A gas generating system (10) including a filter assembly (36) formed from a plurality of nodules (36b) positioned and secured in relation to each other so as to form a porous structure (36a). In one embodiment, the nodules (36b) are metallic and are secured in relation to each other using either a sintering process or a brazing process. The nodules (36b) may be bonded directly together, or the nodules may be secured within a metallic matrix material. The gas generating system may also include a first baffle plate (40) positioned between the plurality of nodules (36b) and a gas source of the gas generating system (10), and a second baffle plate (42) positioned between the plurality of nodules (36b) and a housing wall (12c) of the gas generating system (10). The baffle plates (40, 42) provide added structural integrity to the porous structure (36a) and increase the length of a tortuous flow path of gases through the filter assembly (36). Apertures (40a, 42a) and are provided in the baffle plates (40, 42) to aid in directing the flow of gases through the porous structure (36b), thereby ensuring a tortuous flow path for the gases. A vehicle occupant protection system (480) incorporating the filter assembly (36) is also described.