Patent ID: 8584732

Claim:
A method for making parts comprising: forming a mold having a negative shape of a part; coating the mold with a release agent, wherein the release agent has a thickness of from about 0.02 inches and 0.100 inches; depositing part material on the release agent in the mold by gas dynamic cold spray wherein the mold is maintained at a temperature of less than or equal to about 300 degrees Fahrenheit, and further wherein said part material has a measured on the B scale of from about 60 to about 70 HRB and about 40 on the Rockwell C hardness scale; and thereafter separating the release agent from the mold and the part without the need for any machining of the part, wherein said release agent has a lower melting temperature than the part material and wherein said separating step comprises heating the part and the release agent to a temperature greater than the melting point of the release agent but less than the melting point of the part material.