In this study, the flow channels of a PEM fuel cell are fabricated by the EMM process. The parametric effects of the process are Studied by both numerical simulation and experimental tests. For the numerical simulation, the multiphysics model, consisting of electrical field, convection, and diffusion phenomena is applied using COMSOL software. COMSOL software is used to predict the parametric effects of the channel fabrication accuracy such as pulse rate, pulse duty cycle, inter-electrode gap and electrolytic inflow velocity. The proper experimental parameters and the relationship between the parameters and the distribution of metal removal are established from the simulated results. The experimental fabrication tests showed that a shorter Pulse rate and a higher Pulse current improved the fabrication accuracy, and is consistent with the numerical simulation results. The proposed simulation model could be employed as a predictive tool to provide optimal parameters for better machining accuracy and process stability of the EMM process. (C) 2009 Elsevier B.V. All rights reserved.