In order to take better advantage of metallic bipolar plates for producing metallic fuel cells and make it a feasible technology, it is essential that we have an efficient and cost effective fabrication process for creating micro-scaled flow channels. In this study, an electrochemical micro-machining(EMM) process is developed. In order to have better process control a finite element analysis is employed to ensure machine tool platform rigidity; an electric field analysis is applied for the electrode design; and an electrolytic flow analysis is carried out for the fixture design and the selection of the operational parameter. Finally, flow channels measuring 200 mu m in depth and 500 mu m in width are fabricated on SS316 stainless steel sheets measuring 50 mm x 0.6 mm thick. (C) 2008 Elsevier B.V. All rights reserved.