Design and manufacturing alternatives for Proton Exchange Membrane (PEM) fuel cells are described and analysed within the context of vehicle applications. Specifically, following a review of many alternatives, 16 polymer electrolyte membranes, 2 types of gas diffusion layers (GDL), 8 types of anode catalysts, 4 types of cathode catalysts and over 100 bipolar plate designs are recommended for further study. This work not only reviews membrane electrode assembly manufacturing options and synthesis processes for many of the membranes and for the gas diffusion layers, but also adds to the bipolar plate fabrication options described in literature. This work is intended to facilitate material and process selection through the consideration of the variety of design and manufacturing alternatives prior to capital investment for wide-scale production.