One embodiment of the invention includes a product comprising: a solid polyelectrolyte membrane having a first face and an opposite second face; a first catalyst layer overlying the first face of the membrane; a first microporous layer overlying the first catalyst layer, and wherein the first microporous layer includes a plurality of microchannels formed therein open toward the first catalyst layer; and wherein each of the microchannels of the first microporous layer are defined by a surface that is free of cracks.