Abstract: A fan fold resistance bonded metal catalyst substrate is disclosed as well as a method for forming the same. In one method, a length of a continuous sheet of foil is moved bidirectionally through a corrugators. The corrugator engages with the foil sheet to form a corrugated shape in the foil; each of the corrugated shapes have a profile to form substantially “V” shaped corrugations along the length of said foil. The continuous sheel of corrugated foil is fan folded at predetermined places along the length of the corrugagted foil into a fan folded corrugated continous foil shape. The shape has at least two layers of opposed corrugated foil in facing relation to each other. The V shaped corrugations in each layer are positioned relative to each other to form a substantially consistent diamond pattern between opposed separate layers in a substrate face of the fan folded corrugated continuous foil sheet shape.