This paper reports a micro direct methanol fuel cell (mu DMFC) integrated with a heater and a temperature sensor to realize temperature control. A thermal model for the mu DMFC is set up based on heat transfer and emission mechanisms. Several patterns of the heater are designed and simulated to produce a more uniform temperature profile. The mu DMFC with optimized temperature control system, which has better temperature distribution, is fabricated by using MEMS technologies, assembled with polydimethylsiloxane (PDMS) material and polymethylmethacrylate (PMMA) holders, and characterized in two methods, one with different currents applied and another with different methanol velocities. A mu DMFC integrated with the heater of different pattern and another one with aluminum holders, are assembled and tested also to verify the heating effect and temperature maintaining of packaging material. This work would make it possible for a mu DMFC to enhance the performance by adjusting to an optimal temperature and employ in extreme environments, such as severe winter, polar region, outer space, desert and deep sea area. (C) 2009 Elsevier B.V. All rights reserved.