In this work, a new framework and model for the digital generation and characterization of the microstructure of gas diffusion layer (GDL) materials with localized binder and polytetrafluoroethylene (PTFE) distributions were developed using 3D morphological imaging processing. This new generation technique closely mimics manufacturing processes and produces complete phase-differentiated (void, fiber, binder, and PTFE) digital 3D microstructures in a cost- and time-effective manner for the first time. The results for the digital generation of Toray TGP-H-060 with 5 and 0 wt.% PTFE were in close agreement with confocal laser scanning microscope (CLSM) images as well as 3D X-ray tomography studies. The resulting structure can be readily used for analyzing transport processes utilizing commercial CFD software. Copyright (C) 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.