The existing direct methanol fuel cell (DMFC) systems are fed with a fixed concentration of fuel, which are either a diluted methanol solution or an active fuel delivery driven by an attached active pump. Both approaches limit the power conversion density or degrade the overall efficiency of the DMFC system significantly. Such disadvantages become more severe in small-scale DMFCs, which require a high conversion efficiency and a small physical space suitable for portable electronics. In this paper, passive fuel delivery based on a surface tension driving mechanism was designed and integrated in a laboratory-made prototype to achieve consumption depending on fuel concentration and power-free fuel delivery. Unidirectional methanol-to-water smooth flow is achieved through the capillaries of a Teflon PTFE (polytetrafluoroethylene) membrane based on the difference in liquid surface tension. The prototype was demonstrated to exhibit a better polarization performance and to last for an extended operating time compared to conventional DMFCs. Its high efficiency and load regulation performance were also demonstrated in contrast to an active DMFC supplied with a constant concentration fuel. The fuel delivery driven by the liquid surface tension effect demonstrated here is believed to be more applicable for future small-scale DMFCs for portable electronics. (c) 2006 Elsevier B.V. All rights reserved.