Solid oxide fuel cells (SOFC), with its ability to use hydrocarbon fuels and capability to offer highest efficiency, have attracted great attention in India in recent years as an alternative energy generation system for future. But a great deal of problems associated with SOFC is needed to be solved before it can find commercial application. The relatively high operating temperature of 800-1000 degrees C of SOFC imposes a stringent requirement on materials that significantly increases the cost of SOFC technology. Reducing the operating temperature of an SOFC to below 800 degrees C can reduce degradation of cell components, improve flexibility in cell design, and lower the material and manufacturing cost by the use of cheap and readily available materials such as ferritic stainless steel. The operating temperature can be reduced by two possible approaches: (i) developing alternative electrolyte materials with high ionic conductivity at lower temperature, and (ii) developing much thinner and denser electrolyte layer such that the ohmic losses are minimised. In this work we report the use of inexpensive Electrophoretic deposition (EPD) technique in making about 10 micron thin and dense YSZ electrolyte on NiO-YSZ substrate. The effect of different operating parameters such as applied voltage, deposition time etc have been optimised during deposition from YSZ suspension in acetylacetone. The YSZ/NiO-YSZ bi-layers were then co-sintered at 1450 degrees C for 5 h. The single SOFC cells were then fabricated by brush painting LSM:YSZ (50:50) paste on the electrolyte layer followed by sintering at 1200 degrees C for 2 h. The single SOFC cell when tested using H(2) as fuel and ambient air as oxidant exhibited an open circuit voltage (OCV) of 1.03 V and the peak power density of about 624 mW/cm(2) at 800 degrees C. Copyright (C) 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.