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Summary A comprehensive 3D, multiphase, and nonisothermal model for a proton exchange membrane fuel cell has been developed in this study. The model has been used to investigate the effects of the size of the parallel‐type cathode flow channel on the fuel cell performance. The flow‐field plate, with the numerically predicted best performing cathode flow channel, has been built and experimentally tested using an in‐house fuel cell test station. The effects of the operating conditions of relative humidity, pressure, and temperature have also been studied. The results have shown that the fuel cell performs better as the size of the cathode flow channel decreases, and this is due to the increased velocity that assists in removing liquid water that may hinder the transport of oxygen to the cathode catalyst layer. Further, the modelled fuel cell was found to perform better with increasing pressure, increasing temperature, and decreasing relative humidity; the respective results have been presented and discussed. Finally, the agreement between the modelling and the experimentally data of the best performing cathode flow channel was found to be very good.

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