The performance of the Proton Exchange Membrane Fuel Cell (PEMFC) is greatly influenced by the various operating parameters and geometric properties. This paper deals with optimization of both operating and design parameters namely cell temperature, back pressure, anode and cathode inlet velocities, Gas Diffusion Layer (GDL) porosity and thickness, cathode water mass fraction, flow channel dimensions, rib width and porous electrode thickness. The Numerical model of single channel PEM fuel cell was developed and analyzed by using COMSOL Multiphysics 4.2 software package. The optimization of design and operating parameters in software was carried out in two stages using standard orthogonal array of Taguchi method. From the first stage of analysis, it was inferred that back pressure had maximum effect and rib width had least effect on fuel cell performance. In the second stage of analysis, fine tuned optimization was performed on selected factors which caused for 3% increase in power density and the results were also validated using COMSOL Multiphysics 4.2.
