Fabrication of electrodes with multiple nanostructured thin catalytic layers

A method of making a reconstructed electrode decal having a plurality of nanostructured thin catalytic layers comprising:

• providing an acceptor decal comprising a carrying substrate having a first nanostructured thin catalytic layer thereon, the first nanostructured thin catalytic layer having a first surface and a second surface, the first surface of the first nanostructured thin catalytic layer adjacent to the carrying substrate;
• providing an acceptor substrate comprising a porous transfer substrate with an adjacent a first adhesive layer;
• adhering the second surface of the first nanostructured thin catalytic layer adjacent to the first adhesive layer of the acceptor substrate;
• removing the carrying substrate from the first surface of the first nanostructured thin catalytic layer such that the first surface of the first nanostructured thin catalytic layer becomes exposed;
• applying a second adhesive layer to the first surface of the first nanostructured thin catalytic layer;
• and
• providing a first donor decal comprising a donor substrate with a second nanostructured thin catalytic layer having an exposed first surface thereon;
• bonding the first surface of the second nanostructured thin catalytic layer of the donor decal adjacent to the second adhesive layer of the first nanostructured thin catalytic layer of the acceptor decal;
• removing the donor substrate;
• and
• removing the first adhesive layer and the second adhesive layer to form the reconstructed electrode decal comprising the porous transfer substrate, the first nanostructured thin catalytic layer adjacent to the porous transfer substrate, and the second nanostructured thin catalytic layer adjacent to the first nanostructured thin catalytic layer on a side opposite the porous transfer substrate.