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.