The effects of the design parameters of the anode diffusion layer (DL), including the PTFE loading in the backing layer (BL), and the carbon and PTFE loading in the microporous layer (MPL), on water transport through the membrane and the performance of a liquid-feed direct methanol fuel cell (DMFC) are experimentally investigated. The results indicate that increasing the PTFE loading in the BL and introducing a MPL Could decrease water crossover through the membrane without sacrificing cell performance when the feed methanol concentration is increased. It is also found that changing the PTFE loading in the MPL has little effect an water crossover, whereas increasing the carbon loading in the MPL Could noticeably decrease (lie water-crossover flux. Nevertheless, the ability of the MPL to reduce water crossover is limited by the presence of a number of mud cracks. To reduce further the water-crossover flux, a Crack-free MPL made Of multi-walled carbon nanotubes (MWCNTs) and PTFE is proposed. Tests indicate that the DMFC with the nanotube MPL results ill a much lower water-crossover flux than a conventional carbon-powder MPL. More importantly, the use of the nanotube MPL allows the DMFC to be operated with a higher methanol concentration, and thereby increases the fuel cell system energy density. (C) 2009 Elsevier B.V. All rights reserved.