Abstract: Described herein is a method of selectively depositing molten bulk metallic glass (BMG). In one embodiment, a continuous stream or discrete droplets of molten BMG is deposited to selected positions. The deposition can be repeated as needed layer by layer. One or more layers of non-BMG can be used as needed.

Abstract: Provided in one embodiment is a method of forming a movable joint or connection between parts that move with respect to one another, wherein at least one part is at least partially enclosed by at least one second part. The method includes positioning an etchable material over an at least one first part, molding or forming an at least one second part over at least the etchable material, and removing the etchable material.

Abstract: Embodiments herein relate processes for bulk solidifying amorphous metal alloys by rapid capacitor discharge.

Abstract: The disclosure relates to an audio device that includes a diaphragm having a graphene material, such as a graphene flake, that is incorporated into a base material. The audio device may form part of a speaker device, a microphone device, or a headphone device. The concentration of the graphene and/or a size of the graphene flakes may be varied throughout the diaphragm to define a stiff center portion and a flexible portion that surrounds the center portion.

Abstract: An injection molding system and methods for improving performance of the same. The system includes a plunger rod and a melt zone that are provided in-line and on a vertical axis. The plunger rod is moved in a vertical direction through the melt zone to move molten material into a mold. The injection molding system can perform the melting and molding processes under a vacuum. Skull formation in molten material is reduced by providing an RF transparent sleeve in the melt zone and/or a skull trapping portion adjacent an inlet of the mold. It can also be controlled based on the melting unit. Vacuum evacuation can be reduced during part ejection by using a plunger seal, so that evacuation time between cycles is reduced.

Abstract: A method of manufacturing a co-molded housing component for an electronic device is disclosed. A component formed from a ceramic material is placed in a mold. The mold comprises a first section defining a first cavity configured to receive the first component, and a second section defining a second cavity that is in communication with the first cavity when the mold is closed. The second cavity is in the shape of a feature that is to be joined to the ceramic material. A polymer material is injected into the second cavity, thereby forming the feature from the polymer material and bonding the feature to the ceramic material. The polymer material is cured. The first component and the feature together form the housing component for an electronic device.

Abstract: Pressure sensing systems comprising bulk-solidifying amorphous alloys and pressure-sensitive switches containing bulk-solidifying amorphous alloys. The bulk-solidifying amorphous alloys are capable of repeated deformation upon application of pressure, and change their electrical resistivity upon deformation, thereby enabling measurement of the change in resistivity and consequently, measuring the deformation and amount of pressure applied.

Abstract: Touch sensing systems comprising bulk-solidifying amorphous alloys and methods of making touch sensing arrays and electronic devices containing touch sensitive screens that include arrays containing bulk-solidifying amorphous alloys. The bulk-solidifying amorphous alloy substrates have select areas of crystalline and amorphous alloy providing for discrete areas of conductivity and resistivity.

Abstract: An electronic device may have housing structures, electrical components, and other electronic device structures. Stress sensing structures may be formed using coatings on these electronic device structures. Stress sensing structures may have strip-shaped links that extend between pads or may be formed from blanket films. A stress sensing coating may be formed from a transparent thin film. The transparent thin film may be illuminated with monochromatic light while a video camera captures video images of resulting optical interference patterns. The video images may be captured during a test in which a device structure is exposed to stress from an impact between the device and an external object. Stress sensing coatings may also be formed from layers of material that develop cracks upon exposure to stress. Stress sensing structures may be used to evaluate stress during tests and to monitor stress during normal device use.

Abstract: Described herein is a method of combining discrete pieces of BMG in to a BMG feedstock that has at least one dimension greater than a critical dimension of the BMG, by methods such as thermoplastic forming, pressing, extruding, folding or forging. Other embodiments relate to a bulk metallic glass (BMG) component or feedstock having discrete pieces of a BMG, wherein the BMG component or feedstock has at least one dimension greater than a critical dimension of the BMG.

Abstract: Provided in an embodiment is a method for molding, including: providing a molten alloy in a space between a mold cavity and an etchable block shaped to form an undercut on a part formed in the space, cooling the molten alloy to form the part with the undercut, and etching the etchable block. An undercut is a beveled edge caused by an etchant attacking an etchable block laterally and optionally vertically. The formed part can be made of a bulk amorphous alloy. In some cases, the etchable block can also be used to form at least one threaded portion in the part.

Abstract: Described herein is a feedstock comprising BMG. The feedstock has a surface with an average roughness of at least 200 microns. Also described herein is a feedstock comprising BMG. The feedstock, when supported on a support during a melting process of the feedstock, has a contact area between the feedstock and the support up to 50% of a total area of the support. These feedstocks can be made by molding ingots of BMG into a mole with surface patterns, enclosing one or more cores into a sheath with a roughened surface, chemical etching, laser ablating, machining, grinding, sandblasting, or shot peening. The feedstocks can be used as starting materials in an injection molding process.

Abstract: Described herein is a feedstock including a core comprising BMG and a sheath attached the core. The sheath has a different physical property, a different chemical property or both from the core. Alternatively, the feedstock can include a sheath that encloses one or more core comprising BMG. The feedstock can be manufactured by attaching the sheath to the core, shot peening the core, etching the core, ion implanting the core, or applying a coating to the core, etc. The feedstock can be used to make a part by injection molding. The sheath can be used to adjust the composition of the core to reach the composition of the part.

Abstract: Various embodiments provide apparatus and methods for injection molding. In one embodiment, a constraining plunger may be configured in-line with an injection plunger to transfer a molten material from a melt zone and into a mold. The constraining and injection plungers are configured to constrain the molten material there-between while moving. The constrained molten material can be controlled to have an optimum surface area to volume ratio to provide minimized heat loss during the injection molding process. The system can be configured in a longitudinal direction (e.g., horizontally) for movement between the melt zone and mold along a longitudinal axis. A molded bulk amorphous object can be ejected from the mold.

Abstract: Pressure sensing systems comprising bulk-solidifying amorphous alloys and pressure-sensitive switches containing bulk-solidifying amorphous alloys. The bulk-solidifying amorphous alloys are capable of repeated deformation upon application of pressure, and change their electrical resistivity upon deformation, thereby enabling measurement of the change in resistivity and consequently, measuring the deformation and amount of pressure applied.

Abstract: Disclosed is a vessel for melting and casting meltable materials. The vessel may be a surface temperature regulated vessel for providing a substantially non-wetting interface with the molten materials. In one embodiment, the vessel may include one or more temperature regulating channels configured to flow a fluid therein for regulating a surface temperature of the vessel such that molten materials are substantially non-wetting at the interface with the vessel. Disclosed also includes systems and methods for melting and casting meltable materials using the vessel.

Abstract: Various embodiments provide apparatus and methods for melting and introducing alloy feedstock for molding by using a hollow branch having a constraint mechanism therein. In one embodiment, a hollow branch can extend upward from a cold chamber that is substantially horizontally configured. The hollow branch including a constraint mechanism can be capable of containing an alloy feedstock for melting into the molten alloy in the hollow branch and introducing the molten alloy to the cold chamber for molding.

Abstract: Exemplary embodiments described herein related to methods and systems for casting metal alloys into articles such as BMG articles. In one embodiment, processes involved for storing, pre-treating, alloying, melting, injecting, molding, etc. can be combined as desired and conducted in different chambers. During these processes, each chamber can be independently, separately controlled to have desired chamber environment, e.g., under vacuum, in an inert gas environment, or open to the surrounding environment. Due to the flexible, independent control of each chamber, the casting cycle time can be reduced and the production throughput can be increased. Contaminations of the molten materials and thus the final products are reduced or eliminated.

Abstract: Disclosed are systems and methods for mechanically reducing an amount of the skull material in a finished, molded part formed from amorphous alloy using an injection molding system. Skull material of molten amorphous alloy can be captured in a trap before molding such material. A cavity can be provided in the injection molding system to trap the skull material. For example, the cavity can be provided in the mold, the tip of the plunger rod, or in the transfer sleeve. Alternatively, mixing of molten amorphous alloy can be induced so that skull material is reduced before molding. A plunger and/or its tip can be used to induce mixing (e.g., systematic movement of plunger rod, or a shape of its tip). By minimizing the amount of skull material in the finished, molded part, the quality of the part is increased.

Abstract: Disclosed herein are methods of combining at least one bulk-solidifying amorphous alloy and at least one additional metal or alloy of a metal to provide a composite preform. The composite preform then is heated to produce an alloy of the bulk-solidifying amorphous alloy and the at least one additional metal or alloy of the metal.