A three-dimensional, single-phase, multi-component mathematical model has been developed for a liquid-fed direct methanol fuel cell (DMFC). The traditional continuity, momentum, and species conservation equations are coupled with electrochemical kinetics in both the anode and cathode catalyst layer. At the anode side, the liquid phase is considered, and at the cathode side only the gas phase is considered. Methanol crossover due to both diffusion and electro-osmotic drag from the anode to the cathode is taken into consideration and the effect is incorporated into the model using a mixed-potential at the cathode. A finite-volume-based CFD technique is used to develop the in-house numerical code and the code is successfully used to simulate the fuel cell performance as well as the multi-component behavior in a DMFC. The modeling results of polarization curves compare well with our experimental data. Subsequently, the model is used to study the effects of methanol crossover, the effects of porosities of the diffusion layer and the catalyst layer, the effects of methanol flow rates, and the effects of the channel shoulder widths. (c) 2006 Elsevier B.V. All rights reserved.