A method and apparatus for electrostatic spray deposition (ESD) for fabricating a thin-layer yttria-stabilized zirconia (YSZ) electrolyte on a solid oxide fuel cell (SOFC) anode substrate constructed of nickel-YSZ cermet. By reducing the thickness of the electrolyte, and thereby reducing the cell internal IR drop, an intermediate temperature SOFC (ITSOFC) can operate at 600 800.degree. C. A collar positioned at a distance from a discharge end of a spray nozzle enhances a spray pattern of a precursor including the electrolyte material and thus provides a very thin electrolyte layer.