Structural variations in the Gas Diffusion Layer (GDL) can affect material functionalities and performance of the polymer electrolyte and fuel cell power systems. The selection of GDLs depends on their structure, physico-chemical and mechanical properties. The flexural and mechanical properties of different fuel cell GDL materials are reviewed with a focus on synthesis constraints. Emphasis is placed on mechanical degradation and mechanical analysis methods of the GDL. The change of physico-chemical properties is discussed in relation with the fiber orientation, bending behaviour, Teflon dispersion and the compression force. Based on our review, we recommend roll-good GDLs for the fuel cell stack production. © 2015 Hydrogen Energy Publications, LLC.