A micro direct methanol fuel cell (μDMFC) with active area of 1.625cm2 has been developed for high power portable applications and its electrochemical characterization carried out in this study. The fragility of the silicon wafer makes it difficult to compress the cell for good sealing and hence to reduce contact resistance in the Si-based μDMFC. We have instead used very thin stainless steel plates as bipolar plates with the flow field machined by photochemical etching technology. For both anode and cathode flow fields, widths of both the channel and rib were 750μm, with a channel depth of 500μm. A gold layer was deposited on the stainless steel plate to prevent corrosion. This study used an advanced MEA developed in-house featuring a modified anode backing structure with a compact microporous layer. Maximum power density of the micro DMFC reached 62.5mWcm−2 at 40°C, and 100mWcm−2 at 60°C at atmospheric pressure, which almost doubled the performance of our previous Si-based μDMFC.