This paper reports the design and development of a Proton Exchange Membrane (PEM) fuel cell using Aluminum open pore cellular metal foam as the flow plate material. Effective housing designs are proposed for both hydrogen and oxygen sides and through the application of Computational Fluid Dynamic (CFD) modelling and analysis techniques, the flow regime through the open pore cellular metal foam flow plate are identified. Based on the CFD results, the best anode housing design was selected. The fuel cell was then modelled and the findings are reported. The results obtained showed that using the open pore cellular foam material for the modelled fuel cell was more efficient compared to the traditional types of fuel cell in literature.