The graphite bi-polar plates were fabricated using lamination technique with polyether sulfone (PES) films (50 mu m) and graphite foils (400 mu m) in between the two porous graphite plates (CBC) by keeping in a specially designed and fabricated fixture with stainless steel plates at the top and bottom. The fixture was then kept in an hydraulic hot press, at loads of 10-20 tons, and heat treated at 410 degrees C for 30 min. Then these graphite plates were sized to 30 cm x 20 cm x 0.64 cm, leaving 0.4 mm thick graphite foil at the centre of the plate, to avoid the intermixing of the hydrogen and oxygen/air. While, the gas permeability (cm(2)/sec) of the plates was determined, with N-2 gas using differential pressure method, their electrical resistivity (m Ohm m) was measured using milliohmmeter and passing DC current to the graphite plates, at loads from 1-5 kgs. The values of permeability and electrical resistivity of the plates are found to be lower than 0.01 cm(2)/sec and 4-14 m Ohm m respectively. A stack with 6 cells was assembled using the in house developed graphite bi-polar plates, anodes and cathodes with matrix, to generate a DC power of 0.25 kW (3.6 V x 71.0 amps). It was operated for 300 h successfully using H-2 and Air, 1 bar, at 175 degrees C. In this paper, the detailed Fabrication method of graphite bi-polar plates and their characteristics of gas permeability, electrical resistivity and the results of the 0.25 kW PAFC stack operation are presented.