The fabrication of novel fibre composite electrode structures and the performance assessments for oxygen reduction in alkaline electrolyte is reported. An array of 2 mu m diameter activated carbon fibres interlocked within a network of 2 mu m sinter-bonded metal fibres to form the composite structure was used. The resulting electrode structure is stable, highly conductive and can maintain void fraction exceeding 95%. Electrode physical properties including thickness, macroporosity, volume and mass fractions of constituent carbon and metal fibres have been controlled, characterized, and related to the electrode polarization in a KOH half cell. Comparisons have been made with a commercial Teflon-bonded gas diffusion electrode (GDE). It has been demonstrated that this novel method allows reproducible and low-cost fabrication of GDEs with the optimal balance between macropores for gas access, micropores for liquid access, and conductive paths for electron access.