This study has focused on the development of a roll-press based decal transfer method to fabricate membrane electrode assemblies (MEAs) for direct methanol fuel cells (DMFCs). This method exhibits an outstanding transfer rate of catalyst layers from substrates to the membrane, despite hot-pressing at a considerably lower pressure and for a much shorter duration than the flat-press based conventional decal method. The MEA produced by a roll-press (R-MEA) delivers an excellent single-cell performance with power densities more than 30% higher than that fabricated using a flat-press (F-MEA). The new method considerably improves catalyst active sites in both electrodes and renders a high cathode porosity. The superior pore structure of the cathode makes the R-MEA more efficient in terms of performance and operation stability under lower air stoichiometries. Moreover, MEAs can be prepared in a continuous mode using this new method due to the unique design of the roll-press. All these advantages demonstrate the superiority of this method over the conventional flat-press decal method and make it suitable for use in the commercial manufacturing of MEAs for direct methanol fuel cells. Copyright (c) 2012, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.