Abstract: A fuel cell stack including a housing for holding fuel cells is disclosed. Each fuel cell includes a membrane electrode assembly with a proton exchange membrane disposed between carbon bases, a connector for engaging metalized collectors to form an electrical circuit for operating the fuel cell stack, and a sealable two-part housing for supporting an oxidant manifold and a fuel manifold that support the membrane electrode assembly and flexible plenums of each fuel cell. The fuel cell stack includes fuel cell connectors for connecting an anode from one fuel cell with a cathode from an adjacent fuel cell, a fuel intake in communication with a fuel source and an oxidant intake in communication with an oxidant source for providing fuel and oxidant into the fuel cell stack, a controller for monitoring and regulating fuel and oxidant, and a fuel manifold engaging fuel intakes and an oxidant manifold engaging oxidant intakes.

Abstract: A method for making fuel cells is disclosed and includes placing catalyst strips on an anode side and a cathode side of a proton exchange membrane disposed between carbon bases. The method includes metalizing at least two collectors, and drilling a plurality of paths through the body portions to form a first and second metalized collectors, which are placed on opposite sides of the proton exchange membrane to form a membrane electrode assembly. The metalized collectors are connected to form an electrical circuit for operating the fuel cell. A flexible fuel plenum and a flexible oxidant plenum are disposed on opposite sides of the membrane electrode assembly, and a fuel manifold and an oxidant manifold of a sealable two-part housing engage the membrane electrode assembly to provide oxidant to the flexible oxidant plenum and fuel to the flexible fuel plenum forming an operational singe unit fuel cell.