NexTech Materials, Ltd. and Functional Coating Technology, LLC are collaborating on a NIST-funded ATP project to develop the Direct Fuel Power Module (DFPM). The DFPM concept is based on integration of a low temperature solid oxide fuel cell with novel catalytic materials in a compact, modular design that allows for direct utilization of hydrocarbon fuels. The novel design integrates multiple series-connected thick-film onto the faces of porous flat-tube substrates. The design combines the best features of tubular and planar SOFCs by eliminating sealing problems and providing high volumetric efficiency. These modules can be produced using conventional high volume manufacturing techniques and are suitable for use in generators that deliver from tens of watts to kilowatts of power. The scalability and modularity of the DFPM stack design provides opportunities for development of power supplies for a number of potential applications, including propane-fueled 10-100 watt power supplies for portable electronic appliances, 1-3 kilowatt automotive auxiliary power units, and 3-5 kilowatt systems for residential power and heat. Advanced electrolytes and cathode materials are being developed to reduce operating temperature to 650 to 800ºC, and the use of advanced anode materials will allow the direct utilization of dry hydrocarbon fuels. System design is simplified as the fuels will not need to be pre-reformed or hydrated. DFPMs are being developed to run on gaseous (methane) or liquid (propane or butane) fuels. For small-scale (portable) power applications, the DFPM can be designed to provide desired voltage and current output, thus eliminating the need for power conditioning components. In the project, prototype module platforms with 20-watt and 150-watt power outputs will be produced and tested to demonstrate feasibility.