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Polymer-carbon composite bipolar plates (PCCBP) are accepted over graphite bipolar plates (BP) for their use in proton exchange membrane fuel cell (PEMFC), specially in hydrogen fuel cell-powered electric vehicles. This study developed a novel copper fiber-filled PCCBP with epoxy resin as the binder and natural flake graphite (NFG), carbon black (CB), and Cu fiber as filler materials. The fabrication is done by compression molding. Both electrical conductivity and flexural strength increased with the addition of Cu fiber. The composite BP fabricated with 8 vol % Cu fiber, 10 vol % CB, and 42 vol % NFG exhibited electrical conductivity of 169 S/cm, flexural strength of 43 MPa, thermal conductivity of 17 W m−1 K−1 and corrosion current density of 0.972 μA/cm2. The composite also showed acceptable results for contact angle, density and thermal stability tests. This research paper provides insights into further developments of the metal-based PCCBP. • Novel Cu fiber-filled composite bipolar plates were developed for PEM fuel cells. • Effect of content of epoxy resin, carbon black, and copper fiber was investigated. • Enhancement of electrical conductivity and flexural strength achieved concurrently. • Provides insights into future developments of the metal-based PCCBP. [ABSTRACT FROM AUTHOR]