The main constraint for commercialization of micro direct methanol fuel cell (mu DMFC) for small power generation is the performance of the fuel cell. In this study. a high power mu DMFC with a power Output of 56 mW and an active area of 4 cm(2) Was Successfully developed. The cell required low catalyst loading of 5 mg cm(-2) and 0 5 mg cm(-2) at the anode and cathode, respectively Optimal design parameters for methanol concentration and catalyst loading were examined Finally. long-term performance testing was performed and OCV curves are reported. The results obtained for this gives the highest power density at low catalyst loading as compare to other researchers in this area. (C) 2009 Elsevier Ltd All rights reserved.