The invention relates to a method of making fuel cell devices. Anode and cathode layers are applied on respective first and opposing second sides of a first portion of a first green ceramic layer, and a second green ceramic layer of thickness approximately equal to that of the anode and cathode layers is applied on a second portion of each of the first and second sides of the first green ceramic layer. A sacrificial layer is applied over each of the anode, cathode and second green ceramic layers, and a third green ceramic layer is applied over the sacrificial layers. The layered structure is heated to sinter all the layers and burn out the sacrificial layers. A pair of gas passages is thus formed with a thick sintered ceramic therebetween as a passive supporting portion and an anode, thin electrolyte and cathode therebetween as an active portion of the device.