Electrolytes were deposited by atmospheric suspension plasma spraying (SPS) in metal-supported SOFCs having both anode- and cathode-down configurations. The electrodes on the metal supports were intentionally made thin (< 30 μm) and smooth (average roughness < 2.5 μm) to reduce the formation of segmentation cracks and concentrated porosity in the electrolytes. In the anode-down cells, the electrolytes had minimal concentrated porosity and no segmentation cracks were observed. Open circuit voltages (OCVs) were above 1.05 V at 750 °C in cells with 21 μm thick electrolytes. The electrolytes in cathode-down cells had higher leak rates than those in the anode-down cells, and segmentation cracks were observed in some cathode-down cell electrolytes. The cathode-down cells having the most gas-tight electrolytes were electrochemically tested. OCVs were initially above 1.04 V, though performance declined significantly within 2-4 hours. In contrast, the OCVs of the anode-down cells were approximately constant after 12 hours of testing.