decisions.
This paper describes the development of a multi-process cost model that permits the comparison of manufacturing cost for different processing combinations and various materials. Two specific processing methods are discussed, tape casting and screen printing.
The results are compared with data and experience from the fuel cell and electronic packaging industries. Initial comparisons show good agreement with this experience base. Sensitivity of manufacturing costs to SOFC performance requirements such as maximum power density and operation temperature is investigated.