TECHNOLOGY FOCUS - POLYMERS - Preferred Component: The ionomer is in the form of inverse micelles having the hydrophobic portion disposed outwardly and the ionic portion disposed inwardly. It is a graft copolymer having a hydrophobic backbone and pendent ionic portions; or a proton conducting ionomer. The proton conducting ionomer is a perfluorosulfonate ionomer, preferably Nation.Preferred Properties: The ionomer solids content is 6-12 (preferably 10) wt.%. The viscosity is in excess of 10000 centipoise at a shear rate of 10/s.Preferred Method: The nonaqueous solvent is evaporated in the absence of applied heat. The method further comprises cooling the aqueous ionomer gel following the evaporating step; and adding a catalyst to the aqueous ionomer gel following the evaporating step.Prior to the evaporating step, the solution is heated to facilitate solvation of the ionomer. The heating to facilitate solvation is at a temperature up to 40degreesC. The solution is provided by addition of water to a nonaqueous solution of ionomer. The aqueous ionomer gel can also be made by rapidly cooling an aqueous ionomer solution to below -5degreesC to form a frozen form of the aqueous ionomer solution; and thawing the frozen form of the aqueous ionomer solution to produce the ionomer gel.The aqueous ionomer solution is cooled at a rate greater than 6 (preferably greater than 10)degreesC/minute. It is cooled to a temperature below -25 (preferably below -70)degreesC. The aqueous ionomer gel is diluted to achieve a desired viscosity. The catalyst ink is suspended in the aqueous ionomer gel after or simultaneously with formation of the aqueous ionomer gel to yield the catalyst ink. It is applied to surface(s) of the substrate, and is annealed to form an annealed substrate.    TECHNOLOGY FOCUS - ORGANIC CHEMISTRY - Preferred Component: The organic solvent contaminants are at a concentration below 4 (preferably below 2) vol.%. The nonaqueous solvent is an alcohol or ketone. The alcohol is methanol. The ketone is acetone.Preferred Property: The nonaqueous solvent has a boiling point of 50 to less than 100degreesC.    TECHNOLOGY FOCUS - INORGANIC CHEMISTRY - Preferred Component: The catalyst is a noble metal catalyst, preferably platinum.Preferred Property: The catalyst solids content is 4-40 (preferably 20-40) wt.%, based on the weight of the catalyst ink.    TECHNOLOGY FOCUS - IMAGING AND COMMUNICATION - Preferred Component: The catalyst ink further comprises a filler, a binder, and/or a pore forming material.    TECHNOLOGY FOCUS - ELECTRICAL POWER AND ENERGY - Preferred Component: The coated substrate is an electrode, preferably an electrochemical fuel cell electrode. EXAMPLE - Aqueous Nation gel (3 kg) was prepared in approximately 4 hours (i.e., 3-3 one half hour evaporation time). A commercially available solution of 10% aqueous Nation and acetone were combined to form a 3:2 ratio by volume of 10% aqueous Nation to acetone. To facilitate solvation and the extension of the Nation chains, the mixture was stirred and heated to 40degreesC. This mixture was then rotary evaporated, at 100-200 mbar pressure, in the absence of applied heat until the acetone was entirely removed but before a significant amount of water was removed (at the point when the bubbling or foaming of the mixture subsided). Upon thickening (as evidence by the solution coating of the walls of the flask), the evaporated suspension was removed from the evaporator and quenched in an ice bath. The resulting aqueous gel was still approximately 10% Nation.