Considerable effort is ongoing to improve the efficiency and reduce the manufacturing costs of hydrogen fuel cells. Much of the attention has been focused on the cell stack, specifically the catalyst-coated membrane and the gas diffusion layers. Numerous coatings are used in the cell stack, many of which need to be applied in thin layers. Examples of these coatings include copolymers, solvents, and suspensions containing various combinations of solvents and carbon, ceramics, platinum, palladium, and other precious metals. An efficient means to apply thin layers of these materials is an important cost driver. Additionally, the performance of the fuel cell can be improved if the coating layer is applied uniformly and without defects. The precise application of these coatings to substrates in thin layers presents many challenges with the application method and material handling. Some of these challenges include the ability to apply a uniform, thin layer of coating, consistency of the coating application device, and changing coating material properties. Coatings need to be applied to each element of the fuel cell assembly including the anode, cathode, electrolyte, carbon paper layers, etc. Typically, the coating needs to be applied in successive thin layers to achieve the desired thickness, texture and electrical properties. Some of the coating application methods currently used are dip coating, air atomizing ….continue