The paper deals with the use of extrusion to process PEMFC filled and unfilled membranes. Several routes including the sulfonation of filled and unfilled extruded membranes and the extrusion of filled and unfilled ionomers are reported. Thanks to the use of selected water-soluble aid process plasticizers, acid and alkaline forms of sulfonated polyethersulfone were, for the first time, successfully extruded. The extrusion process did not lead to any degradation of the ionomer performances. Decreasing the membrane cost while using environmentally friendly elaboration conditions, it should be helpful to an industrial production. In addition, avoiding filler sedimentation it should allow homogeneous composite membranes to be obtained. (c) 2007 Published by Elsevier Ltd.