Method of forming a component from a green part

A method of forming a component for an aircraft engine from a green part through a powder injection molding process, the method comprising:

• forming the green part having an initial shape, including:
• injection-molding at least one first layer of the green part in the initial shape with a first feedstock, the at least one first layer having a first solid loading;
• injection-molding at least one second layer of the green part in the initial shape with a second feedstock the at least one second layer having a second solid loading smaller than the first solid loading;
• curving the green part having the initial shape by debinding and sintering the green part, wherein the curving includes obtaining a final shape of a curved platform section of the component by having the first and second solid loadings producing a different local volume reduction in the at least one first layer with respect to the at least one second layer.

A method of forming a component of an aircraft engine from a green body through a powder injection molding process, the method comprising:

• forming the green body having an initial shape, including:
• injection-molding at least one first sub-region of the green body with a first feedstock,
• injection-molding at least one second sub-region of the green body with a second feedstock,
• obtaining a gradient of volumetric proportion of binder within the green body;
• and
• obtaining a final shape of the component different from the initial shape of the green body by altering the initial shape via debinding and sintering the green body, wherein the at least one second sub-region undergoes a volume reduction and a change of shape such that a distribution of local deformations is produced to obtain the component having a different geometry and size than the green body;
• and wherein the at least one second sub-region of the green body defines a surface of a platform section in a planar configuration prior to the debinding and the sintering, the surface of the platform section curving during the sintering to obtain the final shape of the component after the sintering.