Lifetime and cost are two main factors that restrict the commercialization of Proton Exchange Membrane (PEM) fuel cells. This paper mainly studies the prediction and the evaluation methods of PEM fuel cell lifetime. A formula to predict the PEM fuel cell lifetime is presented. The formula is based on the vehicular operation records and the tested results in the lab. Also the difference between the vehicular operation condition and the test is taken into consideration. The formula realizes the PEM fuel cell lifetime rapid prediction. A PEM fuel cell residual life evaluation method is also presented. The evaluation method realizes online forecasting of the residual life through updating the environmental affecting factor and voltage degradation rate caused by the operating conditions. Furthermore, the PEM fuel cell economic lifetime is studied. The economic lifetime is the working lifetime which gains the lowest average cost. The synthesis of the lifetime and the cost provides a basis to confirm the best design lifetime. (C) 2015 Elsevier Ltd. All rights reserved.