A method for fabricating catalytic material comprising: providing a first elongated member extending from a first end to a second end, the first end in fluid communication with a liquid precursor feedstock that includes particles; providing a second elongated member extending from a first end to a second end, the first end mounted with respect to the second end of the first elongated member and in fluid communication with the liquid precursor feedstock; providing a channel of a housing, the channel disposed around at least a portion of the second elongated member; supplying a fuel to the channel, the channel configured and dimensioned to supply the fuel along with the liquid precursor feedstock from the second end of the second elongated member to form a substantially co-flow spray; supplying the substantially co-flow spray into the open atmosphere proximal to the second end of the second elongated member and igniting it to form a flame spray; providing a surface of the housing positioned proximal to the second end of the second elongated member and angled relative to the central axis of the second elongated member, the angled surface including a plurality of ports, each port configured and dimensioned to supply a gas stream; igniting the gas stream to stabilize the flame spray; providing a circular quench assembly that includes a plurality of circumferentially-spaced nozzles that define a substantially circular quench zone distal to the second end of the second elongated member; providing high pressure air flow through the plurality of circumferentially-spaced nozzles to establish a low pressure region in the center of the substantially circular quench zone that pulls in a large volume of surrounding air and creates a conical ring of air, thereby introducing turbulence and vapor to the flame spray to rapidly cool the flame spray and dilute the gas stream; and directing the stabilized flame spray toward a substrate for deposition of the particles thereon. providing a first elongated member extending from a first end to a second end, the first end in fluid communication with a liquid precursor feedstock that includes particles; providing a second elongated member extending from a first end to a second end, the first end mounted with respect to the second end of the first elongated member and in fluid communication with the liquid precursor feedstock; providing a channel of a housing, the channel disposed around at least a portion of the second elongated member; supplying a fuel to the channel, the channel configured and dimensioned to supply the fuel along with the liquid precursor feedstock from the second end of the second elongated member to form a substantially co-flow spray; supplying the substantially co-flow spray into the open atmosphere proximal to the second end of the second elongated member and igniting it to form a flame spray; providing a surface of the housing positioned proximal to the second end of the second elongated member and angled relative to the central axis of the second elongated member, the angled surface including a plurality of ports, each port configured and dimensioned to supply a gas stream; igniting the gas stream to stabilize the flame spray; providing a circular quench assembly that includes a plurality of circumferentially-spaced nozzles that define a substantially circular quench zone distal to the second end of the second elongated member; providing high pressure air flow through the plurality of circumferentially-spaced nozzles to establish a low pressure region in the center of the substantially circular quench zone that pulls in a large volume of surrounding air and creates a conical ring of air, thereby introducing turbulence and vapor to the flame spray to rapidly cool the flame spray and dilute the gas stream; and directing the stabilized flame spray toward a substrate for deposition of the particles thereon.