Abstract :  A modified version of the conventional decal transfer method for the fabrication of electrodes for polymer electrolyte membrane fuel cells is introduced. This modified method makes use of a carbon breaking layer to ensure a high catalyst transfer ratio during the process. In order to optimize this method, the effect of the thickness of the microporous layer was also studied using a thin-film / flooded agglomerate model. The structural features of the electrodes made by the modified decal method were investigated by field-emission scanning electron microscopy, electrochemical impedance spectroscopy, mercury intrusion porosimetry and current-voltage polarization measurements. The results indicate that the modified decal method has the potential to be a reliable and facile method of fabricating electrodes with high performance.