AbstractThe direct ethanol fuel cell (DEFC) is a promising fuel cell device, which could provide power to portable and microelectronic equipment in the future. In the present investigation, the influence of a pore‐former, polytetrafluoroethylene (PTFE) and catalyst loadings in the electrocatalyst of the anode on DEFC performance is studied. The decal transfer method is used to prepare the membrane electrode assembly (MEA) using PtRu/C (40:20% by wt) as the anode catalyst, and Pt/C (40% by wt) as the cathode catalyst, a pore‐former, PTFE dispersion and Nafion ionomer. The pore‐former used is 10% (by wt) NaHCO3 in the catalyst ink during the preparation of MEA. The voltage‐current characteristics of DEFC were monitored at different loadings of the catalyst, PTFE and a pore‐former in MEA. The DEFC performance improved with the use of a pore‐former and higher loading of PTFE in MEA. Higher DEFC performance is obtained because PTFE, along with the network of pores in the anode side allowed easy removal of reaction species, thereby rendering the catalyst site available for ethanol oxidation. Further, the use of a pore‐former and PTFE at the anode allowed higher loading of electrocatalyst resulting in an increase in the performance of DEFC. The DEFC, with 1 mg cm−2 of catalyst loading at the anode and cathode, 10% (by wt) NaHCO3 of a pore‐former, 20% (by wt) PTFE loading in catalyst ink gives maximum power density of 8.5 mW cm−2 at a current density of 31.3 mA cm−2. Copyright © 2008 Curtin University of Technology and John Wiley & Sons, Ltd.