The Nafion/polytetrafluoroethylene (Nafion/PTFE) composite membrane is fabricated by a solution-spray process. The performance and morphology of the composite membrane are studied in terms of the mechanical properties, conductivity, and permeability. The results of TEM and X-ray studies show that the morphologies of crystalline and ion cluster of the perfluorosulfonated acid (PFSA) in composite membrane are apparently similar to that of Nafion (R) NR211 membrane. The composite membrane has higher stiffness and strength and lower swelling than that of Nafion (R) NR211. The conductivity at 85 degrees C of 0.375 S cm(-1) is relatively high in comparison to that of 0.300 S cm(-1) for Nafion (R) NR211. The 20 kW stack with the composite membranes is evaluated. The mean single cell voltage is 0.67 V @1000 mA cm(-2). The stack has behaved performance uniformity and steadily operated under low humidifying condition. In consideration of the integration of complex structure and perfect morphology, the solution-spray process is feasible for composite proton exchange membrane manufacture. Copyright (C) 2013, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.