In this manuscript the authors detail the fabrication of permselective palladium membranes within cordierite mini-channel networks, and their subsequent evaluation for hydrogen purification. Cordierite extruded honeycomb monoliths (64cpsi) were first washcoated with micropowder gamma-Al2O3 to realize cylindrical surfaces for subsequent deposition of palladium films. A second nanopowder gamma-Al2O3 layer provides a uniform surface for deposition of defect-free palladium films. Electroless plating under kinetic-limited conditions enabled plating of thin (8 mu m) defect-free palladium films with crystallite sizes of similar to 2 mu m. Analysis of resulting two-channel membrane systems for hydrogen separation at 350 degrees C demonstrated hydrogen flux of 1.0-5.5 x 10(-3) mol m(-2) s(-1) and hydrogen-to-helium selectivities of 40-360:1. Lastly, the authors detail a novel microreactor design strategy to employ resulting mini-channel membrane networks as part of a thermally integrated portable reformer for high-purity hydrogen production. (C) 2009 Elsevier B.V. All rights reserved.