The present invention relates to a method of making fuel cell devices. A stack structure is formed having plural ceramic layers, anode layers, cathode layers, and sacrificial layers, where the sacrificial layers are sized to provide internal gas passages. Removable structures are placed in contact with the sacrificial layers and extend to an edge. After laminating the stacked structure, the removable structures are pulled out to form bake-out paths that facilitate removal of the sacrificial material during a heating step, which paths are later sealed.