A fuel cell device has a composite particle electrode (200) formed using
particles (210) having a combination of ion conductor material, electron
conductor material, and catalyst material. Each composite particle (210)
is preferably formed to have a substantially spherical outer layer (480)
of ion conductor material (481) with conductive and catalyst particles (482,
484) are dispersed throughout the outer layer (480). An array of composite
particles (210) is layered in a substantially structured or ordered manner
on a membrane support structure (220) to form the fuel cell electrode. A
fuel cell electrode so formed has interstitial gaps between the composite particles
that result in a structure permeable to oxygen and other fluids.
