Reactive impinging flow (RIF) is a novel quality-control method for defect detection (i.e., reduction in Pt catalyst loading) in gas-diffusion electrodes (GDEs) on weblines. The technique uses infrared thermography to detect temperature of a nonflammable (<4% H-2) reactive mixture of H-2/O-2 in N-2 impinging and reacting on a Pt catalytic surface. In this paper, different GDE size defects (with catalyst-loading reductions of 25, 50, and 100%) are detected at various webline speeds (3.048 and 9.144 m min(-1)) and gas flowrates (32.5 or 50 standard L min(-1)). Furthermore, a model is developed and validated for the technique, and it is subsequently used to optimize operating conditions and explore the applicability of the technique to a range of defects. The model suggests that increased detection can be achieved by recting more of the impinging H-2, which can be accomplished by placing blocking substrates on the top, bottom, or both of the GDE; placing a substrate on both results in a factor of four increase in the temperature differential, which is needed for smaller defect detection. Overall, the RIF technique is shown to be a promising route for in-line, high-speed, large-area detection of GDE defects on moving weblines. (C) 2016 Elsevier B.V. All rights reserved,