In this paper. the stability and flashback resistance of catalytic and non-catalytic premixed metal fiber burners are investigated by means of a model analysis. The burner model consists of a set of transient conservation equations that account for a detailed kinetic mechanism for the description of methane reactivity in the gas phase. On the side of the catalytic reactivity, the occurrence of a hetero-homogeneous combustion regime sustained by the catalyst activity is assumed. After a preliminary model validation on the grounds of some experiments carried out ad hoc, the mathematical model is used for the analysis of the flashback phenomenon, so as to point out the key parameters that affect burner operation stability. A sensitivity analysis is finally proposed, so as to formulate some general guidelines for the design of improved performance premixed burner. A bi-layer burner structure with smaller pores ahead and larger pores on the downstream side seems to be the way to go in order to enlarge the power modulation range of the burner and improve flashback resistance. (C) 2003 Elsevier B.V. All rights reserved.