Screen-printing technology was developed to fabricate Ce0.8Sm0.2O1.9 (SDC) electrolyte films onto porous NiO-SDC green anode substrates. After sintering at 1400 degrees C for 4 h, a gas-tight SDC film with a thickness of 12 mu m was obtained. A novel cathode material of Ba0.5Sr0.5Co0.8Fe0.2O3-delta Was subsequently applied onto the sintered SDC electrolyte film also by screen-printing and sintered at 970 degrees C for 3 h to get a single cell. A fuel cell of Ni-SDC/SDC (12 mu m)/Ba0.5Sr0.5Co0.8Fe0.2O3-delta provides the maximum power densities of 1280, 1080, 670, 370, 180 and 73 mW cm(-2) at 650, 600, 555, 505, 455 and 405 degrees C, respectively, using hydrogen as fuel and stationary air as oxidant. When dry methane was used as fuel, the maximum power densities are 876, 568, 346 and 114 mW cm(-2) at 650, 600, 555 and 505 degrees C, respectively. ne present fuel cell shows excellent performance at lowered temperatures. (c) 2006 Elsevier B.V. All rights reserved.