Sputter deposition was investigated as a tool for manufacturing proton-exchange membrane fuel cell (PEMFC) electrodes with improved performance and better catalyst utilization vs. commercial electrode. Nanosized (diameter 2-5 run) platinum clusters were deposited on gas diffusion electrodes (carbon paper+PTFE/C diffusive layer). The activity for methanol oxidation was increased about 14 times compared to 2 commercial catalyst, with loading < 0.02 mg cm(.)(-2) SEM-FEG characterization and cyclic voltammetry were carried out to study the morphology, and the behavior of the Pt clusters as cathodic electrocatalyst of a polymer electrolyte fuel cell. (c) 2005 Elsevier B.V. All rights reserved.