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A porous fuel cell component, such as an electrode substrate, has a densified edge which forms an improved gas seal during operation when soaked with electrolyte. The edges are made from the same composition as the rest of the component and are made by compressing an increased thickness of this mate

A porous fuel cell component, such as an electrode substrate, has a densified edge which forms an improved gas seal during operation when soaked with electrolyte. The edges are made from the same composition as the rest of the component and are made by compressing an increased thickness of this material along the edges during the fabrication process.

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In a process for fabricating a fuel cell component comprising a fully graphitized gas porous, resin bonded carbon fiber sheet having first and second oppositely facing surfaces and a pair of parallel edge portions separated by a central portion, wherein said edge portions are more dense than said ce

In a process for fabricating a fuel cell component comprising a fully graphitized gas porous, resin bonded carbon fiber sheet having first and second oppositely facing surfaces and a pair of parallel edge portions separated by a central portion, wherein said edge portions are more dense than said central portion, the steps of: forming an intermediate product comprising a homogeneous layer of carbon fibers and thermosetting resin, wherein the resin in said intermediate product has not been thermoset, said intermediate product including a pair of parallel edge portions separated by a central portion, said step of forming including building up the thickness of said edge portions such that they are thicker than said central portion with a material having substantially the same composition as said central portion; densifying at least said edge portions by compressing said edge portions to a thickness which is substantially the same as the desired final thickness of said central portion, said step of densifying including applying heat to cure said resin; and heating said edge portions and said central portion to carbonize said resin and fully graphitize said resin and carbon fibers.