Method for making a metal part with a complex geometry with a thin wall

A metal part with a wall thickness less than 5 mm formed by a process comprising:

• mixing a metal powder with a polymer binder to form a composite mixture, the metal powder being particles of an atomized metal alloy;
• making a flexible composite sheet from the composite mixture;
• cutting, in the flexible composite sheet, a preform of the metal part;
• applying the preform in a mold having a face defining a relief of the metal part;
• and
• debinding and sintering the preform to form the metal part;
• wherein an appended insert has a fastening portion that is sandwiched between a rear end of the preform and a flexible composite sheet segment,
• wherein, before the debinding and the sintering steps, the composite sheet segment forms a bridge over the fastening portion, the bridge defining a gap between the composite sheet segment, the rear end of the preform, and the fastening portion, and
• wherein, during the debinding and sintering steps, the composite sheet segment deforms to fill the gap and to enclose the fastening portion of the appended insert.

A metal part with a wall thickness less than 5 mm, the metal part comprising:

• a preform cut from a flexible composite sheet;
• an appended insert disposed on the preform and extending from a rear end of the preform;
• and
• a flexible composite sheet segment enclosing a portion of the appended insert to the preform.