The formation of metastable alumina phases due to the oxidation of commercial FeCralloy® rods (0.5 mm thickness) at various temperatures and time periods was examined. This structured layer acts as an anchor to bind additional coatings of alumina via wash-coat techniques, thereby improving the layer thickness and increasing adhesion of the catalytic surface. In addition, thin films of structured zeolite catalysts (ZSM–5 and Y) were grown onto the surface of a metal substrate using in-situ hydrothermal synthesis. All catalysts were fully characterised by SEM, TEM, TGA and XRD.The cracking of n–heptane over the pellets and structured catalysts for both ZSM–5 and USY zeolite showed very similar product selectivities compared with similar traditional pelleted catalyst forms. The alumina coated FeCralloy® rods were impregnated with 1% platinum and also tested in a fixed bed reactor to assess the impact on yield for the dehydrogenation of methylcyclohexane.This paper demonstrates that structured catalysts can be manufactured with excellent alumina and zeolite adherence and when suitably activated/modified give comparable catalytic results to the pelleted powder forms. These structured catalysts will improve temperature distribution in highly exothermic and endothermic catalysed processes.