Continuous process for manufacture of gas diffusion layers for fuel cells

The invention relates to the field of electrochemical cells and fuel cells, more specifically to membrane fuel cells such as polymer-electrolyte-membrane fuel cells (PEMFC) and DMFC and describes a continuous process for the manufacture of gas diffusion layers (GDLs). The process comprises a continuous compression step by hot rolls to flatten the GDL prior to the assembly to membrane-electrode-assemblies (MEAs). Due to the low total surface roughness of the GDLs, less damage and perforation of the ionomer membrane occurs and the MEAs made therefrom reveal improved performance.