Air Breathing Proton Exchange Membrane (AB-PEM) Fuel cell is a clean energy conversion device that convert chemical energy of fuels like Hydrogen directly into electrical energy without combustion. In this study, lab scale development efforts have been demonstrated for realization of AB-PEM fuel cell taking an advantage of simulations and analysis. The objective of this research is to develop a thorough understanding of AB-PEM fuel cell design, electrochemical models, simulations, manufacturing processes and testing for sustainable energy solution. PEM fuel cell device was designed for a small Unmanned Aerial Vehicle (UAV) application. MATLAB and ANSYS fluent tools were used to predict fuel cell performance. Based on optimized simulation results, prototype device was fabricated for performance evaluation. Fuel cell testing was carried out for getting insights of operating parameters and comparison between simulated and actual device performance results. The techniques can be utilized to improve fuel cell design & fabrication processes to ensure robust performance. Fulfillment of the objectives will provide a comprehensive realization of the fuel cell performance theoretically and then validation through experimentation. Results from this study will lead to improved design and manufacturing of AB-PEM fuel cell as well as improved performance.