A thermoplastic carrier sheet is die-cut to have a size and shape matching that of a PEM bipolar plate. A plurality of holes are punched in the carrier sheet in the pattern of gasket beading to be formed subsequently. In a mold, liquid gasket resin fills the mold on both sides of the carrier sheet to form the gasket, flowing through the holes in the sheet and thereby causing the gasket to become mechanically attached to the sheet. A carrier element having a flange portion substantially identical with the outer profile of the bipolar plates is laminated to the sheet edge. During assembly of a fuel cell, the carrier element automatically positions the gasket correctly on the plate and prevents the gasket from twisting or shifting. In a currently preferred embodiment, a membrane electrode assembly is attached within an appropriate opening in the carrier sheet.