To improve the energy conversion of a micro-channel reactor, an innovative micro-channel catalyst support with a micro-porous surface is proposed and fabricated by a layered powder sintering and dissolution method (LPSDM). The catalyst adhesion strength is analyzed by an ultrasonic vibration test and results show the catalyst has a 7 wt. % loss on the catalyst support with micro-porous surface and a 16 wt. % loss on the non-porous surface. Subsequently, the coated catalyst support is applied to methanol steam reforming for hydrogen production. Results show that the micro-channel catalyst supports with micro-porous and non-porous surfaces respectively have a hydrogen production rate of 18.07 ml/min and 9.65 ml/min at 573 K under the inlet flow rate of 30 mu l/min. Compared with the catalyst support with a non-porous surface, the catalyst support with a micro-porous surface shows better catalyst adhesion and obvious advantages in hydrogen production rate and methanol conversion. Copyright (C) 2015, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.