In recent years, development of polymer electrolyte membrane fuel cells (PEMFCs) has been considered to generate electricity and heat. Among main components of PEMFCs, bipolar plates (BPPs) have significant influence on cost and performance of the system. Metallic BPPs, formed using thin sheets, have been developed as alternative to conventional graphite plates because of advantages such as suitable cost, mechanical strength and power density. Flexibility of the sheets and spring back during forming process make dimensional errors inevitable and lead to inappropriate contact pressure distribution between BPPs and gas diffusion layer (GDL), resulting in decrease of fuel cell performance. Excessive accuracy in BPP production leads to increase the final cost and decrease the general usability of the technology. Therefore, to reduce unnecessary costs, managing design process and improving efficiency, analysis of BPP dimensional errors is done using finite element method and Monte Carlo simulation (MCS). First, contact model of the metallic BPP and GDL is developed and heights of each channel and each rib of BPP are fully parameterized due to stochastic variations of dimensional errors with normal distribution. Then, contact pressure distributions of GDL (Pave, Pstd) for different dimensional errors are obtained by MCSs. Increasing dimensional tolerance from 0.015 mm to 0.075 mm, average contact pressure (Pave) has decreased by 11% and standard deviation of contact pressure (Pstd) has increased up to 90%. Namely desirable distribution of GDL pressure is reduced by increasing the dimensional error and suitable dimensional tolerances for BPPs can be determined according to engineering requirements.