The Micro-Porous Layer (MPL) is a porous, thin layer commonly used in fuel cells at the interfaces between the catalyst layers and gas diffusion media. It is generally made from spherical carbon nanoparticles and PTFE acting as hydrophobic agent. The scale and brittle nature of the MPL structure makes it challenging to study experimentally. In the present work, a 3D stochastic model is developed to virtually reconstruct the MPL structure. The carbon nanoparticle and PTFE phases are fully distinguished by the algorithm. The model is shown to capture the actual structural morphology of the MPL and is validated by comparing the results to available experimental data. The model shows a good capability in generating a realistic MPL successfully using a set of parameters introduced to capture specific morphological features of the MPL. A numerical model that resolves diffusive transport at the pore scale is used to compute the effective transport properties of the reconstructed MPLs. A parametric study is conducted to illustrate the capability of the model as an MPL design tool that can be used to guide and optimize the functionality of the material. (C) 2015 Elsevier B.V. All rights reserved.