Crossword Genius

Sword made from thin sheet of metal (4)

Ross

I believe the answer is:

foil

This clue is a double definition.

'sword' is the first definition.
(foil is a kind of sword)

'thin sheet of metal' is the second definition.
(as in tin foil)

'made from' acts as a link.

(Other definitions for foil that I've seen before include "Baffle" , "Repulse" , "Parry" , "blunt weapon" , "Blunt sword with a button on the end" .)

I've seen this clue in The Times.
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