A mixed powder of electrolyte and matrix support materials with a proper proportion was used for the fabrication of an electrolyte matrix sheet. The purpose of this study is to reduce the large change in MCFC cell thickness occurring in the initial start-up period when separate sheets of electrolyte and support are used. A focus was put on how small the carbonate particles could be made. The particle size of the carbonate powder was controlled by ball milling and the distribution was measured using a particle size analyser. The thickness change was reduced to 20% by this approach, which could be compared to 27% observed in a conventional cell. The thickness changes of electrolyte matrix have linear relation sizes of carbonate powders.