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A method of manufacturing a seamless self-supporting metal part using nickel vapor deposition, where the part has a selected minimum thickness, a first aerodynamically contoured surface and a second substantially parallel surface. The method replaces labor intensive welding of individually manufactu

A method of manufacturing a seamless self-supporting metal part using nickel vapor deposition, where the part has a selected minimum thickness, a first aerodynamically contoured surface and a second substantially parallel surface. The method replaces labor intensive welding of individually manufactured sheet metal segments for complex aerodynamic shapes, and produces a part with higher accuracy, less cost, controlled strength and hardness properties. Nickel vapor deposition is commonly used for plating electronic components, and for producing a metallic lining for plastic injection moulds. The seamless sheet metal part is cast by: fabricating a mould with at least one mould surface being a negative of the first surface of the part; enclosing the mould in a nickel vapor deposition chamber; depositing nickel on the mould surface by nickel vapor deposition until a blank of nickel is deposited having at least the minimum thickness and an external deposition surface; and separating the blank from the mould.

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1. A method of manufacturing a seamless self-supporting metal part using nickel vapour deposition, the part having a selected minimum thickness, a first aerodynamically contoured surface and a second substantially parallel surface, the method comprising the steps of:fabricating a mould with at least

1. A method of manufacturing a seamless self-supporting metal part using nickel vapour deposition, the part having a selected minimum thickness, a first aerodynamically contoured surface and a second substantially parallel surface, the method comprising the steps of:fabricating a mould with at least one mould surface comprising a negative of the first surface of the part, said mould including a plurality of removable reusable mould segments; enclosing the mould in a nickel vapour deposition chamber; depositing nickel on the mould surface by nickel vapour deposition until a blank of nickel is deposited having at least said minimum thickness, and an external surface; and separating the blank from the mould by individually withdrawing the reusable mould segments intact from the mould assembly and then individually removing the reusable mould segments intact from the blank.