Patent ID: 8215371

Claim:
A method for building a three-dimensional object in a layer-by-layer manner with an extrusion-based digital manufacturing system having a build chamber, the method comprising: providing a supply source to the extrusion-based digital manufacturing system at a remote location from the build chamber, the supply source comprising a modeling material, wherein the modeling material comprises an amorphous metallic alloy having a melting temperature, a glass transition temperature less than about 450° C., a creep relaxation temperature, and a solidification temperature, wherein the difference between the glass transition temperature and the melting temperature is at least about 20° C., and wherein the modeling material has a wire geometry formed from a reheated and shaped solid material of the amorphous metallic alloy; heating the build chamber of the extrusion-based digital manufacturing system to one or more temperatures within a window ranging from the solidification temperature and the creep relaxation temperature of the modeling material; feeding the modeling material from the supply source disposed at the remote location from the build chamber, through a portion of the extrusion-based digital manufacturing system, and to a liquefier assembly retained by the extrusion-based digital manufacturing system; heating the modeling material of the solid feedstock in the liquefier assembly to an extrudable state; and depositing the heated modeling material within the heated build chamber in a predetermined pattern to form the three-dimensional object.