Patent ID: 8511366

Claim:
A method for spray forming a metal component having an elongated open channel therein, the method comprising firstly spray forming a layer of the desired metal onto a deposition substrate, placing an elongated spray blocking object on the already sprayed layer for forming the channel, and continuing the spray forming process covering the already sprayed layer and the elongated spray blocking object until the desired total thickness of the metal component is achieved, wherein the metal component and the elongated spray blocking object form the channel, and the elongated spray blocking object is not removed after spray forming process, wherein a portion of a cross-sectional boundary of the channel is defined by the elongated spray blocking object being in contact with the metal component, and wherein the spray blocking object is a strip, the cross-sectional profile of the strip being fully open in the direction of an axis in a cross-sectional plane of the strip, and that the strip is placed on the already deposited layer with said axis directed substantially parallel to the direction of the incident metal spray.