An air-breathing direct methanol fuel cell with a novel cathode shutter current collector is fabricated to develop the power sources for consumer electronic devices. Compared with the conventional circular cathode current collector, the shutter one improves the oxygen consumption and mass transport. The anode and cathode current collectors are made of stainless steel using thermal stamping die process. Moreover, an encapsulation method using the tailor-made clamps is designed to assemble the current collectors and MEA for distributing the stress of the edges and inside uniformly. It is observed that the maximum power density of the air-breathing DMFC operating with 1 M methanol solution achieves 19.7 mW/cm(2) at room temperature. Based on the individual DMFCs, the air-breathing stack consisting of 36 DmFC units is achieved and applied to power a notebook computer. (C) 2010 Professor T. Nejat Veziroglu. Published by Elsevier Ltd. All rights reserved.