NOVELTY - A method for forming a fuel cell stack (12) involves providing die-cut stainless steel sheets (14) each having a thickness of less than 0.2 mm, first face and an opposing second face; using an electromagnetic brush printing apparatus to electrostatically deliver a precursor layer having a generally uniform thickness of less than 0.3 mm onto a first face of at least one of the die-cut stainless steel sheets, where the precursor layer has particles having an average diameter less than 125 microns, and having a one component substantially solid precursor formulation.    USE - For forming a fuel cell stack used in fuel cell (claimed).    ADVANTAGE - The precursor layer exhibits relatively high impact resistance, desirable toughness and/or T-peel strengths (preferably at least 5.5 N/mm).    DETAILED DESCRIPTION - A method for forming a fuel cell stack (12) involves providing die-cut stainless steel sheets (14) each having a thickness of less than 0.2 mm, first face and an opposing second face; using an electromagnetic brush printing apparatus to electrostatically deliver a precursor layer having a generally uniform thickness of less than 0.3 mm onto a first face of at least one of the die-cut stainless steel sheets, where the precursor layer has particles having an average diameter less than 125 microns, and having a one component substantially solid precursor formulation including 4-type solid bisphenol A based epoxy in an amount greater than 80 wt.%; solid epoxy-CTBN adduct, having an epoxide equivalent weight of 1500 g/mole, the solid epoxy-CTBN being present in an amount of 1:5 to 1:6 pts. wt. relative to the 4-type solid bisphenol A based epoxy, dicyanamide curing agent in an amount of less than 4 wt.% and at least one pigment in an amount for imparting a visibly detectable contrast between the precursor layer and the die-cut stainless steel sheet; physically transforming the particles of the precursor layer to form a precursor layer film that is tack-free and dry to the touch while on a respective die-cut stainless steel sheet to which it has been delivered and thus forming at least a temporary adhesive bond between the precursor layer and such die-cut stainless steel sheet; heating each precursor layer film to a temperature above a cross-linking activation temperature for cross-linking the a 4-type solid bisphenol A based epoxy and the solid epoxy-CTBN adduct to define a cross-linked reaction product material layer; forming a stack of at least 200 of the die-cut stainless steel sheets having the cross-linked reaction product material layer on it by stacking consecutive sheets so that respective first faces of the sheets oppose respective second faces of the sheets with a respective cross-linked reaction product material layer between them, and defining an outermost cross-linked reaction product material layer; bonding the consecutive sheets to each other while maintaining a gap between a portion of each adjoining substrate; applying a die-cut stainless steel cover sheet over the outermost cross-linked reaction product material layer thus defining a fuel cell stack. An INDEPENDENT CLAIM is included for a fuel cell stack comprising die-cut stainless steel sheets; and a layer selectively disposed between at least one of the sheets of a cured cross-linked reaction product of the one component formulation, where the layer selectively disposed between each of the sheets is of sufficient thickness and is located so as to define a gap into which a fluidic material can be introduced to form a fuel cell.    DESCRIPTION OF DRAWING(S) - The figure shows a portion of an exemplary fuel cell.    Fuel cell assembly (10)    fuel cell stack (12)    Stainless steel sheets (14)    Membrane electrode assembly (16)