A new technology for the production of a membrane electrode gasket assembly (MEGA) for polymer electrolyte fuel cells (PEFCs) is defined. The MEGA system was prepared by sealing a previously prepared membrane electrode assembly (MEA) in a moulded gasket. For this aim, a proprietary silicone based liquid mixture was injected directly into the MEA borders. Gaskets obtained in different shapes and hardness grades are stable in a wide temperature range. The MEGA technology shows several advantages with respect to traditional PEFCs stack assembling systems: effective membrane saving, reduced fabrication time, possibility of quality control and failed elements substitution. This technology was successfully tested at the ENEA laboratories and the results were acquired in laboratory scale, but industrial production appears to be simple and cheap.