NOVELTY - A solid oxide gas electrolytic device comprises several monolithic electrolytic assemblies (30) each containing metallic structural component having a thin planar aspect with a first side and a second side, and an active region providing an electrolytic function; and several bipolar interconnect structures (2) interleaving the electrolytic assemblies and containing sheet metal, several gas channels formed into the bipolar structures by chemical etching.    USE - As solid oxide gas electrolytic device useful in solid oxide fuel cells (SOFC) (claimed), oxygen generation systems (OGS), gas separation systems, and gasification systems.    ADVANTAGE - The solid oxide electrolytic devices use chrome-containing components, is a reliable and durable interconnect for both structural and electrical components of such devices. The interconnect structure relies on a dual-layer, high-temperature seal which provides an effective diffusion barrier for both chrome and oxygen, thus corrosion or loss in electrical conductivity in such solid oxide electrolytic devices is avoided. The device provides an economical and high-integrity structure that utilizes interconnect structure, thus thin film solid oxide fuel cells and solid oxide oxygen generators can be fabricated using only metal alloys as bulk components. The metallic support structure is such that, for a given degree of stress experienced as a result of differences in thermal expansion between various materials of the resulting electrode/electrolyte assembly, the planar support structure itself provides a degree of flexure to accommodate such stress. The method provides more economical fabrication way of forming structural elements of the electrolytic structures, since all structural or bulk elements are readily fabricated by methods of metal alloy foils or sheet metal fabrication. The underlying layers of the diffusion barrier is electrically non-conductive, such that the electrically-conductive outer layer provides the majority of electrical current, thus the device has relatively compact nature, where the relatively small volume occupied by the cell combined with large effective electrolyte surface area allows for smaller current densities to be realized for the same per-unit-volume power generation, or alternatively, oxygen/hydrogen generation. The methods and thin films thinner than those previously used provide a more effective diffusion barrier compared to those prior art thick films, when such thin films are incorporated into the dual layer. Rather than using nickel or various porous substrates, the diffusion barrier allows for an electrode support structure to be composed of a chromium (Cr) alloy component covered with the thin film interconnect structure, thus, instead of porous ceramics, bulk, industrially available alloys is used as either a cathodic or anodic support structure in the device. Porous conducting over layer is deposited over either first or second electrode grids to provide additional three-phase boundaries in the electrode/electrolyte/gas system, and provides various reforming functions, or other functionality relevant to device operation. Thus small through-hole size and stress relieving structures incorporated in the thin film electrolyte, macroscopic strain and stress is substantially avoided, so that thermal expansion coefficients do not need to be as precisely matched as is required in the case of more macroscopic electrolytic membranes. The use of materials less well-matched coefficients of thermal expansion (C.T.E.) is due to the higher stresses sustainable by vapor deposited thin/thick film structures, as opposed to bulk ceramic structures or films created from sprayed nanocrystalline particles. The electrolyte assembly which exists on and incorporates the electrode support structure, is easily integrated into a variety of SOFC or OGS geometries. Because all bulk components of device structure are coated with the interconnect structure, the device requires only relatively trivial high temperature seals between the similar alloys that comprise its bulk components.    DETAILED DESCRIPTION - INDEPENDENT CLAIMS are included for the following:    (1) a solid oxide fuel cell having the monolithic electrolytic assembly comprising a thin planar support structure formed from a non-porous material and having a first side and a second side (where the structure is patterned with several through-hole structures (19) each having a hole interior surface extending between the first side and the second side, the hole interior surface defines an opening in the support structure, an electrolytic layer disposed within each through-hole structure, the electrolytic layer comprises a solid oxide electrolyte, and has a first region in which a first layer side is attached to the interior surface, a second region in which the first layer side is not attached to the interior surface and the second region spans the opening, the boundary between the first region and the second region with a contact angle (less than 20degrees ) between the first layer side and the interior surface; and    (2) forming the solid oxide electrolytic assembly involving forming the structural element from a flexible metal strip in the form of the thin layer, having several predetermined hole structures formed in the first side, and the hole structures are integral to a sacrificial material forming a bottom surface within each hole structure and the bottom surface a non-planar surface; positioning the structural element in a material deposition system, vacuum system having a rotating surface, structural element disposed to flexibly conform to the surface, deposition system for forming an electrolytic layer over the hole structure and bottom surface, and electrolytic layer of solid oxide electrolyte; removing the sacrificial material to provide a free-standing electrolytic layer which remains disposed within each hole structure to form gas barrier to a gas adjacent the through-holes; and forming electrode layers on opposing sides of the electrolytic layer, where the electrode layers are disposed for enabling an electrolytic function.    DESCRIPTION OF DRAWING(S) - The figure shows cross-section of a portion of the active region in the solid oxide electrode/electrolyte assembly.    Bulk alloy structure (1)    Dual-layer interconnect structure (2)    Solid oxide electrolyte (20)    Through-holes (19)    Counter-electrode structure (21)    Surface relief features (24)    Electrolyte assembly (30)    Electrode/electrolyte structure. (34)