This paper presents a cradle-to-grave comparative Life Cycle Assessment (LCA) of new gas atomised (GA) sponge nickel catalysts and evaluates their performance against the both cast and crush (CC) sponge nickel and platinum standards currently used in commercial alkaline fuel cells (AFC). The LCA takes into account the energy used and emissions throughout the entire life cycle of sponge nickel catalysts ranging from the upstream production of materials (mainly aluminium and nickel), to the manufacturing, to the operation and finally to the recycling and disposal. Through this assessment it was found that the energy and emissions during the operational phase associated with a given catalyst considerably outweigh the primary production, manufacturing and recycling. Primary production of the nickel (and to a lesser extent dopant materials) also has a significant environmental impact but this is offset by operational energy savings over the electrode's estimated lifetime and end of life recyclability. From the results it can be concluded that higher activity spongy nickel catalysts produced by gas atomisation could have a significantly lower environmental impact than either CC nickel or platinum. Doped GA sponge nickel in particular showed comparable performance to that of the standard platinum electrode used in AFCs. (C) 2013 Elsevier B.V. All rights reserved.