This study aims at the fabrication of lightweight and high performance nanocomposite bipolar plates for the application in polymer electrode membrane fuel cells (PEMFCs). The thin nanocomposite bipolar plates (the thickness < 1.2 mm) consisting of multiwalled carbon nanotubes (MWCNTs), graphite powder and PP were fabricated by means of compression molding. Three types of polypropylene (PP)with different crystallinities including high crystallinity PP (HC-PP), medium crystallinity PP (MC-PP), low crystallinity PP (LC-PP) were prepared to investigate the influence of crystallinity on the dispersion of MWCNTs in PP matrix. The optimum composition of original composite bipolar plates was determined at 80 wt.% graphite content and 20 wt.% PP content based on the measurements of electrical and mechanical properties with various graphite contents. Results also indicate that MWCNTs was dispersed better in LC-PP than other PIP owing to enough dispersed regions in nanocomposite bipolar plates. This good MWCNT dispersion of LC-PP would cause better bulk electrical conductivity, mechanical properties and thermal stability of MWCNTs/PP nanocomposite bipolar plates. In the MWCNTs/LC-PP system, the bulk electrical conductivities with various MWCNT contents all exceed 100 S cm(-1). The flexural strength of the MWCNTs/LC-PP nanocomposite bipolar plate with 8 phr of MWCNTs was approximately 37% higher than that of the original nanocomposite bipolar plate and the unnotched Izod impact strength of MWCNTs/LC-PP nanocomposire bipolar plates was also increased from 68.32 J m(-1) (0 phr) to 81.40 J m(-1) (8 phr), increasing 19%. In addition, the coefficient of thermal expansion of MWCNTs/LC-PP nanocomposite bipolar plate was decreased from 32.91 mu m m(-1) degrees C-1 (0 phr) to 25.79 mu m m(-1) degrees C-1 (8 phr) with the increasing of MWCNT content. The polarization curve of MWCNTs/LC-PP nanocomposite bipolar plate compared with graphite bipolar plate was also evaluated. These results confirm that the addition of MWCNTs in LC-PP leads to a significant improvement on the cell performance of the nanocomposite bipolar plate. (C) 2008 Elsevier B.V. All rights reserved.