Apatite type rare earth silicates are being extensively studied as electrolyte material for intermediate temperature solid oxide fuel cells (SOFC). In this paper we presents results on synthesis of Al and/or Fe-doped ATLS, the design of compatible anode materials, thermal expansion properties and co-sintering of half-cells from expansion matched materials using the advanced pulsed electric current sintering (PECS) technique. The issues related to the co-sintering of half cells have been addressed successfully by the combined use of nano powders and PECS. (C) 2010 Elsevier B.V. All rights reserved.