Extended reaction zone anodes for formic acid oxidation have been prepared by the spontaneous deposition of Pd on polyaniline coated carbon fibre paper. The PANI supports, deposited on carbon fibre paper either galvanostatically, potentiostatically, or potentiodynamically, were characterized by electron microscopy, cyclic voltammetry and impedance spectroscopy. Pd was deposited on them by spontaneous reduction of Pd(II) by the reduced form of the PANI in order to preserve the characteristics of each type of PANI layer. It was found that galvanostatically deposited PANI produced electrodes that were much more active for formic acid oxidation than PANI produced under potential control. The morphology and mean particle size of Pd was found to depend strongly on the way in which the PANI was prepared and also correlated with the resistance and capacitance of the PANI at low potentials. It is proposed that the electrochemical characteristics of the PANI play a significant role in determining the morphology, particle size, and electrocatalytic activity for formic acid oxidation of the spontaneously deposited Pd. (C) 2011 Elsevier Ltd. All rights reserved.