The lamination-plate structure patterned with microchannels and triangle manifolds regarded as one of the preferred constructions for micro fuel reformers. Learned from the microchannel plate structure, a similar plate structure with cube-post array and triangle manifolds is proposed in this work. A micromilling process is applied to fabricate the cube posts on the plate surface, and the influences of cutting parameters on the burr formation are analyzed. Experimental results indicate that larger cutting speed, smaller feed rate and cutting depth are in favor of obtaining relatively small burrs. Two plates with different cube-post dimensions and manifold structures are experimentally investigated the performances of methanol steam reforming over the Cu/Zn/Al/Zr catalyst. It indicates that the reactor with small-scale cube posts and acute triangle manifold presents better reforming performances at 260 degrees C than that of the one with large-scale cube posts and right triangle manifolds. However, their performances are closed to each other at relatively high reaction temperature since the catalyst activity is situated in dominated position at the time. (C) 2011 Elsevier Ltd. All rights reserved.