Abstract: A process for preparing catalyst coated membranes and membrane electrode assemblies for use in direct methanol fuel cells is provided. Cathode and anode layers are formed by spraying catalyst-containing inks onto a novel framed electrolytic membrane to form a catalyst coated membrane. The spraying process optionally employs one or more masks, which carefully control where the catalyst-containing ink is deposited. Following application of the cathode and anode layers, diffusion layers are prepared and inserted onto the catalyst coated membranes, and pressed to form membrane electrode assemblies.