A cost effective production of the membrane electrode assemblies (MEA) is a crucial issue for the generation of electricity by proton exchange membrane fuel cells (PEMFC). The deposition of the exact catalyst content on the electrodes in a single printing step is desirable to save processing time and enable cost reduction. In this study, an innovative MEA production process by screen print is developed to produce high performance catalyst layers. The control of the surface tension of the catalyst ink is fundamental to allow the catalyst layer deposition in a single printing step. The electrodes prepared in this way show higher performance than those prepared in several steps. The optimal ink developed shows a viscosity of 2.75 Pa s, a total solid content of 33.76 wt.%, a density of 1.294 g cm(-3), and tack value of 92 U.T. (C) 2011 Elsevier B.V. All rights reserved.