Direct formic acid fuel cells (DFAFCs) possess the advantages of high power density and theoretical cell potential. Exploring robust catalysts for electrochemical formic acid electro-oxidation (FAO) is greatly essential for the wide spread uptake of DFAFCs. However, many electrodes with attractive catalysts suffer limited mass transport due to sluggish CO 2 bubble growth and departure steps on its surface. In this study, a superaerophobic electrode is developed by depositing fern-shaped palladium nanostructured arrays on the carbon paper (Pd-nanoarray@CP). Its unique superaerophobic feature successfully facilitates the CO 2 bubble releasing from the catalyst surface in a significantly small size. With the merits of specific nanoarray morphology, superior under water superaerophobicity, and rapid gas bubble release, the Pd-nanoarray@CP shows fast charge/mass transport rate, high electrocatalytic activity, and great stability for FAO. A direct formic acid fuel cell equipped with the Pd-nanoarray@CP anode is successfully fabricated on a microfluidic platform. A peak power density of 35.8 mW cm −2 and limiting current density of 173.3 mA cm −2 are obtained, respectively, which are 49.2% and 33.0% higher than that of conventional Pd-black anodes. The electrode with superaerophobic interface allows deeper insight into the mechanism of FAO efficiency and holds promise for possible applications of commercially viable DFAFCs.