In this work, a MFC fabrication procedure including two non-conventional techniques (partial baking and cap-sealing) were employed for the development of an up-scaled microfluidic fuel cell (MFC). Novel carbon-based electrode materials were employed, including carbon foam, fibre, and cloth, the results from which were compared with traditionally-employed carbon paper. The utilization of carbon cloth led to 15% of the maximum power that resulted from carbon paper;​ however, carbon fibre led to a 24.6% higher power density than carbon paper (normalized by electrode volume). When normalized by projected electrode area, the utilization of carbon foams resulted in power densities up to 42.5% higher than that from carbon paper. The impact of catalyst loading on MFC performance was also investigated, with an increase from 10.9 to 48.3 mgPt cm⁻² resulting in a 195% increase in power density.