Direct borohydride fuel cell (DBFC) as a liquid type fuel cell is promising for portable applications. In this study, we report our recent progress in the micro-fuel cell development. A power density of 80mWcm−2 was achieved in passive mode at ambient conditions when using the anode containing nickel, carbon-supported Pd catalyst and Nafion ionomer. Current efficiency was also found to be greatly increased due to the use of Nafion rather than polytetrafluoroethylene (PTFE). Based on improvements on single cell performance, planar multi-cell power modules were assembled to study the feasibility of making high-performance and practical DBFC power units. A power of 2.5W was achieved in a fully passive eight-cell module after significantly simplifying cell structure.