This paper presents discharge characteristics and fabrication processes of the face-to-face sustain electrode structure in AC-plasma display panel. The fabrication process of the 6-in. test panels with two different types of electrodes such as face-to-face and coplanar electrodes are compared. For both structures, the discharge characteristics, such as the luminance and luminous efficiency, are compared and examined. The luminance efficiencies for two structures are measured at a 4% Xe-content and a pressure of 450Torr, and driving frequencies of 100kHz with a duty ratio of 40%, respectively. As a result, the luminance of the face-to-face sustain electrode structure is improved by about 3.5 to 4 times than that of the coplanar structure. The luminance efficiency of the face-to-face structure is improved by about 1.35 times than that of the coplanar structure in the 42-in. high definition (HD) grade AC-PDPs.