Gradient permeable metallic substrate material consisting of two layers of NiAl alloy was developed for the SOFC design. The open-cell foam layer (thickness 1-2 mm, cell density 60 ppi) provides the structure robustness, while a thin (100-200 μm) mesoporous layer facilitates supporting functional layers. Cathode layers (LSM, LSFN and their nanocomposites with GDC or YSZ) and anode layers (NiO/YSZ, NiO/YSZ +Ru/Ln-Sr-Mn-Cr-O nanocomposite catalyst) were deposited by slip casting, electrophoretic deposition or air brushing. Thin (5-10 μm) YSZ layer was deposited by MO CVD. Power density up to 550 mW/cm2 at 700oC was obtained on button-size cells using wet H2-air feeds.