A new and simple process has been developed for the fabrication of catalyst layer of the PEMFC electrodes, scalable to large area electrodes in order to reduce the interfacial contact between the catalyst layer and the electrolytes. The catalyst layers of the PEMFC electrodes prepared by this process have been structurally characterized by EDAX and SEM studies. The fuel cell experiments carried out on the laminated electrode membrane assembly (EMA) were analysed, in order to get the dependence of the performance of the fuel cell electrode on proton network, electronic network and interface between the electrolyte and the electrocatalysts. The interfacial resistance has been evaluated for EMAs made by conventional method and the new process and compared. The catalyst layer prepared by this process showed higher platinum utilization in the electrodes and also amenable for scaling up. (c) 2006 Elsevier B.V. All rights reserved.