Thin-film Fabrication Methods Research Articles

UV Irradiation as a Versatile Low-Temperature Strategy for Fabricating Templated Mesoporous Titania Films.

Mesoporous titania thin films offer promising applications in sensors, batteries, and solar cells. The traditional soft templating methods rely on high-temperature calcination, which is energy-intensive, incompatible with thermosensitive flexible substrates, and destructive for titania structures. This work demonstrates UV irradiation as a versatile low-temperature and energy-saving alternative for mesoporous crystalline titania fabrication. Grazing incidence wide-angle X-ray scattering analysis reveals a three-stage crystallization process with increasing UV irradiation time supported by photoluminescence data. UV-irradiation-derived samples exhibit crystallinity and crystal size comparable to that of calcination. Integration with block copolymer templated sol-gel synthesis enables the creation of various morphologies, including cylindrical, ordered spherical, and hybrid structures. Characterizations via scanning electron microscopy and grazing incidence small-angle X-ray scattering confirm the homogeneity of morphology in the resulting films. The resulting films maintain similar optical properties despite morphological differences, as demonstrated by photoluminescence and UV-vis measurements. The versatility of UV irradiation extends to different titanium precursors, underscoring it as a flexible and efficient method for mesoporous titania thin film fabrication at low temperatures.

Simultaneous Solid Electrolyte Deposition and Cathode Lithiation for Thin Film Batteries

Interest in thin film solid state lithium-ion batteries (TFSSLIBs) continues to grow because of their increased safety over flammable liquid electrolytes and their compatibility with well-established thin-film fabrication methods and characterization techniques. TFSSLIBs are also attractive for addressing fundamental questions because they generally comprise fewer components (no binders or conductive additives), and are commonly used to investigate the formation and evolution of solid electrode/electrolyte interfaces. TFSSLIBs are well suited to study the inherent capacity retention and rate performance of cathode materials in a symmetric battery structure, e.g., cathode/SSE/cathode. V2O5 is a candidate with a high theoretical capacity and insertion chemistry of up to 3 Li ions per V2O5, but which practically is unable to achieve highly reversible cycling of even Li2V2O5 due to the structural phase change upon lithiation. By designing a TFSSLIB model system with a solid electrolyte that forms a stable electrode/electrolyte interface, e.g. lithium phosphorous oxynitride (LiPON), in a symmetric configuration, we are able to study the performance of LixV2O5 thin film cathodes without the additional deleterious effects related to anode performance.We will discuss the fabrication and cycling performance of two different symmetric V2O5 TFSSLIB configurations. The first is a V2O5/LiPON/LixV2O5 TFSSLIB, where the cyclable lithium in this system is included via simultaneous electrolyte deposition and lithiation of one V2O5 cathode during the RF sputtering process, as discussed in our recent publication.1 The second configuration is an LixV2O5/LiPON/LixV2O5 TFSSLIB where lithium is included during the auto-lithiation step of the first V2O5 electrode as well as during the co-sputtered deposition of the second V2O5 electrode. A comparison of the two TFSSLIB symmetric cell performances will be discussed, as well as a comparison to similar symmetric cells cycled in liquid electrolyte. We show that the deposition of the solid-state electrolyte LiPON onto thin film V2O5 leads to a uniform lithiation of up to 2.2 Li per V2O5, without affecting the Li concentration in the LiPON and its ionic conductivity. In the LixV2O5/LiPON/LixV2O5 system, we demonstrate cycling of >270 mAh/g at a rate of 20C, for 1600 cycles with only 8.4% loss in capacity.1. Warecki, Z. et. al., Simultaneous Solid Electrolyte Deposition and Cathode Lithiation for Thin Film Batteries and Lithium Iontronic Devices, ACS Energy Lett, 2024, 9, 2065-2074

Fabrication of Zinc Oxide Thin Films by Sol-Gel Dip Coating Process

Zinc oxide (ZnO) is a non-toxic material known for its distinctive physical and chemical properties, including a direct band gap energy of 3.37 eV and a large exciton binding energy of 60 meV, which contribute to its significant thermal and chemical stability at room temperature. Due to these characteristics, ZnO plays a critical role in various applications, such as UV light emitters, transparent conducting thin films in electronic devices, gas sensors, piezoelectric materials, transducers, and as a transparent conductive oxide (TCO) layer in thin-film photoelectrochemical cells. Numerous fabrication techniques have been employed to produce ZnO thin films. However, many of these methods require costly equipment, high vacuum environments, and elevated temperatures. In contrast, the sol-gel process stands out as a convenient, cost-effective, and versatile method for ZnO thin film fabrication. It offers advantages such as simplicity, low crystallization temperature, ease of reproducibility, molecular-level homogeneity, and precise compositional control. In this study, ZnO thin films were deposited onto Indium Tin Oxide (ITO) glass substrates using the sol-gel dip coating method, with varying preparative parameters: sol concentrations and annealing temperatures. The resulting samples were characterized using a UV-visible spectrophotometer, X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), and energy dispersive X-ray spectroscopy (EDX). The results demonstrated that the unique properties of ZnO thin films are highly dependent on the preparative parameters. Specifically, the band gap energy decreased from 3.25 eV to 3.18 eV with increasing sol concentration and also showed a similar decline with higher annealing temperatures. XRD patterns revealed a smaller full width at half maximum (FWHM) of the most intense peak (002) at higher sol concentrations and annealing temperatures, indicating an increase in crystallite size. FESEM images highlighted distinct morphological changes corresponding to the variations in sol precursor concentration and annealing temperature, while EDX analysis confirmed the formation of highly pure ZnO thin films on ITO glass substrates.

Crystallization Morphology and Self-Assembly of Polyacrylamide Solutions During Evaporation

This study investigates the crystallization and self-assembly phenomena of polyacrylamide (PAM) solutions during evaporation. While traditional thin-film fabrication methods such as spin coating and drop casting are commonly used, this study utilizes a simple evaporation approach to gain insights into the self-assembly processes of PAM solutions. We examined PAM solutions with varying concentrations (1%, 2%, and 5%) and observed the resulting crystalline structures and morphological changes during evaporation. Spectroscopic absorbance measurements were employed to analyze concentration gradients and crystallization patterns. The findings reveal that the concentration gradient during evaporation significantly impacts the crystallization behavior of PAM solutions. The 2% solution exhibited the clearest and most regular crystalline patterns, whereas the 1% and 5% solutions displayed more complex and irregular morphologies. These observations provide new insights into how solution concentration influences PAM crystallization, contributing to a better understanding of polymer thin-film self-assembly. The novelty of this study lies in exploring PAM self-assembly through controlled evaporation, offering valuable insights for the development of polymer films.

Highly Conformal Solid Electrolyte for Li-Ion Batteries By Atomic Layer Deposition

Lithium phosphorus oxynitride (LiP x O y N z , commonly known as LiPON) is a state-of-the-art solid electrolyte material with suitably low resistivity and high ionic conductivity for all-solid-state thin-film microbatteries [1,2]. Thin and pinhole-free layers of LiPON can be fabricated using atomic layer deposition (ALD) [3]. Uniquely among thin-film fabrication methods, ALD is a technique that works for coating even challenging 3D interfaces [4,5]. In this work, LiPON ALD processes were optimized for two different lithium precursors at reasonable temperatures (~300 °C) and precursor pulse/purge lengths (< 5 s), and LiPON films were deposited onto PillarHall® lateral high-aspect-ratio (LHAR) test structures to investigate the conformality of the material. Comparative testing was performed between the two lithium precursors.The results indicated that more conformal LiPON films can be deposited using the appropriate precursors – in this case, lithium tert-butoxide (LiO t Bu) yielded greater penetration depths than lithium hexamethyldisilazide (Li-HMDS). The improved conformality observed when using LiO t Bu indicates that this precursor is a better choice for LiPON coatings on high-aspect-ratio structures. The ALD technique allowed for the deposition of highly conformal LiPON films, ~50–115 µm deep into 100–500 nm gaps. This opens possibilities for the use of LiPON as a solid electrolyte in batteries with high-surface-area electrodes. High surface areas are important not only for unlocking higher power densities (faster charging and discharging) in batteries, but also for enabling the use of thin-film technology in fabricating microbatteries with meaningful energy storage capacities.

Recent Advances and Challenges in Thin-Film Fabrication Techniques for Low-Temperature Solid Oxide Fuel Cells

Solid oxide fuel cells (SOFCs) are amongst the most widely used renewable alternative energy systems with near-zero carbon emission, high efficiency, and environment-friendly features. However, the high operating temperature of SOFCs is still considered a major challenge due to several issues regarding the materials’ corrosion, unwanted reactions between layers, etc. Thus, low-temperature SOFCs (LT-SOFCs) have gained significant interest during the past decades. Despite the numerous advantages of LT-SOFCs, material selection for each layer is of great importance as the common materials have not shown a desirable performance so far. In addition to the selection of the materials, fabrication techniques have a great influence on the properties of the SOFCs. As SOFCs with thinner layers showed lower polarisation resistance, especially in the electrolyte layer, different thin-film fabrication methods have been employed, and their effect on the overall performance of SOFCs has been evaluated. In this review, we aim to discuss the past and recent progress on the materials and thin-film fabrication techniques used in LT-SOFCs.

Fabrication of flexible carbon heaters and silver interdigitated electrodes using ink-jet printing technology for electro-chemical gas sensor applications

PurposeThe purpose of this paper is to deal with an identification of a novel ink-jet printing sensor fabrication technology for fabricating flexible carbon heaters of macro and micro sizes, carbon interdigitated (IDT) electrodes and silver IDT electrodes. The technology involved in the proposed ink-jet printing method and materials used for the formulation of homemade nano-conductive inks (digital inks) are discussed in detail. The ink-jet printed flexible carbon heaters of different sizes (macro and micro) and carbon IDT electrodes and flexible silver IDT electrodes can be used as the flexible sensing layers in electrochemical gas sensors for sensitive and selective gas sensing applications. The characterization of ink-jet printed carbon heaters on Kapton substrate and its results are discussed. Similarly, the results of formulation of silver nano-conductive ink and printing of silver IDT electrodes on Kapton and its characterization are reported here for the first time.Design/methodology/approachFlexible carbon heaters of different sizes (macro and micro), carbon micro-IDT electrodes and silver IDT electrodes patterns were developed using AutoCAD 2D and printed on the Kapton (polyimide sheet) flexible substrate using the home-made nano-conductive inks with the help of EpsonT60 commercial piezo-head-based drop-on demand technology printer with standard printing options.FindingsThe proposed novel method is able to print heater patterns and IDT electrode patterns of approximately 12 µm and approximately 1 µm thickness, respectively, on flexible substrate using the home-made nano-conductive inks of carbon and silver by using a commercial low-cost printer. The home-made nano-conductive inks can be re-used for multiple prints up to six months shelf life. The resistance of the carbon heater was measured as 88 O under normal atmospheric condition. The novel flexible carbon heater was tested for its functionality and found to be satisfactory. The resistance of the silver IDT flexible electrodes was measured as 9.5 O which is better than the earlier works carried out in this paper.Research limitations/implicationsThe main challenge is associated with cleaning of printing ink ejection system in the existing commercial printers. The customization of the existing printer in the near future can minimize the printing challenges.Practical implicationsThe novel ink-jet printing technology proposed in this work is cost-effective, capable of achieving bulk production of flexible sensor elements, and consumes the least device fabrication time and high material yielding. The printing can be done with commercial piezo-head-based ink-jet printers with custom-prepared nano-conductive inks. There is a huge market potential for this paper.Originality/valueBoth the carbon heaters and silver IDT electrodes were printed on Kapton flexible substrate by using the commercial printer for the first time. The paper is promising the revolution in flexible low-cost sensor fabrication for mass production, and it is an alternate for thin film and thick sensor fabrication methods. The future of sensor fabrication technology will be the ink-jet printing method. In this paper, the research developments of flexible carbon heaters and flexible silver IDT electrodes for the time are reported. The characterization of carbon heaters and silver IDT electrodes were carried out and confirmed that the results are favourable for gas sensor applications.

MXenes Thin Films: From Fabrication to Their Applications.

Two-dimensional MXenes possessed exceptional physiochemical properties such as high electrical conductivity (20,000 Scm−1), flexibility, mechanical strength (570 MPa), and hydrophilic surface functionalities that have been widely explored for energy storage, sensing, and catalysis applications. Recently, the fabrication of MXenes thin films has attracted significant attention toward electronic devices and sensor applications. This review summarizes the exciting features of MXene thin film fabrication methods such as vacuum-assisted filtration (VAF), electrodeposition techniques, spin coating, spray coating, dip-coating methods, and other physical/chemical vapor deposition methods. Furthermore, a comparison between different methods available for synthesizing a variety of MXenes films was discussed in detail. This review further summarizes fundamental aspects and advances of MXenes thin films in solar cells, batteries, electromagnetic interference shielding, sensing, etc., to date. Finally, the challenges and opportunities in terms of future research, development, and applications of MXenes-based films are discussed. A comprehensive understanding of these competitive features and challenges shall provide guidelines and inspiration for further growth in MXenes-based functional thin films and contribute to the advances in MXenes technology.

Solvent-Induced Crystallization Method for High-Performance and Long-Term Stability Flexible Perovskite Photodetectors

Herein, we report a novel solvent-induced fabrication method to synthesize a perovskite thin film on flexible substrates. The high-quality CH3NH3PbI3 (MAPbI3) thin film is successfully fabricated, which is applied to prepare the stable flexible photodetector (PD). Compared with the reported results, this method achieved a low-temperature and low-cost perovskite thin film fabrication process on a flexible substrate. The constructed MAPbI3 layer possesses the advantages of being highly crystalline, uniform, and compact in a large area. The flexible PD based on the as-prepared perovskite thin film exhibits excellent performance and long-term stability. The EQE and R of the flexible PDs reached 8 × 102% and 3.6 A/W, respectively. At the same time, the flexible PDs still showed superior stability and high performance after 15 days of continuous working. The presented high-quality perovskite thin-film fabrication method and high-performance flexible perovskite PDs are expected for application in the development of novel optoelectronic devices.

Aerosol-deposited freestanding Na3V2(PO4)3 thin-film microbattery

High energy density on chip microbatteries that can provide necessary power capability is highly sought to power miniaturized and smart electronics. Currently, various thin-film electrode fabrication methods are struggling to upscale the production. Herein, a thin all-electrochemical-active sodium-ion electrode consisting of Na3V2(PO4)3 and carbon is prepared using aerosol deposition method without postthermal treatment. The freestanding Na3V2(PO4)3 thin film exhibits an increase in charge transfer efficiency, higher sodium ions diffusion coefficient, and a smaller overpotential than conventional bulk electrode. Consequently, the thin-film half-cell delivers a high reversible areal capacity of 32.2 μAh/cm2, a high energy density of 0.106 mWh/cm2, at 96.4 μA/cm2, and an excellent cyclic stability (88.6% after 1000 cycles at 100 μA/cm2). In addition, the full cell delivers a high initial energy density of 213.6 Wh/kg at 15.8 W/kg. This work presents a viable process to prepare a high-performance electrode thin film for practical application.

Development of device to study evaporation behavior of micro-droplets at high temperatures.

Leidenfrost phenomenon is one of the unique behaviors of droplets. In Leidenfrost phenomenon, liquid closing to a surface that is significantly hotter than the liquid's boiling point, produces an insulating vapor layer that keeps the liquid from boiling rapidly. This non-contact state between the droplet and the hot surface leads to the decrease in heat transfer and the increase in evaporation time. This phenomenon occurs for the micro-order droplets. For example, it is influence the combustion efficiency of the engine in which fuel sprayed. For another example, the mist CVD, which is one of the functional thin film fabrication methods, also makes a good use of the Leidenfrost phenomenon to make high quality thin films. This has been indirectly proven by the previous experiments, but there was no direct observation, which needs to be verified. In recent years, the evaporation behavior of microdroplets is also involved in the removal of bacteria from the air due to the spread of infectious diseases. In this study, we developed an observation device for checking the evaporation behavior of micro droplets and a program for measuring the droplet diameter, analyzed the evaporation behavior of droplets by optical observation. The experimental results shown that the range of observation conditions was improved and the accuracy of droplet measurement was enhanced. In the future, we will continue to enhance the accuracy of machine and study the observation methods to further improve the measurement accuracy.

Highly practical and reproducible BiVO4 thin film fabrication using automatic dip-coating machine towards for photoelectrocatalytic activities improvement

ABSTRACT This research developed a simple method for bismuth vanadate (BiVO4) thin film using an automatic dip-coating method. A precursor solution concentration, dipping speed, and calcination temperature were optimized to obtain the highest photoelectrocatalytic (PEC) BiVO4 electrode for water oxidation. The BiVO4 electrode was applied to organic dye degradation and studied the catalytic mechanism at the electrode surface. A calcination temperature of 450 °C was optimized for BiVO4 photoanode preparation for the highest PEC water oxidation and had good charge transfer process properties. The proposed automatic dip-coating method presents high efficiency for the large scale of BiVO4 electrode fabrication, and it was highly reproducible at a low relative standard deviation of less than 5%. The developed BiVO4 electrode can eliminate methyl red organic dyes by more than 70% within 1 hour. This research offers a new alternative approach for a simple, convenient, reproducible, and scaled-up method for semiconductor thin film fabrication.

Phase-gradient atomic layer deposition of TiO2 thin films by plasma-induced local crystallization

Atomic layer deposition (ALD) is a thin-film fabrication method that can be used to deposit films with precise thickness controllability and uniformity. The low deposition temperature of ALD, however, often interrupts the facile crystallization of films, resulting in inferior optical and electrical properties. In this study, the extremely localized crystallization of TiO2 thin films was demonstrated by per-cycle plasma treatment during the plasma-enhanced ALD process. By layering crystalline and amorphous films, a phase-gradient TiO2 film with precisely modulated optical and electrical properties was fabricated. Moreover, the ratio between the amorphous and crystalline layer thicknesses for a high dielectric constant and low leakage current density was optimized.

Resistive Switching Effects of Crystal‐Ion‐Slicing Fabricated LiNbO3 Single Crystalline Thin Film on Flexible Polyimide Substrate

AbstractThe fabrication process and resistive switching properties of flexible single crystalline LiNbO3 (LN) thin films are reported in this paper. Single crystalline LN thin films are transferred onto polyimide (PI) substrate by crystal‐ion‐slicing (CIS) technique using benzocyclobutene (BCB) as bonding layer. Low energy Ar+ irradiation is carried out to introduce a layer with high concentration oxygen vacancies. Uniform and stable resistive switching behaviors are observed in different memristor cells on the same thin film, which can be attributed to the single crystalline properties of the fabricated LN thin films. The on/off ratio is almost the same even when the LN thin film is bended either to different radii or thousand times. Thus, based on CIS technique and Ar+ irradiation, the fabrication method of flexible single crystalline thin films for flexible memristor is established. These results indicate that single crystalline LN thin film on PI substrate is a promising candidate structure for flexible memristor devices. A novel conduction model combined filamentary mechanism and Schottky emission mechanism is proposed to explain the resistive switching behavior.

Optical properties of zinc oxide thin film fabricated by spraying deposition method

Zinc oxide (ZnO) is a semiconductor material which commonly used for optoelectronic devices due to its several advantages. Various ZnO thin film synthesis or fabrication method have widely developed to produce the desired material with excellent properties, such as low resistivity, high transmittance, and simpler experiment procedures. This work focused on the utilization of spraying deposition as a new method to fabricate ZnO thin film. Based on UV-Vis measurement, all of the fabricated ZnO thin films presented high transmittance over 80%. In addition, the optimum spraying distance was found to be 20 cm which resulted transmittance and Eg value of 98.6% and 3.95 eV, respectively. This method presented a lower cost and simpler method to fabricate ZnO thin film.

Development of eco-friendly thin film manufacturing process using poeroxo titanium complex solution and potential for resistive random access memory

Here we report on the development of thin film manufacturing processes based on new and sustainable green solutions. We focused on utilizing green based surface solutions. The peroxo titanium complex (PTC) solution-based thin film fabrication method used does not require additional heat treatment and complex processes to remove organic matter. Conditions suitable for thin film fabrication were derived through optimization of precursor concentration and reaction temperature. As a result of I-V test of TiN/TiO2/FTO samples fabricated by applying this technology, it has been proven that it can operate as a resistive random-access memory (RRAM). The measured I-V curve suggests that TiN/TiO2/FTO RRAM exhibits bipolar resistive switching (RS) characteristics through the formation of oxygen vacancy (Vo) filament conduction paths. We also used the double logarithmic plot analysis to confirm that the dominant conduction mechanism of the device is the space charge limited conduction (SCLC) model.

Transfer-Free PZT Thin Films for Flexible Nanogenerators Derived from a Single-Step Modified Sol-Gel Process on 2D Mica.

Piezoelectric materials enable emerging self-powered wearable and implantable devices. The sol-gel technology with the lowest cost for large-scale production has shown its potential for producing high-quality PZT thin films. However, fabricating PZT films with a sufficient thickness for different application scenarios requires a long and repeated coating and heat-treatment process. The traditional solution-based method usually requires at least 20 coating cycles to fabricate 2 μm-thick PZT thin films. To save cost and improve fabrication efficiency, we develop a simplified thin-film fabrication method assisted by PZT powder. The new method can fabricate 2 μm-thick PZT films in a single step, one spin coating and annealing. Experiments indicate that the powder-based PZT thin films have porous structures and outstanding piezoelectric performances. The measured d33 of the powder-based PZT thin film is 47 pm/V. Both solution-based and powder-based PZT thin films show high flexibility and good fatigue resistance. Furthermore, we explore 2D mica as the substrate and achieve the transfer-free fabrication of flexible PZT thin-film nanogenerators that effectively simplify the complicated physical or chemical thin-film lift-off processes. The nanogenerator prototypes demonstrate the capability of accurately monitoring dynamic responses of flexible and soft human tissues.

Microstructure evolution of thin nickel films with embedded chromium oxide nanoparticles

We developed a fabrication method of thin metal matrix composite films reinforced with ceramic nanoparticles. To this end, we deposited a 20 nm Ni / ultrathin Cr-oxide layer / 20 nm Ni tri-layer on a sapphire substrate, and annealed the sample at the temperature of 700°C. We found that after annealing for 10 min the Cr-oxide layer agglomerates into single- or bi-crystalline faceted Cr2O3 nanoparticles, with the orientation relationship of (111¯)Ni∥(0006)Cr2O3and [112]Ni∥[12¯10]Cr2O3 to the Ni matrix. We encountered a surprising vertical spread of the centers of mass of the Cr-oxide particles with respect to the initial position of the Cr-oxide layer. We developed a kinetic model of the evolution of particles shape and of their vertical drift, which enabled an estimate of the effective diffusion coefficient of the Ni-Cr2O3 interface (Di=7.4·10−19m2s). Though much slower than grain boundary diffusion in Ni, this interface diffusion enables fast transformation of ultra-thin Cr-oxide layer into an array of isolated Cr2O3 nanoparticles embedded in the Ni film. The insight into the kinetics of the system obtained in the present work paves the way for the design of particle reinforcement of thin metal films with a precise control over the spatial positions of the particles.

Microstructure Evolution of Thin Nickel Films with Embedded Chromium Oxide Nanoparticles

We developed a fabrication method of thin metal matrix composite films reinforced with ceramic nanoparticles. To this end, we deposited a 20 nm Ni / ultrathin Cr-oxide layer / 20 nm Ni tri-layer on a sapphire substrate, and annealed the sample at the temperature of 700 °C. We found that after annealing for 10 min the Cr-oxide layer agglomerates into single- or bi-crystalline faceted Cr2O3 nanoparticles, with the orientation relationship of (111)Ni Ι Ι (000) Cr203 and [112] NiΙ Ι [1210] Cr2O3 to the Ni matrix. We encounter a surprising vertical spread of the centers of mass of the Cr-oxide particles with respect to the initial position of the Cr-oxide layer. We developed a kinetic model of the evolution of particles shape and of their vertical drift, which enabled an estimate of the effective diffusivity of the Ni-Cr2O3 interface ( Di = 7.4 . 10 -19 m2/s). Though much slower than grain boundary diffusion in Ni, this interface diffusivity enables fast transformation of ultra-thin Cr-oxide layer into an array of isolated Cr2O3 nanoparticles embedded in the Ni film. The insight into the kinetics of the system obtained in the present work paves the way for the design of particle reinforcement of thin metal films with a precise control over the spatial positions of the particles.

Fabrication of high‐quality electrode films for solid oxide fuel cell by screen printing: A review on important processing parameters

Solid oxide fuel cell (SOFC) is known as the most efficient fuel cell, with an efficiency of 60% in converting fuel to electricity and up to 80% in fuel to energy conversion (including heat). A SOFC consists of three primary components, namely, anode, electrolyte and cathode. Given the demand for reducing the operating temperature below 800°C, not only thin electrolytes have become a necessity for their ability to reduce ohmic losses but also high-quality porous electrode (anode and cathode) films for their ability to accelerate electrochemical reactions with fuels. In this context, screen printing is known for its capability to form high-quality porous electrode films in a cost-effective manner. In addition, screen printing offers fabrication-related parameters that can be easily manipulated to produce different film qualities depending on the requirements which have been explored in various applications. However, screen printing is only utilised in SOFC application as a fabrication tool to produce electrode films, neglecting the effects of its fabrication-related parameters on electrode performance, as indicated by the limited number of related works. Despite limited resources, this study aims to review the fabrication-related parameters in producing SOFC electrodes through screen printing and their effects on electrochemical performance. The parameters at different stages (ie, prior, during and post printing), including ink formation, printing numbers and sintering, are extensively reviewed. To the best of our knowledge, this study is not only the first review that discusses the effects of screen-printing fabrication-related parameters on electrode potentials but also offers suggestions on future directions regarding these parameters towards the improvement of SOFC performance. Novelty Statement Among all thin-film fabrication methods, screen printing is known for its capability to form homogenous-porous SOFC electrode films; however, the processing parameters of screen printing at three primary stages (prior, during, and postprinting) are rarely explored. As such, the current paper highlights important parameters in screen printing, such as ink rheology, printing number, and sintering, to contribute to the understanding of the influence of these parameters on SOFC electrode film quality and their effects on electrochemical performance.