The authors consider a free interface problem which stems from a gas-solid model in combustion with pattern formation. A third-order, fully nonlinear, self-consistent equation for the flame front is derived. Asymptotic methods reveal that the interface approaches a solution to the Kuramoto-Sivashinsky equation. Numerical results which illustrate the dynamics are presented. The authors consider a free interface problem which stems from a gas-solid model in combustion with pattern formation. A third-order, fully nonlinear, self-consistent equation for the flame front is derived. Asymptotic methods reveal that the interface approaches a solution to the Kuramoto-Sivashinsky equation. Numerical results which illustrate the dynamics are presented.