A novel method for preparing proton exchange membrane fuel cell electrodes by the ultrasonic-spray technique

► Ultrasonic spray was used as a fabrication technique for proton exchange membrane fuel cell (PEMFC) electrodes. ► Five commercial gas diffusion layers (GDLs) were used as gas diffusion electrodes (GDEs) and compared for their performances in membrane electrode assemblies (MEAs). ► Ultrasonic-sprayed GDEs exhibited better performances in MEAs compared to hand-painted GDEs. ► Various Platinum loadings in the range 0.40-0.05 mg cm−2 were investigated. ► Peak power ratings were found to be up to 10.9 W mg−1 for cathode platinum loading as low as 0.05 mg cm−2.