Display omitted •Electrically-conductive Pt-coated spacers achieved early pore wetting detection.•The spacers were tested in MD process with gradually developed pore wetting.•A significant amplification of the electrical signal was observed in a 1–2 V region.•Permeate flux increased with no adverse coating effect on MD performance.•Effect of spacer design on flux was more pronounced at higher feed temperature. Membrane distillation (MD) suffers from pore wetting which deteriorates membrane separation properties and causes water protrusion to permeate side. The early detection of pore wetting is a challenge which needs to be addressed to achieve stable MD performance. In this study, electrically-conductive Pt-coated spacers placed inside the feed and coolant channels with a dual purpose of maximizing permeate flux and instantaneous wetting detection once first membrane pores are compromised are proposed. Upon wetting, permeate salt concentration increases thereby initiating redox reactions at two spacer electrodes under the applied electrical potential. As a result, electrical current is produced and measured. The competence of the proposed wetting detection method was explored in MD process in the presence of organic substances with high wetting propensity. An increase in generated electrical current upon wetting development and substantial signal amplification with the voltage increase was demonstrated. The new wetting detection method achieved a faster response comparing to conventional conductivity measurements. Moreover, this method allows to define the wetting onset which can serve as an indication of early membrane impairment. Different spacer geometries and observed no adverse effect of spacer coating on MD performance were further compared. Experimental and numerical simulations accentuated an importance of spacer design by providing specific permeate flux gain for a 1-helical spacer comparing to a spacer with a smooth cylindrical filament. This effect became more evident at higher feed water temperature, condition that favors greater temperature polarization.