A low-cost fluorine-free proton conducting polymer electrolyte was investigated for application in direct methanol fuel cell (DMFC) mini-stacks. The membrane consisted of a sulfonated polystyrene grafted onto a polyethylene backbone. DMFC operating conditions specifically addressing portable applications, i.e. passive mode, air breathing, high methanol concentration, room temperature, were selected. The device consisted of a passive DMFC monopolar three-cell stack. Two designs for flow-fields/current collectors based on open-flow or grid-like geometry were investigated. An optimization of the mini-stack structure was necessary to improve utilization of the fluorine-free membrane. Titanium-grid current collectors with proper mechanical stiffness allowed a significant increase of the performance by reducing contact resistance even in the case of significant swelling. A single cell maximum power density of about 18 mW cm(-2) was achieved with the fluorine-free membrane at room temperature under passive mode. As a comparison, the performance obtained with Nation 117 membrane and Ti grids was 31 mW cm(-2). Despite the lower performance, the fluorine-free membrane showed good characteristics for application in portable DMFCs especially with regard to the perspectives of significant cost reduction. (C) 2010 Elsevier Ltd. All rights reserved.