This study explores the feasibility of using a relatively rapid technique, die-sinking micro-electrical discharge machining, to fabricate miniature metallic bipolar plates. The flow field is a three-pass serpentine structure, of which both the rib and channel widths are 500μm and the channel depth is 600μm (aspect ratio=1.2) in a reaction area of 20mm×20mm. The material-removal rate of the proposed method can reach up to 7.2mm3 min−1. However, a high material-removal rate also increases the surface roughness of flow channels. In single-cell tests, the peak power densities are 674mWcm−2 and 647mWcm−2 for flow channels with a surface roughness of 0.715μmRa and 0.994μmRa, respectively. Though the increase in surface roughness lowers cell performance, the effect is not statistically significant.