In future energy concepts, water splitting by polymer electrolyte membrane (PEM) electrolysis is well suited for converting regenerative energy from wind or sun into hydrogen. One of the cost drivers in PEM electrolysis is the porous current collector, which is usually made of titanium. In the present work, the potential of tape casting for manufacturing current collectors with improved microstructure and electrochemical performance was investigated. Gas atomized and hydrogenation-dehydrogenation (HDH) powders were used as starting materials. For both powders, slurry preparation, tape casting and sintering parameters were optimized separately aiming on the production of plane, undistorted tapes with well-defined thickness and porosity. Systematic electrochemical studies were conducted to point out the relationship between processing parameters, microstructure and electrochemical performance. The best electrochemical performance was achieved by using titanium tapes with porosity higher than 30 % and thickness of 250 µm or below. Currently, the technology is up-scaled for larger units.