. By combining novel platinum and ruthenium chemistry, we have succeeded in developing a new process for making thoroughly mixed Pt:Ru alloy with minimum undesirable phases at all loadings, as evidenced by XRD analysis. XRD analysis indicated that most other commercial PtRu products have oxide impurities (RuO2 xH2O), or unalloyed Ru phase. Correlation of RDE (rotating disk electrode) results and XRD spectra indicates these phases are ineffective for catalysis. These phases reduce the electronic interaction for weakening Pt-CO bond and the bimolecular reaction rate for CO removal. A good PtRu catalyst should have thorough atomic mixing with large surface area. Oxygen cathodes are also crucial for DMFC performance. Newly developed high performance Pt black cathode catalysts possess high surface areas. 60%-80% Pt on carbon shows similar performance and is easier to process. DMFC anode structure needs to reach a compromise between catalyst access by methanol and cross-over; cathode structure needs to find the compromise between catalyst wetting and proton conduction.