A co-planar micro Direct Methanol Fuel Cell (p.DMFC) configuration was designed, developed and tested. The system geometry consisted of anodic and cathodic micro-channels arranged in the same plane. Firstly, micro-channels for a uniform distribution of oxygen and methanol were designed and realized on a polymeric substrate of polycarbonate. Then, the deposition of the catalytic elements inside the micro-channels by a spray-coating technique was carried out. Micro-channels were then covered by a catalyzed membrane containing separate anode and cathode layers. Different cell configurations were built, tested and evaluated. It was observed that the open circuit voltage varied significantly as a function of the membrane humidification degree and distance between anode and cathode channels in this planar design. In the presence of a large distance between the anode and cathode channel, the OCV reached 0.97 V. This high OCV reflected the absence of methanol cross-over due to the specific planar configuration. Regrettably, the overall cell impedance (ohmic and polarization resistance) limited the performance. A maximum power density of 1.3 mW cm(-2) (active area) was achieved at room temperature with the smallest distance between anode and cathode (0.25 mm). Copyright (C) 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.