A novel process for preparing a matrix using non-volatile n-methyl-2-pyrrolidone (NMP) solvent was developed to increase its productivity and reproductivity, while maintaining high porosity and high phosphoric acid absorbency which supply the advantages of silicon carbide (SiC) whisker-polyethersulfone (PES) binder matrix system. The effect of the change from the volatile solvent to the non-volatile one on the properties of matrix and the performance of fuel cell was investigated. The change from the volatile solvent to the non-volatile one decreased the porosity and increased the bubble pressure of matrix. The electrolyte resistance under the same thickness increased due to the decrease of phosphoric acid absorbency, and the fuel cell performance slightly decreased. When the thickness of the matrix was reduced to the 170 mum, the electrolyte resistance decreased and the performance of single cell increased. (C) 2003 Published by Elsevier B.V.