Thin wall thickness (0.25–0.35 mm) tubes, as tubular electrolytes of solid oxide fuel cells, were successfully fabricated from yttria stabilised zirconia (YSZ) by way of extrusion. Water-based additives and organic additives were studied. An economic and practical process was developed to achieve smooth, linear, and dense ceramic tubes with 2.7–2.8 mm diameter. The microstructures of the selected tubes were examined. This paper describes the fabrication procedure, formulations and optimisation parameters for successfully extruding thin YSZ tubes.