TECHNOLOGY FOCUS - CHEMICAL ENGINEERING - Preferred Method: Making the fuel cell component comprises shaping the polymer extending beyond the edge into a selected flap geometry. The shaping involves machining the polymer extending beyond the edge to selectively remove at least some of the polymer; and/or providing a mold cavity near the edge of the component layer; and allowing the polymer extending beyond the edge to fill the cavity during a molding process. The component layer has a first thickness; the selected flap geometry includes a flap length extending in a direction away from the edge and a second, flap thickness in a direction transverse to the length. The second thickness is smaller than the first thickness. The selected flap geometry includes a generally rectangular cross section. The method involves applying a first pressure to the polymer and component layer while heating the polymer until a temperature of at least the polymer reaches a melting temperature of the polymer; and applying a second, greater pressure to the polymer end component layer while increasing a temperature of at least the polymer to a second temperature above the melting temperature of the polymer. The polymer is chemically resistant to phosphoric acid. Preferred Component: In the fuel cell component, the component layer has a first thickness and the flap has a second thickness. The second thickness is smaller than the first thickness. The polymer material comprises a high melt flow polymer that is non-wetting and thermally stable below a temperature of approximately 220 degrees C. The substrate comprises a porous graphitized substrate. The component comprises at least one of an electrode or a gas diffusion layer. The polymer is chemically resistant to phosphoric acid. The flap has a selected geometry including a flap length extending in a direction away from the edge and a flap thickness in a direction transverse to the flap length. The flap length is at least about twice the flap thickness. The selected flap geometry includes a generally rectangular cross section.