We developed an innovative processing technology, liquid condensation process (LCP) to produce thin and large size anode substrate with very high uniformity which allowed easy manipulation of the microstructure and/or pore structure of anode substrate. The anode substrate made with LCP had very homogeneous microstructure, which would be helpful to induce homogenous physico-chemical properties of the anode substrate. Microstructure of anode substrate was critically evaluated in terms of pore structure development by varying compaction pressure. According to electrical and microstructural characterizations of the anode substrate, the physico-chemical properties of the anode substrate including gas permeability and electrical conductivity were closely related with the microstructure and/or pore structure of anode substrate. Proper method to manipulate the processing variables to control the microstructure of anode substrate to achieve superior performance of solid oxide fuel cell was discussed. (C) 2003 Elsevier B.V. All rights reserved.