The performance of the fuel cell is affected by many parameters. One of these parameters is assembly pressure that changes the mechanical properties and dimensions of the fuel cell components. Its first duty, however, is to prevent gas or liquid leakage from the cell and it is important for the contact behaviors of fuel cell components. Some leakage and contact problems can occur on the low assembly pressures whereas at high pressures, components of the fuel cell, such as bipolar plates (BPP), gas diffusion layers (GDL), catalyst layers, and membranes, can be damaged. A finite element analysis (FEA) model is developed to predict the deformation effect of assembly pressure on the single channel PEM fuel cell in this study. Deformed fuel cell single channel model is imported to three-dimensional, computational fluid dynamics (CFD) model which is developed for simulating proton exchange membrane (PEM) fuel cells. Using this model, the effect of assembly pressure on fuel cell performance can be calculated. It is found that, when the assembly pressure increases, contact resistance, porosity and thickness of the gas diffusion layer (GDL) decreases. Too much assembly pressure causes GDL to destroy; therefore, the optimal assembly pressure is significant to obtain the highest performance from fuel cell. By using the results of this study, optimum fuel cell design and operating condition parameters can be predicted accordingly. (C) 2010 Elsevier Ltd. All rights reserved.