A co-tape casting process has an advantage of cost-effectiveness for mass production. To fabricate solid oxide fuel cells (SOFCs) with high electrochemical performance by co-tape casting, high solid loading and binder content of tape cast slurry are required to improve particle network strength. However, high solid loading and binder content cause high viscosity of the slurry, which makes removal of air bubbles and handling difficult. In this study, a new method to fabricate uniform green tapes with high solid loading and binder content by controlling solvent ratio under vacuum condition is proposed. As a result, high solid loading and binder content with 39% improved storage shear modulus, 26% improved LVR length, tensile strength of 5.0 MPa, and packing density of 57.5% were achieved at solvent ratio of 22 wt%. To fabricate unit cells using the green tapes, thermal decomposition and shrinkage behavior are characterized, and heat treatment steps at 250 degrees C, 350 degrees C, and 500 degrees C and co-sintering temperature were determined at 1250 degrees C. A fabricated unit cell showed open circuit voltage (OCV) of 1.10 V and the maximum power density of 1.20 W cm(-2) at 800 degrees C. To fabricate crack-free Phi 5.0 cm unit cells, the mechanical strength of the anode support tapes after thermal decomposition was measured to determine the tape compositions that can minimize cracks at the unit cell. As a result, a crack-free unit cell with a diameter of 5.0 cm was fabricated, achieving OCV of 1.05 V and power of 4.3 W at 800 degrees C. (C) 2016 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.