A method of forming a plurality of micro fuel cells (100, 200, 300, 400, 900), comprising the steps of: forming a plurality of first apertures (135, 235, 335, 435) defined by a first aperture surface (130, 230, 330, 430) through a first electrode layer (110A, 210A, 310A, 410A), wherein the first apertures (135, 235, 335, 435) extend from a first surface (112, 212, 312, 412) of the first electrode layer (110A, 210A, 310A, 410A) to a second surface (114, 214, 314, 414) of the first electrode layer (110A, 210A, 310A, 410A), wherein the first electrode layer (110A, 210A, 310A, 410A) comprises a conductive substrate, or a non-conductive substrate having a conductive material applied to the first and second surfaces (112,114) thereof and feed-through contacts electrically connecting the conductive material on the first and second surfaces (112, 114) or the conductive material applied to a surface of the apertures; forming a plurality of second apertures (135, 235, 335, 435) defined by a second aperture surface (130, 230, 330, 430) through a second electrode layer (110B, 210B, 310B, 410B), wherein the second apertures extend from a first surface (112, 212, 312, 412) of the second electrode layer (110B, 210B, 310B, 410B) to a second surface (114, 214, 314, 414) of the second electrode layer (110B, 210B, 310B, 410B), wherein the second electrode layer (110B, 210B, 310B, 410B) comprises a conductive substrate, or a non-conductive substrate having a conductive material applied to the first and second surfaces (112,114) thereof and feed-through contacts electrically connecting the conductive material on the first and second surfaces (112, 114) or wherein the conductive material is applied to a surface of the apertures; providing a proton exchange membrane (140, 240, 340, 440) with a catalyst on both surfaces of the proton exchange membrane (140, 240, 340, 440); laminating the proton exchange membrane (140, 240, 340, 440) between the first electrode layer (110A, 210A, 310A, 410A) and the second electrode layer (110B, 210B, 310B 410B), where the first apertures (135, 235, 335, 435) of the first electrode layer (110A, 210A, 310A, 410A) are at least partially aligned with the second apertures (135, 235, 335, 435) of the second electrode layer (110B, 210B,310B, 410B), thereby exposing the proton exchange membrane (140, 240, 340, 440) on both surfaces in the apertures to form a plurality of micro fuel cells; and dicing the plurality of fuel cells into single fuel cells or arrays of fuel cells. forming a plurality of first apertures (135, 235, 335, 435) defined by a first aperture surface (130, 230, 330, 430) through a first electrode layer (110A, 210A, 310A, 410A), wherein the first apertures (135, 235, 335, 435) extend from a first surface (112, 212, 312, 412) of the first electrode layer (110A, 210A, 310A, 410A) to a second surface (114, 214, 314, 414) of the first electrode layer (110A, 210A, 310A, 410A), wherein the first electrode layer (110A, 210A, 310A, 410A) comprises a conductive substrate, or a non-conductive substrate having a conductive material applied to the first and second surfaces (112,114) thereof and feed-through contacts electrically connecting the conductive material on the first and second surfaces (112, 114) or the conductive material applied to a surface of the apertures; forming a plurality of second apertures (135, 235, 335, 435) defined by a second aperture surface (130, 230, 330, 430) through a second electrode layer (110B, 210B, 310B, 410B), wherein the second apertures extend from a first surface (112, 212, 312, 412) of the second electrode layer (110B, 210B, 310B, 410B) to a second surface (114, 214, 314, 414) of the second electrode layer (110B, 210B, 310B, 410B), wherein the second electrode layer (110B, 210B, 310B, 410B) comprises a conductive substrate, or a non-conductive substrate having a conductive material applied to the first and second surfaces (112,114) thereof and feed-through contacts electrically connecting the conductive material on the first and second surfaces (112, 114) or wherein the conductive material is applied to a surface of the apertures; providing a proton exchange membrane (140, 240, 340, 440) with a catalyst on both surfaces of the proton exchange membrane (140, 240, 340, 440); laminating the proton exchange membrane (140, 240, 340, 440) between the first electrode layer (110A, 210A, 310A, 410A) and the second electrode layer (110B, 210B, 310B 410B), where the first apertures (135, 235, 335, 435) of the first electrode layer (110A, 210A, 310A, 410A) are at least partially aligned with the second apertures (135, 235, 335, 435) of the second electrode layer (110B, 210B,310B, 410B), thereby exposing the proton exchange membrane (140, 240, 340, 440) on both surfaces in the apertures to form a plurality of micro fuel cells; and dicing the plurality of fuel cells into single fuel cells or arrays of fuel cells.