Abstract: A process is disclosed for forming a pressed metal part in which a preform is inserted into a pressed metal mold. The mold is then filled with powdered metal. The powdered metal and preform are compacted to create a compacted metal part wherein the preform defines an adjacent volume next to the compacted metal part. The compacted metal part is ejected from the mold and sintered to create a sintered metal part. The preform is removed by the sintering step in such a way that the adjacent volume becomes a void region. The preform can be formed of copper so that, upon sintering, the preform is removed from the sintered metal part through infiltration. Alternatively, the preform can be formed of zinc so that, upon sintering, the preform is vaporized and thereby removed from the sintered metal part. The void region created by the removal of the preform can be an undercut, a taper, an annular groove, a thread or an internal cavity.