A gas diffusion layer (GDL) for proton exchange membrane fuel cell has been developed using a new form of partially ordered graphitized nano-carbon black (PUREBLACK (R) Carbon). This material represents a new class of nano-carbons jointly developed by Superior Graphite Co. and Columbian Chemicals Co. The GDL was characterized by physico-chemical as well as electrochemical methods. The unique process developed for GDL fabrication exhibits excellent fuel cell performance using hydrogen/air at ambient pressure. The microstructure as seen under scanning electron microscope shows excellent surface morphology without any cracks. The membrane electrode assembly (MEA) with PUREBLACK (R) Carbon based GDLs shows power density as high as 0.55 W/cm(2) at 70 degrees C using hydrogen/air as reactants without any back pressure. (c) 2006 Elsevier B.V. All rights reserved.