Porous metal with uniform honeycomb structure was successfully produced by sintering using Fe-Cr-Al nano powder, which was prepared by the pulsed wire evaporation (PWE) in ethanol. Its process consisted of the several steps; 1) coating on the surface of polyurethane sponge with the liquid droplets generated from the ethanol-based slurry where the Fe-Cr-Al nano powders were uniformly dispersed, 2) heat treatment of debinding to remove the polyurethane sponge and 3) sintering of the porous green body formed by Fe-Cr-Al nano powders. The strut thickness of porous Fe-Cr-Al was increased by the increase of spraying times in ESP step. Also, The shrinkages and the oxidation resistance of the sintered porous body was increased with increase of sintering temperature. The optimal sintering temperature was shown to 1450°C in views to maximize the oxidation resistance and sinterability.