A carbon-filled gas diffusion layer (CFGDL), which is in the configuration similar to conventional carbon cloth gas diffusion layer(GDL) coated with carbon layer on both faces,was investigated and compared with conventional carbon paper-based single-layer and dual-layer GDLs. Like the carbon cloth GDL, CFGDL has presented superior performances over the single-layer or dual-layer GDL in all three polarization (activation, ohmic and concentration) controlled regions under electrochemical characterizations (steady-state polarization and electrochemical impedance spectra). The results from SEM showed that CFGDL has the same thickness of 0.11 mm as that of single-layer GDL, while dual-layer GDL has a thickness of 0.18 mm. The fully filled carbon paper with carbon/PTFE filler, as seen in the SEM image, displayed good support for the catalyst layer and electrolyte phase, allowing good electrical contact between the GDL/catalyst/membrane and GDL/flow field plate to be achieved. From porosimetry analysis, CFGDL presented a lower porosity of 67% and a Much smaller average pore diameter of 4.7 mu m compared to the single-layer GDL (porosity of 77% and Pore diameter of 35.8 mu m) and dual-layer GDL (porosity of 73% and pore diameter of 25.5 mu m); however, it also gave the largest limiting current density, which reflects the improvement in mass transportation. This phenomenon is likely attributed to the fast removal of micro-water droplets formed in the CFGDL structure of the electrode. (c) 2008 Elsevier Ltd. All rights reserved.