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Abstract: Direct methanol fuel cell operation with uniaxially pre-stretched recast Nafion® membranes (draw ratio of 4) was investigated and compared to that with commercial (un-stretched) Nafion®. The effects of membrane thickness (60–250μm) and methanol feed concentration (0.5–10.0M) on fuel cell power output were quantified for a cell temperature of 60°C, ambient pressure air, and anode/cathode catalyst loadings of 4.0mgcm−2. Pre-stretched recast Nafion® in the 130–180μm thickness range produced the highest power at 0.4V (84mWcm−2), as compared to 58mWcm−2 for Nafion® 117. MEAs with pre-stretched recast Nafion® consistently out-performed Nafion® 117 at all methanol feed concentrations, with 33–48% higher power densities at 0.4V, due to a combination of low area-specific resistance (the use of a thinner pre-stretched membrane, where the conductivity was the same as that for commercial Nafion®) and low methanol crossover (due to low methanol solubility in the membrane). Very high power was generated with a 180-μm thick pre-stretched recast Nafion® membrane by increasing the cell temperature to 80°C, increasing the anode/cathode catalyst loading to 8.0mgcm−2, and increasing the cathode air pressure to 25psig. Under these conditions the power density at 0.4V for a 1.0-M methanol feed solution was 240mWcm−2 and the maximum power density was 252mWcm−2. [Copyright &y& Elsevier]