In this paper, a 6-cells direct methanol fuel cell (DMFC) stack with the volume of only 13.25 cm(3) and the weight of 24.075 g is designed, fabricated and tested. First, the material characterization of the Au-coated Al current collector is investigated to exhibit superior characteristics in electric conductivity, weight and electrochemical corrosion resistance. And then the steady-state performance of the stack is tested, the maximum power output of the stack reaches 568.4 mW at room temperature. The dynamic performance and durability of the stack are also investigated in consideration of practical conditions. Results indicate that stack performance represents good responding and reproducible ability. Finally, the DMFC stack proves its good performance in powering experimental fan two times in 30 days successfully. (C) 2013 Elsevier Ltd. All rights reserved.