Although cathode catalyst layers (CCLs) are at the center of water management in polymer electrolyte fuel cells (PEFCs), the understanding of water movement in CCLs and their roll on fuel cell performance is still limited. In this present study, several CCLs with controlled microstructure, including main pore size, pore volume and porosity ranging from 30 to 70 nm, 0.443 to 0.962 cm(3)/g(Pt/C), and 45.4 to 64.4%, respectively, were prepared by changing the hot-pressing pressure in a decal process, and their water management ability and cell performance were evaluated. The electrochemical analyses reveal that, as the pore size and pore volume of CCLs increase, the diffusion resistance mainly arising from water accumulation in the pores is evidently reduced by capillary water equilibrium, which leads to better cell performance. Water balancing between accumulation and discharging in the pores also depends on the CCL pore structure, and the CCLs with greater pore sizes and larger pore volumes reveal more stable cell performance by better water management in steady state operation, even under extremely humid conditions. Based on these MEA technologies such as fabrication of CCLs, further study will be performed to understand microscopic phenomena in nano pores of CCLs by combining the experimental approach with CCL numerical modeling. (C) 2011 Elsevier Ltd. All rights reserved.