We have developed the novel design and the fabrication processes for micro-direct methanol fuel cell (mu-DMFC). The membrane-electrode assemblies (MEA) consist of two identical polymer chips positioned on both sides of the proton exchange membrane, which play the roles of current collector, fuel-diffusion layer, and catalyst supporter. The detailed fabrication steps for the polymer chips are described. Each chip has 300 mum thru holes for catalyst supporter and 400 mum thru holes for fuel-diffusion layer. The total thickness of our all polymer R-DMFC applying this MEA is about 500 mum including the thickness of Nation(R). The measured maximum power density of the all polymer micro-DMFC was 8 mW/cm(2) and current density was 37 mA/cm(2). (C) 2004 Elsevier Ltd. All rights reserved.