Current collectors of the direct methanol fuel cell (DMFC) are of significant importance for portable power sources, and greatly determine the weight energy density and cost of the cell. In this paper, the air-breathing aluminum (Al) current collectors have been developed for powering portable applications. The anode and cathode current collectors with the area of 4.5 cm(2) were fabricated on the Al substrates utilizing Computer Numerical Control (CNC) technology. To obtain strong anti-corrosion resistance, a 3-mu m-Au layer was deposited on the current collectors using chemical plating. Compared with the graphite and stainless steel, the characterization of the Au-coated Al current collector was investigated to exhibit superior characteristics in electric conductivity, weight and electrochemical corrosion resistance. The current collector was applied to a DMFC and the cell performance was experimentally investigated under different operating conditions. The measured maximum power density of the DMFC could reach 19.8 mW cm(-2) at current density of 98 mA cm(-2) with 2 M methanol solutions. The results indicated that the Au-coated Al current collectors presented in this paper might be helpful for the development of portable power sources applied in future commercial applications. Copyright (C) 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.