Sputter deposition was investigated as a tool for manufacturing proton-exchange membrane fuel cell (PEMFC) electrodes with improved performance and better catalyst utilization vs. commercial electrode. Nanosized (diameter 2–5 nm) platinum clusters were deposited on gas diffusion electrodes (carbon paper + PTFE/C diffusive layer). The activity for methanol oxidation was increased about 14 times compared to commercial catalyst, with loading < 0.02 mg cm− 2.SEM–FEG characterization and cyclic voltammetry were carried out to study the morphology, and the behavior of the Pt clusters as cathodic electrocatalyst of a polymer electrolyte fuel cell.