Abstract : Small direct-methanol fuel cells (DMFCs) have recently been highlighted as possible power sources for applications ranging from cellular phones and wireless digital devices to autonomous sensors and micro-electro mechanical devices. One of the key issues in commercializing miniaturized DMFCs for portable applications is to improve the electrochemical performance of the cells with a small quantity of catalysts. Up to now, the spraying or brush method has been used to fabricate a catalyst layer, which uses a slurry of nano-sized Pt or Pt/Ru catalysts. However, these methods produce a poor electrochemical interface that reduces the catalytic activity and the reproducibility of their performance tests. In this study, a unique process known as a