Thin composite cathodes for air reduction were manufactured using microfibre-based papermaking technology. The electrodes have a thin structural design, less than 0.15 mm in thickness. Composite cathode materials for oxygen reduction applications were fabricated by entrapping carbon particles in a sinter-locked network of 2-8 mum diameter metal fibres. The thin structure not only results in electrodes that are 30-75% thinner than those commercially available, but also offers an opportunity for custom-built air cathodes optimized for high-rate pulse applications. Using a thin composite structure for the air cathode in a zinc-air battery that is part of a zinc-air/capacitor hybrid is likely to increase the pulse capability of the hybrid power system. The thin cathode structure provides a better, more efficient three-phase reaction zone. In a half-cell test, the ultrathin air cathode generated more than 1.0 V vs Zn/ZnO for a current of 200 mA cm(-2). Half-cell, full-cell and pulse-power tests revealed that thin composite cathodes have a better rate and pulse performance than the air cathodes commonly used.