To reduce the Pt loadings in cathode catalysts for polymer electrolyte fuel cells, we focused on the catalyst material and catalyst-layer (CL) fabrication method, and prepared low Pt loading CLs with Pt/Ta-SnO 2 by the electrospray (ES) method. Two CLs were prepared by the ES method with different mass ratios of ionomer binder to support material (I/S), I/S = 0.7 and 0.2, and are compared to that prepared by the pulse-swirl-spray (PSS) method. Both ES CLs have higher porosity than that for the PSS CL, and have improved ionomer coverage and increased electrochemically active surface area (ECA) and mass activity at 0.85 V. In particular, that for the ES with I/S = 0.2 has high porosity and remarkably increased cell performance. The improvement obtained by use of the ES method can be explained on the basis that the coverage and uniformity of ionomer are increased due to the small droplet size. The performance of the ES cells is high, particularly under high backpressure conditions, because of the improved transport of both O 2 and protons. ES is an attractive method for the reduction of the Pt loading while improving cell performance. Polymer electrolyte fuel cells (PEFCs) have the potential to reduce the emission of greenhouse gases and air pollutants in comparison to the use of fossil fuels. [1][2][3][4][5][6] There has been a strong effort to reduce the cost of PEFC components, with attempts being made to decrease catalyst loadings while maintaining similar or improved cell performance. In order to address these challenges, several different approaches have been proposed, including the synthesis of Pt alloy catalysts and the optimization of Pt particle size or Pt interparticle distance.7-9 Our group evaluated the practical utilization of Pt under operating conditions, finding that the effectiveness of Pt was only on the order of 7.5% in air at 65• C and 0.1 MPa. 10 In order to increase the effectiveness of Pt, we examined its relationship with catalyst layer (CL) thickness and use of a Pt alloy catalyst. 11,12 In particular, the mass activity of a CL was increased by reducing the Pt loading to about 0.05 mg cm −2 . However, we also found that a new preparation method, which can construct a highly uniform layer, is necessary to improve performance of thin CLs with micrometer-order thickness. CLs are usually fabricated from a catalyst ink, which includes the Pt catalyst, an ionomer binder and a dispersing solvent. Researchers have reported the use of inkjets, 13 electrospinning 14 and electrospray (ES) 15,16 to fabricate CLs with low Pt loadings. In case of the ES method, micrometer-sized droplets of the catalyst ink can be synthesized. The ES method essentially makes use of a nozzle, which is connected to an ink reservoir, and the substrate to be coated (Fig. 1). When the ink is ejected by the influence of a strong electric field, the resulting spray can take on several different forms, according to the ink meniscus formation at the tip of the nozzle. One of these modes is the cone-jet, 17,18 involving a Taylor c...