The PEM fuel cell stack design and assembly parameters significantly affect the durability and performance of fuel cell. The mechanical means of end plates is to unitize the various components to be a fuel cell stack. Too much pressure changes the porosity of GDL, can damage the bipolar plate and ultimately reduces the performance of fuel cell and life. On the other hand, insufficient pressure may cause leakage of fuel and increase of contact resistance between various layers, in the result it also decrease the fuel performance. Uniformity of pressure distribution in fuel cell is one of the critical parameter which highly affects the fuel cell performance. Uneven pressure distribution in layers reduces the cell performance and produce hot spots which reduces the fuel cell life. Clamping methods influence the uniformity of pressure distribution. From the structural point of view, the variables which affect the pressure distribution, durability and performance of fuel cell are thickness of end plate, number of clamping bolts and tightening torque. But unfortunately very little scientific research has been focused to optimize the fuel cell in accordance to above parameters. In traditional clamping methods while assembling and clamping the stack, deformation occurs in end plates which results a non uniform pressure distribution in fuel cell stack. FEM methods are not enough to understand and achieve the optimum level of pressure distribution and fuel cell performance. Because clamping pressure is related to the electrical and mass flow characteristics.In this study, a very thick end plate 30 mm is developed to control the deformation in end plates. To get the uniform pressure distribution and better fuel cell performance, number of bolts and applied torque was selected through FEM and experiments. To check the end plate deflection, strain gage is used. To check the durability of fuel cell components, FEM and experiment methods were used. This new design provides uniform pressure distribution, not only on perimeters but also on the central area in fuel cells. In future this new clamping method will enhance the performance and life of fuel cell stacks.