A proton conduction fuel cell has an anode support made of metal having a fuel flow channel, an anode comprising an anode active material in contact with the anode support, a cathode support made of metal having a cathode gas flow channel, a cathode comprising a cathode active material in contact with the cathode support, and an electrolyte layer. The electrolyte layer comprises a first layer of electrolyte formed in a lock pattern on the anode and a second layer of the electrolyte formed in a key pattern on the cathode. The second layer fits in the lock pattern of the first layer to form the electrolyte layer.