Proton Exchange Membrane Fuel Cells (PEMFC) are the most appropriate for energy source of small robot applications. PEMFC has superior in power density and thermodynamic efficiency as compared with the Direct Methaol Fuel Cell (DMFC). Furthermore, PEMFC has lighter weight and smaller size than DMFC which are very important factors as small robot power system. The most significant factor of mobile robots is weight which relates closely with energy consumption and robot operation. This research tried to find optimum specifications in terms of type, number of cell, active area, cooling method, weight, and size. In order to find optimum 500W PEMFC, six options are designed in this paper and studied to reduce total stack weight by applying new materials and design innovations. However, still remaining problems are thermal management, robot space for energy sources, and so on. For a thermal management, design options need to analysis of Computational Fluid Dynamics (CFD) for determining which option has the improved performance and durability.