A miniaturized methanol steam reformer with a serpentine type of micro-channels was developed based on poly-dimethylsiloxane (PDMS) material. This way of fabricating micro-hydrogen generator is very simple and inexpensive. The volume of a PDMS micro-reformer is less than 10 cm(3). The catalyst used was a commercial Cu/ZnO/Al2O3 reforming catalyst from Johnson Matthey. The Cu/ZnO/Al2O3 reforming catalyst particles of mean diameter 50-70 mu m was packed into the micro-channels by injecting water based suspension of catalyst particles at the inlet point. The miniaturized PDMS micro-reformer was operated successfully in the operating temperatures of 180-240 degrees C and 15%-75% molar methanol conversion was achieved in this temperature range for WHSV of 2.1-4.2 h(-1). It was not possible to operate the micro-reformer made by pure PDMS at temperature beyond 240 degrees C. Hybrid type of micro-reformer was fabricated by mixing PDMS and silica powder which allowed the operating temperature around 300 degrees C. The complete conversion (99.5%) of methanol was achieved at 280 degrees C in this case. The maximum reformate gas flow rate was 30 ml/min which can produce 1 W power at 0.6 V assuming hydrogen utilization of 60%. (C) 2010 Elsevier B.V. All rights reserved.