As a promising candidate for conventional micro-power sources, the micro-direct methanol fuel cell (mu DMFC) is currently attracting increased attention due to its various advantages and prospective suitability for portable applications. This paper reports the design, fabrication and analysis of a high-performance mu DMFC with two metal current collectors. Employing micro-stamping technology, the current collectors are fabricated on 300-mu m-thick stainless steel plates. The flow fields for both cathode and anode are uniform in shape and size. Two sheets of stainless steel mesh are added between the membrane electrode assembly (MEA) and current collectors in order to improve cell performance. To avoid electrochemical corrosion, titanium nitride (TiN) layers with thickness of 500 nm are deposited onto the surface of current collectors and stainless steel mesh. The performance of this metallic mu DMFC is thoroughly studied by both simulation and experimental methods. The results show that all the parameters investigated, including current collector material, stainless steel mesh, anode feeding mode, methanol concentration, anode flow rate, and operating temperature have significant effects on cell performance. Moreover, the results show that under optimal operating conditions, the metallic mu DMFC exhibits promising performance, yielding a maximum power density of 65.66 mW cm(-2) at 40 degrees C and 115.0 mW cm(-2) at 80 degrees C. Crown Copyright (C) 2010 Published by Elsevier B.V. All rights reserved.