In this paper, electric field assisted fabrication of membrane electrode assemblies (MEAs) for fuel cells is proposed, with the aim of improving the electronic and ionic connections in the catalyst layers and increasing the efficiency of catalyst utilization. Anodic and cathodic electrodes have been prepared by the perpendicular application of a low-frequency ac electric field to the catalyst ink spread on the Surface of a gas diffusion layer (GDL) while the ink is drying. The thus prepared electrodes were hot-pressed onto a Nafion membrane to form the MEAs. Direct methanol fuel cells (DMFCs) with the electric field-treated MEAs (E-MEA) showed a Substantial improvement in performance as compared with common MEAs (C-MEA) without electric field treatment. Under the same operating conditions, the maximum power density of a DMFC was increased from 42.3 to 60.0 mW cm (2) when a C-MEA was replaced by an E-MEA treated with a 5000 V cm(-1) and 0.1 Hz ac electric field. Electrochemical impedance spectroscopy (EIS) measurements have shown that the through-plane ohmic resistances in the E-MEAs are lower than that in the C-MEA, while both the electronic and ionic resistances of the catalyst layer in the in-plane direction are higher for the E-MEAs, suggesting the formation of an oriented structure in the catalyst layers under the electric field treatment. EIS measurements have also shown that both the total reaction resistance and the anode reaction resistance in the E-MEAs are lower than in the C-MEA. Based on cyclic voltammetry (CV) data, it has been shown that Pt utilization in the cathode reaches a maximum of 62% for the E-MEA, as opposed to 37% for the C-MEA. (c) 2008 Published by Elsevier B.V.