New catalytic FeCrAlloy premixed fiber burners for natural gas combustion in domestic applications were developed according to an accurate microstructural design consisting of subsequent optimized steps: (i) optimal preoxidation of the FeCrAlloy fiber mat so as to develop the best possible Al 2 O 3 layer for simultaneous prevention of deeper fiber oxidation at high temperature and optimal catalyst anchoring over the fiber surface, (ii) deposition via the either spray-pyrolysis or wash-coating technique of a previously developed perovskite catalyst (LaMnO 3 ‚ 17MgO), and (iii) extensive testing of the catalyst-burner bonding strength and burner performance. Even after extensive aging under practical operating conditions (repeated on-off cycles and prolonged durations under high-temperature radiating conditions), the best developed burners (i.e., those obtained by spray pyrolysis) exhibit very limited catalyst loss and still remarkably lower (30-50%) NO and CO emissions than noncatalytic, virgin FeCrAlloy burners at the specific power densities of practical interest (150-650 kW/m 2 ).