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One of biggest challenges for fuel cell manufacturing companies is to bridge the gap from the research and development stage to a high volume production environment, while, at the same time, achieving quality results consistent with those found in the laboratory. This paper discusses an investigation into the feasibility of using automated ultrasonic spraying technology to deposit catalyst inks onto fuel cell electrodes. Deposition technologies currently used for high volume fuel cell electrode coating have been found to produce electrodes with poor uniformity and repeatability, in addition to unwanted agglomeration of particles and low mass transfer efficiency to the substrate. In order to quantify this variability in catalyst distribution uniformity, commercially available electrodes were measured using X-ray fluorescence (XRF). An automated FC electrode coating testbed was designed and built for conducting research on uniform thin film deposition. In addition to atomization and drying capabilities, the testbed includes a continuous flow liquid delivery system that utilizes two ultrasonically agitated syringes capable of reducing problematic agglomeration. The method of optimizing spraying parameters for thin film deposition will be discussed. The testbed allows for control the of atomized ink droplet size through the use of different ultrasonic frequencies, which can affect the morphology and porosity of the catalyst layer. Due to the low droplet velocity produced by ultrasonic atomization, overspray is reduced (high transfer efficiency), resulting in less waste of the expensive catalyst materials.