An improved gas burner for a gas burner assembly and method of making is disclosed comprising a porous burner element extending between a first and a second end. The porous burner element comprises a sintered matrix of metallic fibers. A first end cap is formed from a rigid metallic material and is secured to the first end of the porous burner element. A second end cap comprises a sintered matrix of metallic fibers. The second end cap is secured to the second end of the porous burner element solely by the metallic fibers of the porous burner element bonding with the metallic fibers of the second end cap. In another embodiment of the invention, the porous burner element has a plurality of pleats for increasing the surface area of the porous burner element.