Patent ID: 8882940

Claim:
A method of forming a three-dimensional object having minimum dimensions of at least 0.5 mm in all dimensions and at least 50% amorphous phase by volume throughout the three-dimensional object from an alloy comprising a bulk-solidifying amorphous alloy, the method comprising: providing a molten volume of the alloy; quenching the entire volume of the alloy from above its melting temperature to a temperature below its glass transition temperature to form an as-cast object, wherein the quenching occurs at a sufficient rate to prevent formation of more than about 50% crystalline phase by volume; reheating the as-cast object having no more than about 50% crystalline phase by volume in a supercooled region after quenching to form a reheated alloy, and re-quenching the alloy from the supercooled region to a temperature below its glass transition temperature at a sufficient rate to prevent formation of more than about 50% crystalline phase by volume; wherein during or after the reheating the as-cast object is put under vacuum until no bubble flotation is present.