TECHNOLOGY FOCUS - ORGANIC CHEMISTRY - Preferred Process: The second ionomer overcoat layer is dried to provide a second electrode ionomer overcoat layer. A third ionomer overcoat layer (125), comprising an ionomer and a third solvent, is deposited on the second electrode ionomer overcoat layer, and dried to produce a third electrode ionomer overcoat layer. A fourth ionomer overcoat layer, comprising an ionomer and a fourth solvent, is deposited on the third electrode ionomer overcoat layer. The fourth ionomer overcoat layer is dried to produce a fourth electrode ionomer overcoat layer. Ionomer overcoat layers are applied onto electrodes supported on the gas diffusion media material or on microporous layer on gas diffusion media material. The process further comprises a surface treatment coating on the substrate to improve catalyst layer transfer. The surface treatment comprises sand-blasting or plasma-etching. Preferred Components: The first solvent comprises a wetting solvent. The second solvent comprises a less wetting or non-wetting solvent. The first, second, third and fourth solvents comprise methanol, or 2C or higher alcohol. The first, second, third and fourth solvents comprise methanol, ethanol, n-propyl alcohol, iso-propyl alcohol, n-butyl alcohol, sec-butyl alcohol, and/or tert-butyl alcohol. The second, third and fourth solvents comprise water and/or glycol. The third solvent is less wetting than the second solvent, or is a non-wetting solvent. The fourth solvent is less wetting than the third solvent, or is a non-wetting solvent.    TECHNOLOGY FOCUS - POLYMERS - Preferred Materials: The substrate comprises a porous decal support, a non-porous substrate, PTFE, expanded PTFE, gas diffusion media structure, porous expanded PTFE, porous polypropylene, porous polyethylene, or other porous substrates. The substrate is porous having pores less than 1 microns, a void volume of 10-90%, and a thickness of 10-100 microns. The substrate comprises ethylene tetrafluoroethylene, polyethylene terephthalate, polyethylene naphthalate, or nonporous PTFE.