This study explores the feasibility of using a relatively rapid technique, die-sinking micro-electrical discharge machining, to fabricate miniature metallic bipolar plates. The flow field is a three-pass serpentine structure, of which both the rib and channel widths are 500 mu m and the channel depth is 600 mu m (aspect ratio = 1.2) in a reaction area of 20 mm x 20 mm. The material-removal rate of the proposed method can reach up to 7.2 mm(3) min(-1). However, a high material-removal rate also increases the surface roughness of flow channels. In single-cell tests, the peak power densities are 674 mW cm(-2) and 647 mW cm(-2) for flow channels with a surface roughness of 0.715 mu m Ra and 0.994 mu m Ra, respectively. Though the increase in surface roughness lowers cell performance, the effect is not statistically significant. (C) 2011 Elsevier B.V. All rights reserved.