Abstract: A method of manufacturing porous, irregularly-shaped particles having high surface areas and a particle made thereby is disclosed wherein small grains of a material are adhered together to form larger particles of porous, irregularly shaped form having high surface areas. Thereafter, the larger particles are injected into the effluent of a liquid stabilized plasma gun device to fuse together the individual grains forming each larger particle, thereby increasing the adherence of the individual grains, while maintaining the porous, irregularly-shaped properties thereof.