A method of processing BMGs in a non-ideal environment (such as air) to create a uniform and smooth surface is provided. By utilizing the contact-line movement and an engineered flow pattern during TPF the method is able to create complex BMG parts that exhibit uniform smooth appearance or even can be atomically smooth. In addition, to mending surface imperfections, this method also eliminates void formation inside the material, allows for the creation of precise patterns of homogeneous appearance, and forms improved mechanical locks between different materials and a BMG.

A metal fused deposition printer can use the thixotropic properties of a metal (e.g., alloy) to control the viscosity of the material being deposited. The viscosity of the metal can be controlled by shearing the metal before, during, or after the deposition process. Use of the thixotropic properties can allow the viscosity of the metal to be controlled independent of the temperature of the metal. This can allow for more precise control of the temperature differential between the layer being deposited and the substrate layer, for example, such that the temperatures are substantially the same.

A metal fused deposition printer can use the thixotropic properties of a metal (e.g., alloy) to control the viscosity of the material being deposited. The viscosity of the metal can be controlled by shearing the metal before, during, or after the deposition process. Use of the thixotropic properties can allow the viscosity of the metal to be controlled independent of the temperature of the metal. This can allow for more precise control of the temperature differential between the layer being deposited and the substrate layer, for example, such that the temperatures are substantially the same.

Tools for use in solid state manufacturing processes are described. Certain configurations of the tool include multiple different components that can reversibly couple to each other. The tools can be used in solid state manufacturing processes to deposit high strength alloy materials without the need to use a lubricant with the materials to be deposited.

Tools for use in solid state manufacturing processes are described. Certain configurations of the tool include multiple different components that can reversibly couple to each other. The tools can be used in solid state manufacturing processes to deposit high strength alloy materials without the need to use a lubricant with the materials to be deposited.