It is important to make the catalyst layer of Membrane Electrode Assembly (MEA) thin to decrease platinum loading of the Polymer electrolyte fuel cell (PEFC) For traditional spray methods, the catalyst layer cannot be applied thinly and uniformly on MEA because a lot of aggregates are formed in catalyst ink In this study, inside structure and composition of the aggregates were investigated, and a comparison was made between catalyst layers applied with traditional spray methods and the powdery catalyst dispersion method proposed by the authors The mechanism of aggregate formation and how to prevent it were clarified It was shown that there were possibilities of catalyst loading reduction and performance improvements by both of the two methods