TECHNOLOGY FOCUS - INORGANIC CHEMISTRY - Preferred Properties: The first surface comprises particles having a nominal diameter size distribution of less than 1 micronsm. The second surface comprises a coating having a nominal thickness of less than 100 nm. The first surface has a thickness in the nominal range of greater than ca. 30 micronsm, and a porosity of at least 50%. The adhesion of the second surface tolerates a processing temperature of up to ca. 1000degreesC.Preferred Components: The substrate comprises a thin metallic film having two surfaces. The first surface comprises ceria and palladium. The second surface comprises palladium.Preferred Configuration: The substrate includes several folds which are spaced apart a predetermined distance corresponding to predetermined apexes (A1-A4) in a folded member forming channels of a predetermined depth. The folds are curvilinear or angular, and are formed in the substrate by stamping.    TECHNOLOGY FOCUS - CHEMICAL ENGINEERING - Preferred Process: A surface to be coated by a physical deposition process is cleaned by an ion-gun in an oxygen atmosphere and in an argon atmosphere prior to deposition. The substrate is supported upon a rigid heat sink conforming to the shape of the substrate during the thermal spraying of the surface. The thermal spraying of the surface precedes the physical deposition of a metal composition on the surface opposite the surface which is thermally sprayed with particulates. Coating the opposite surface of the substrate by a physical deposition process comprises an electron beam vapor deposition or plasma sputtering of a noble metal composition. The manufacture of a micro channel catalytic device further comprises squeezing the substrate laterally such that the preformed folds of the substrate narrow from their apexes to form the micro channels. Pre-forming of the substrate with longitudinal folds comprises stamping the folds into a sheet material. The preformed substrate is supported during the thermal spraying in contact with a rigid heat sink having an upper surface with a shape corresponding to the supported side of the pre-folded substrate. The method further includes brazing the apexes of the folds on each side of the substrate to a plate to form enclosed channels defined by the apexes of the folds. The surface is grit-blasted prior to thermal spraying. The physical deposition of a noble metal on the surface is performed subsequent to the thermal spraying of the surface.