design guide 4.

2
Disclaimer: This Liquidmetal® Design Guide is subject to change and update at
any time without notice and any errors are subject to correction without liability.
Copyright: Liquidmetal Technologies, Inc. April 30, 2017
LIQUIDMETAL TECHNOLOGIES
®

DESIGN GUIDE REV. 4.0

TABLE OF CONTENTS
7 Chapter 1: WHAT ARE AMORPHOUS METALS?
13 Chapter 2: METAL MOLDING PROCESS OVERVIEW
• Cold-crucible systems
• Hot-crucible systems
• Mold requirements
21 Chapter 3: MATERIAL PROPERTIES (DATA SHEET)
27 Chapter 4: APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS
• Application characteristics
• Cold-crucible molding
• Hot-crucible molding
• Shot size/ part weight/ number of mold cavities
• Dimensional accuracy & repeatability
• Recent studies
• Technology comparisons
• As-molded surface finish
• Reflectivity properties
• Biocompatibility
• Corrosion resistance
• Magnetism
47 Chapter 5: WHY CHOOSE LIQUIDMETAL; MARKETS & APPLICATIONS
51 Chapter 6: DRAFT REQUIREMENTS
55 Chapter 7: WALL THICKNESS

3
57 Chapter 8: RADII & FILLETS
59 Chapter 9: HOLES & SLOTS
61 Chapter 10: THREADS
63 Chapter 11: SURFACE FEATURES & TEXTURING
65 Chapter 12: MOLDING BEHAVIOR & PART AESTHETICS
• Material flow
• Gating
• Heat checking
• Shrinkage & sink marks
• Parting line & witness marks
69 Chapter 13: EJECTION
71 Chapter 14: UNDERCUTS
73 Chapter 15: OVERMOLDING
• Metal overmolding
77 Chapter 16: POST PROCESSING ALTERNATIVES
• Bead & media blasting
• Machining
• Welding
• Painting & PVD
INTRODUCTION
Welcome to the new Liquidmetal® Technologies Design Guide. Our
ultimate goal is to help you get the most benefit from the technology
by enabling you to design the best parts possible for your product
application. In the following chapters you will discover Liquidmetal’s
technology background, process overview, as well as significant
material properties and how they pertain to various applications.
You’ll also have the opportunity to explore practical design rules
and manufacturing best practices that will help you take advantage
of the unique Liquidmetal properties and process in a number of
example applications.
 WHAT ARE AMORPHOUS METALS?

1
WHAT ARE
AMORPHOUS METALS?
Interest in amorphous metals is appearing in a diverse range of sources,
including news articles, trade magazines, scientific journals, and investment
publications. Many of the exotic metal alloys being described are actually
the same material being referred to by different names. For example,
Liquidmetal® alloy, Vitreloy, amorphous metal, and metallic glass are basically
synonyms for the same new class of metals, which exhibit an amorphous
(random or disordered) microstructure. To understand what these metals
are, and more importantly, to better understand how they are utilized, we
will step back and review some history and include a few basic principles of
“metallurgy.”
Metallurgy is an ancient practice which focuses on the development and
processing of metal alloys for specific applications. Ancient metallurgists
devised bronze and carbon steel alloys for improving weapons while modern
metallurgists have developed aircraft-grade aluminum and titanium alloys
for the latest demanding aerospace applications. Despite centuries of
technological advancement, metal alloys have almost always shared the
common thread of having a crystalline microstructure; that is, their atoms are
arranged in naturally occurring patterns that represent the most stable form
of the material (try shaking a glass jar full of marbles and then watch as the

7
spheres settle into a closely packed arrangement). The crystalline structure of
conventional metals is both an advantage and a disadvantage when it comes
to processing and mechanical properties.
These materials exhibit broad trends that limit what can be done with them.
For example, a metal’s melting temperature is usually proportional to its
hardness and a material’s strength is usually inversely proportional to its
ductility. This means that alloys with low melting points (which can be cast
readily) are often soft and have low-strength while alloys with high melting
points (which cannot be cast easily) are often hard, brittle, and have high-
strength.
These empirical rules have governed the development of metal alloys for
centuries and it explains the traditional competition between materials for
specific applications. For example, if one were to design a metal case there
might be a competition between aluminum alloys, titanium, and steel.
Aluminum alloys can be die-cast into near net-shapes, which would lower the
production costs, but are soft and scratch easily. Steel sheets can be stamped
and are very scratch resistant, but steel is much denser than aluminum and
cannot form smaller, complex features. Low-density titanium alloys have high-
strength; however, their high melting points are not easily cast or subsequently
machined. This is a simplified illustration of the complex tradeoff decisions
that designers and engineers must balance when using metal alloys in a vast
universe of applications.
The fundamental innovations leading up to Liquidmetal® technology date
back to the early 1960s with the development of gold-silicon alloys that could
be formed into a non-crystalline (also known as “amorphous”) microstructure
at extremely high cooling rates. By designing alloy compositions around
deep melting points (also called “eutectics”), the alloy could be cooled from
 WHAT ARE AMORPHOUS METALS?

the liquid state (where no

<
crystal structure exists) to
room temperature without
109 ← Pure Metals forming a crystalline
structure (since the
106 ← Early Metallic Glasses formation of crystals takes

Rc (K/s)
time, as with the shaking
jar analogy). By rapidly
103 cooling, one could trap the
← Liquidmetal ®
Alloys “liquid-like” microstructure
0 into the non-crystalline
10
(or “amorphous”) solid,
← Silicate Glasses creating a new class of
10-3 metal alloys, which can be
called amorphous.
Early amorphous
metals could only be
Figure 1. Cooling rates required to achieve an manufactured in very
amorphous microstructure in various materials.
thin ribbons, using a
sputtering method to
achieve the massive cooling rates required to defeat the normal crystallization
that occurs when metal changes from a liquid to a solid. Nevertheless, low-
cost commercial sheet fabrication of these thin ribbon materials led to a very
successful industry. Amorphous metal ribbons have been wound and used as
transformer coils and anti-theft I.D. tags due to their magnetic properties.
In the early 1990s with support from NASA, Caltech formulated Vitreloy,
the first bulk metallic glass (BMG) alloy with a thickness much greater than

9
 Alloy in Molten State

1mm. Adding to this significant discovery, it

was the first amorphous alloy that required
modest cooling rates of only tens of degrees
per second (providing orders of magnitude
improvement over earlier alloys—Figure 1).

<
<
Liquidmetal® alloy has remarkable physical Amorphous Atomic Ordinary Alloys
properties compared to conventional alloys. Structure Naturally Crystallize
In the molten state, conventional alloys also
possess an amorphous structure or liquid- Equiaxed Grains
like atomic arrangement. However, during
the cooling process while transitioning to its < < Columnar Grains
solid phase, conventional alloys naturally
tend to crystallize into regular geometric < Chill Crystals
microstructures beginning with the chill
crystals that start forming on the outer surface.

<
<
Columnar grains begin to form after the chill AMORPHOUS ATOMIC CRYSTALLINE ATOMIC
crystals and the equiaxed grains are last to STRUCTURE STRUCTURE
form in the center furthest from the outer
cooling surfaces.
These structures often result in weak regions
along the boundaries of these crystalline
geometric structures, which are commonly
referred to as grain boundaries. In contrast,
Liquidmetal alloys retain an amorphous,
liquid-like microstructure in their solid state.
Liquidmetal alloys solidify as a frozen liquid

<
without a phase transformation. Liquidmetal

Figure 2. WEAK REGION

 WHAT ARE AMORPHOUS METALS?

alloys are generally stronger than conventional alloys because they do not
have grain boundaries or crystal defects such as vacancies, interstitials,
dislocations, or stacking faults—Figure 2.
In addition to high strength, Liquidmetal® parts exhibit very high elastic strain
limits compared to conventional alloys. We occasionally hear concerns of
amorphous alloys being “brittle” or easy to break, but usually the criticism
comes in the absence of recognizing the highly elastic characteristic of the
material. Combining these levels of strength and elasticity produces a very
robust material. When amorphous alloys do fail, the failure mode is quite
abrupt. However, part-design freedom is tremendous due to the overall
unique properties of the alloys, which we discuss in more detail in the
following chapters.

(Right) A three-point bend test

demonstrates the high elastic limit of
Liquidmetal alloys. The 0.85mm thick
plate is under approximately 1.5%
strain and returns to its exact original
as-molded size and shape when the
load is released. Since the entire elastic
region is within the proportional limit,
all stress-strain responses are linear
and the original geometry is fully
recoverable up to 1.8% strain.
11
WHAT IS TECHNOLOGY?

MOLDING METAL UNIQUE SET OF PROPERTIES

PRECISION PARTS IN ONE STEP OUT OF THE MOLD
MANUFACTURING STEPS TO COMPLEX PRECISION PARTS
STRENGTH
MPa 1,524
HARDNESS
1
LIQUIDMETAL
TECHNOLOGY HRC 53
METAL INJECTION DENSITY
4 MOLDING (MIM) g/cm3 6.57
5+ CNC MACHINING

INVESTMENT
ELASTICITY
1.8%
6 SURFACE FINISH
CASTING
Ra, µm <0.1

UNBEATABLE PRECISION, REPEATABILITY

& CORROSION RESISTANCE
ZERO POST PROCESSING REQUIRED
AMORPHOUS STRUCTURE
DIFFERENT FROM TRADITIONAL METALS
AMORPHOUS ATOMIC CRYSTALLINE ATOMIC ±0.020mm 0.08% 0
STRUCTURE STRUCTURE
TYPICAL TOLERANCE FOR 6σ TOLERANCE MASS LOSS
CRITICAL LINEAR AS-MOLDED CONTROL DURING ASTM B117
LIQUIDMETAL PART FEATURES (% of feature size) CORROSION TEST

WEAK
REGION
 METAL MOLDING PROCESS OVERVIEW

2
METAL MOLDING
PROCESS OVERVIEW
Amorphous Liquidmetal® parts are formed in one of two ways: on a
cold crucible molding system or a hot-crucible molding system. Each
platform offers the same great benefits of Liquidmetal technology, with
small differences to better manufacture a wide range of applications. The
Liquidmetal molding process begins with crystalline material, which is
automatically loaded into the machine for melting. Liquidmetal alloy ingots
weighing up to 350 grams (depending on the process) are heated under
vacuum to protect the alloys from unwanted contamination, such as exposure
to oxygen. When the alloy is fully molten, the metal is injected under pressure
into permanent steel molds similar to conventional plastic injection molds.
Mold temperatures are controlled to cool and solidify the Liquidmetal alloy
into final part geometries until the part is ready for ejection. By the time the
part is ejected from the mold it has achieved full material properties in this
single-step molding process. Parts can be designed to include the same level
of three-dimensional complexity as plastic injection molded parts.

COLD-CRUCIBLE SYSTEM
The cold-crucible molding machines used for the Liquidmetal process replace
a conventional plastic injection molding screw and barrel assembly with a
special injection unit tailored for the Liquidmetal process. The injection of

13
amorphous metals is completely different from traditional plastics processing,
requiring precise control over melt temperatures and viscosities while under
vacuum.
In partnership with ENGEL, Liquidmetal® Technologies has developed a
machine that can process amorphous alloys, the e-motion: Liquidmetal
edition. The injection molding machine has a very efficient, compact material
melting and injection system with a melt chamber that holds the cylindrical
rod or ingot. The ingot is heated to a molten state by a special induction
heating system that heats the material to temperatures >1000°C.
Once the alloy is molten, the material is injected into the mold using profile
parameters that are similar to conventional plastic injection molding. The
entire system is kept under an extreme vacuum level to prevent the formation
of crystals and oxides, allowing for the best possible amorphous alloy parts.
Cycle times for the Liquidmetal process range from two to three minutes (i.e.,
mold close to open).
A sophisticated and real time control system manages the end-to-end
molding process—including data recording, sensors, safety, maintenance,

(Left) Liquidmetal ingot next to a

U.S. quarter coin for scale.
 METAL MOLDING PROCESS OVERVIEW

and the challenge of managing the entire injection cycle. The machine
carefully controls each parameter for precise part-to-part repeatability.
The molding process is automated to provide hands-free continuous
production. Ingots are loaded into the melt chamber using a servo-driven
robot. After ingot insertion, the robot then removes the finished parts from the
previous molding cycle within the same sequence, and places them onto a
conveyor belt with integrated cooling fans.
Once parts have been injection molded, they are ready to use except for
removing gates and runners. To remove gates and runners, there are a few
suitable approaches depending on the requirements of the finished part. If
slight gate vestige is acceptable, waterjet cutting can be used. In cases where
little or no gate witness is desired, CNC machining can be employed to
remove the gate and runner system.

HOT-CRUCIBLE SYSTEM
The hot-crucible molding of amorphous metals is different than the
die casting of traditional die cast materials. The main difference is that
Liquidmetal® hot-crucible molding machines replace the traditional melt and
injection system on a horizontal die-casting machine. Like the cold-crucible
system, amorphous metals require precise control over melt temperatures and
viscosities while under vacuum.
Liquidmetal Technologies established a cross-license agreement with Asia-
based EONTEC, which has developed a hot-crucible amorphous molding
system. By the machine’s nature of hot-crucible design, the injection unit is
very different than that of the injection molding machine developed with
ENGEL. Regardless of the differences, the ingot is also heated to a molten
state by a special induction heating system that heats the material to
temperatures >1000°C under vacuum to protect the alloy.

15
Like the cold-crucible molding machine, the hot-crucible molding process
is automated to provide hands-free continuous production. Ingots, or
granulated material, are loaded into the melt chamber using a servo-driven
robot. After ingot insertion, the robot then removes the finished parts from the
previous molding cycle within the same sequence, and places them onto a
conveyor belt with integrated cooling fans.
Again, like parts produced with the cold-crucible system, once parts have
been formed, they are ready to use except for removing gates and runners.

MOLD REQUIREMENTS
Liquidmetal® technology yields net-shape parts through a one-step molding
process with little to no shrinkage (0.4%). Because of this, and the general
strength and hardness of amorphous alloy, mold wear and durability is a
primary focus. Several measures are taken to ensure the mold lasts as long
as possible. The following design requirements characterize molds used with
our technology.
• Cavity material: specialized and
standard alloys
• Vacuum: 0.003 torr
• Maximum cavitation: 64
• Flash gap: 0.0155-0.0250mm
• O-rings required between plates
• All air trap areas are individually
evacuated
• Cavity inserts used in high-wear areas
(non-P/L shut-off areas)
METAL MOLDING PROCESS OVERVIEW

17
ENGEL e-motion cold-crucible molding machine for
processing amorphous alloys.

ENGEL injection
molding machine parts
conveyor belt
EONTEC hot-crucible machine for processing
amorphous alloys.
 (Above) Precise process and flow controls allow small
parts with high cavitation molds to fill with high yields.

(Above Left) Liquidmetal®

parts colored with multiple
surface treatment processes.
(Right) Liquidmetal parts
cooling on a conveyor belt.
 MATERIAL PROPERTIES

3
MATERIAL PROPERTIES
As discussed in previous chapters, Liquidmetal® alloy has a distinctive
combination of mechanical, thermal, environmental, and other physical
properties due to its amorphous atomic microstructure. These properties
should underpin the decision by designers and engineers to successfully
apply Liquidmetal alloys to particular applications. We encourage the use of
finite element analysis and other modeling tools that harness the material
property data (provided on the following page) in order to make informed
design decisions that enable novel or superior component performance. Our
solutions engineers are equipped to walk customers through this process
when necessary. Additional details concerning more advanced material
properties can also be provided by our research and development team.

21
 Table 1. INJECTION MOLDING DIE CASTING

INJ-LM105 INJ-105s DC-105s DC-106c

COMPOSITION Zirconium based alloy Zirconium based alloy Zirconium based alloy Zirconium based alloy

DENSITY, ρ

g/cm 3 6.68 6.69 6.83 6.72

3
(lb/in ) 0.241 0.242 0.247 0.243

HARDNESS

Vickers 563 532 535 530

Rockwell C 53 51 51 51
GENERAL

CHARPY IMPACT

J/cm2 3.5 TBD 2.5

FATIGUE STRENGTH

MPa @ 10 7 cycles 304 TBD TBD

7
(ksi @ 10 cycles) 44.1 TBD TBD

SPECIFIC STRENGTH, s/r

MPa•cm 3/g 228 196 226

3
(ksi•in /lb) 917 785 907

POISSON’S RATIO, ν

0.38 TBD 0.38

ELASTICITY, e

(% of Original Shape) 1.80% 1.52% 1.73%

ULTIMATE TENSILE STRENGTH

TENSILE

MPa 1524 1312 1542 1500

(ksi) 221 190 224 218

YOUNG’S MODULUS, E

GPa 92.7 86.0 89.1

 MATERIAL PROPERTIES

Table 1. cont. INJECTION MOLDING DIE CASTING

INJ-LM105 INJ-105s DC-105s DC-106c

ULTIMATE STRENGTH

MPa 1890 TBD 1791

COMPRESSIVE

(ksi) 274 TBD 260

ELASTIC STRAIN

(% of Original Shape) 2.3% TBD 1.0%

MODULUS

GPa 86.5 TBD 204.8

ULTIMATE STRENGTH

MPa 2096 1868 1707 2200

FLEXURAL

(ksi) 304 271 248 319

ELASTIC STRAIN

(% of Original Shape) 1.73% 1.66% 1.59%

TANGENT MODULUS OF ELASTICITY

GPa 101.7 99.9 97.8 80.0

GLASS TRANSITION TEMPERATURE, T g

°C 399 404 406

°F 750 759 763

CRYSTALLIZATION TEMPERATURE, T x

°C 468 474 475

THERMAL

°F 874 885 887

LIQUIDUS TEMPERATURE

°C 785 784 788

°F 1445 1443 1450

SOLIDUS TEMPERATURE

°C 858 858 859

°F 1576 1576 1578

23
 Table 1. cont.
INJECTION MOLDING DIE CASTING

INJ-LM105 INJ-105s DC-105s DC-106c

STD. OPERATING TEMPERATURE

°C <250 <250 <250 <250

°F <482 <482 <482 <482

BIO & ENVIRONMENTAL

SALT SPRAY (ASTM B117)

No detectable degradation at 330
After 336 hours No corrosion until 72 hours No corrosion until 72 hours No corrosion at 144 hours
hours
SEAWATER IMMERSION

After 30 days No detectable degradation Pitting after 30 days Some pitting after 30 days

RESISTANCE TO ACIDITY Yes TBD TBD

RESISTANCE TO ALKALINITY Yes TBD TBD

BIOCOMPATIBILITY
Toxicity, Irritation, Sensitization, Systemic
Pass TBD TBD
Toxicity, Hemocompatibility
Mutagenicity, Pyrogenicity Pass TBD TBD
ELECTRICAL & SURFACE

SURFACE FINISH Functional and Cosmetic Functional and Cosmetic Functional and Cosmetic Functional and Cosmetic

Type As-cast, Blasted, Polished As-cast, Blasted, Polished As-cast, Blasted, Polished As-cast, Blasted, Polished

ROUGHNESS, Ra

μm 0.05 0.05 0.05 0.05

μin 2 2 2 2

ELECTRICAL RESISTIVITY, r

μΩ.cm 160 TBD TBD

μΩ.in 63 TBD TBD

 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

4
APPLICATION
CHARACTERISTICS OF THE
LIQUIDMETAL PROCESS
Liquidmetal technology offers part designers several unique capabilities. At
the most basic level, the process is a simple one-step molding operation that
produces three-dimensionally complex metal parts with impressive physical
properties. This unique combination of capabilities is not known to exist with
any other commercial metalworking process.
Liquidmetal technology is well suited for smaller, complex, high-strength, and
high-precision metal parts. Generally, parts up to 180 grams are candidates
for the process. Since the molding process is similar to plastic injection
molding, many of the same design rules and requirements are employed.
Unlike machining, where designers must consider the cost and time to remove
material to achieve a final geometry, the Liquidmetal process allows designers
the freedom to design products for efficient assembly and functional
requirements. This eliminates material scrap and the sensitivity to incremental
costs associated with discrete machining steps required to produce final part
geometry.

27
APPLICATION CHARACTERISTICS
Liquidmetal® is an excellent solution for applications requiring three or more
of the following characteristics:
• Exceptional dimensional control and repeatability
• Excellent corrosion resistance
• Brilliant surface finish
• High strength
• High hardness, scratch & wear resistance
• High elastic limit
• Non-magnetic
• Ability to form complex shapes

COLD-CRUCIBLE MOLDING HOT-CRUCIBLE MOLDING

Here are a few basic guidelines for identifying
candidate Liquidmetal parts:
• Part weight up to 80 grams (100 grams maximum
total shot size of which 80 grams is usable)
• Maximum dimension of 100mm
• Outer draft angles of 0.5° to 3°
• Inner draft angles of 1° to 5°
• Wall thickness 0.6mm to 4.0mm
• Dimensional tolerances of ±.020 mm for critical
dimensions
• Production volumes from tens of thousands to
millions of parts
• Part weight up to 180 grams (300 grams maximum
total shot size of which 180 grams is usable)
• Maximum dimension of 200mm
• Outer draft angles of 0.5O to 3O
• Inner draft angles of 1O to 5O
• Wall thickness 0.3mm to 3.0mm
• Dimensional tolerances of ±.020 mm for critical
dimensions
• Production volumes from tens of thousands to
millions of parts
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

SHOT SIZE / PART WEIGHT / NUMBER OF MOLD

CAVITIES
The maximum shot size for the Liquidmetal molding process today is 300
grams. Approximately 20-40% of the shot is consumed by cold-wells and
runners in the mold, depending on the process used. Since the Liquidmetal
process is able to form net-shape parts in a single molding step, excellent
part-cost economies can be realized. Designers quickly learn that small parts
benefit from the technology by allowing multiple mold cavities to produce
several parts in a one-step operation. Larger parts limited to one or two mold
cavities are possible; however, the best applications for larger parts are ones
that require substantial amounts of conventional machining and labor.
The density of Liquidmetal LM105 alloy is 6.68 g/cm3, which results in a
maximum part volume of 12 cm3 to 26 cm3. The low specific gravity of
Liquidmetal alloys compared to wrought stainless steels and other steel alloys
provides another interesting and unique advantage, by providing weight
reduction in combination with the high strength and performance properties.

DENSITY (g/cm3)

LIQUIDMETAL MAGNESIUM ALUMINUM TITANIUM STAINLESS STEEL

LM105 AZ-91 380 Series 6A1-4V 17-4PH

Table 2. Density
comparison between 6.57 1.8 2.8 4.4 7.7
various materials.

29
DIMENSIONAL ACCURACY AND
REPEATABILITY
The Liquidmetal® process can achieve dimensional accuracy
and repeatability results that are usually only common to
production CNC (Computer Numerical Control) machining
processes, but at a much lower cost. Today, designers can
expect dimensional accuracy and repeatability of ±0.08%
of a given part dimension. Of course, recognition of
mold fabrication tolerance capabilities, especially on high
cavitation molds, needs to be considered before committing
to part specifications. Liquidmetal alloy solidifies during the
molding process nearly isotropically, so design sensitivities
to the 0.4% solidification shrinkage of the material and
dimensional tolerances of part features are insignificant.
The challenge for the Liquidmetal process is working with
mold fabricators that emphasize dimensional accuracy of
mold cavities and those who specialize in accomplishing
this with high-cavitation tooling.
Freezing incompressible molten metal during the
molding process without changes to the atomic structure
of the material plays a significant role in the resulting
dimensional accuracy and repeatability of the process.
This highly unique aspect of dimensional control is
not inherent to any other metalworking technology.
Furthermore, high-performance material properties
are achieved without any post-molding heat-treating or
annealing requirements that are common with other
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

crystalline metal alloys. This benefit avoids further loss of dimensional control
from residual stress, part warpage, distortion, or growth with many heat
treating processes used by conventional crystalline metal alloys.
Because the Liquidmetal process has a high level of accuracy and
repeatability, over-specifying tolerances for non-critical or standard features
may unnecessarily increase the cost of the mold tooling. Similar tolerances
should be specified for the mold cavities that are desired on the final part.

DIMENSION METRIC ENGLISH

Critical to Function ±0.0203mm for dimensions up to 25.4mm ±0.0008” for dimensions up to 1.0”
Linear Features ±0.0203mm for each additional 25.4mm ±0.0008” for each additional 1.0”

Non-Critical/Standard ±0.05mm for dimensions up to 25.4mm ±0.002” for dimensions up to 1.0”

Linear Features ±0.025mm for each additional 25.4mm ±0.001” for each additional 1.0”
Flatness 0.05mm 0.002”
Table 3. This chart displays Straightness 0.05mm 0.002”
typical tolerances for
Angularity 0.001mm/mm 0.0004” in/in
as-molded Liquidmetal
parts. Please note the Concentricity 0.05mm (// to parting line) 0.002” (// to parting line)
two categories of linear
Circularity 0.05mm (// to parting line) 0.002” (// to parting line)
features.

31
RECENT STUDIES
Liquidmetal® Technologies conducted an initial dimensional analysis study on
a single cavity tool that produced a hollow box 45mm long by 28mm wide.
The extraordinary results showed no two parts varied more than 2.5 μm from
one another. This increased our curiosity and begged the question, could
similar results come from a multi-cavity mold?
The four-cavity mold used for this study was built specifically to produce a
sales sample rather than a production part. Since the mold was not intended
for production and only to produce a give-away sample, no dimensional
tolerances were specified for the mold cavities prior to construction. With
only a solid model to build the mold, and greater variation in cavity-to-cavity
mold dimensions than would be expected in a production mold, the study
was conducted. The data that follows demonstrates an unusually high level
of precision and repeatability. The results are significantly better than what is
possible in other near-net metal forming processes, and are competitive with
volume CNC production machining processes.
Figure 3 is a drawing with specifications for the sales sample component used
in our study. Of the dimensional specifications indicated, the following four
specifications were included in the study: 41.81 ± 0.025mm, 900 ± 0.250,
20.81 ± 0.025mm, and 2.27 ± 0.013mm. The inspection of these features
was conducted by an independent inspection source that used a Zeiss Micura
E0=0.7μm CMM. Thirty-two parts were inspected per cavity for a total of 128
parts.
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

Figure 3. Liquidmetal
sales sample drawing with
specifications

33
A gage R&R was conducted prior to collecting inspection data on the sample
parts from each cavity to ensure that an acceptable inspection process had
been defined. Ten measurements were completed for each characteristic on
three samples, by three operators. Table 4 displays the results of the study.

90º Table 4. Results of Gage

DIMENSION 41.81MM 20.81MM 2.27MM
SPECIFICATION R&R
Part Variation 4.731% 17.148% 9.621% 6.884%
Repeatability 1.050% 4.327% 0.545% 2.396%
Reproducibility 0.952% 6.740% 0.051% 0.0000%
Gage R&R 1.417% 8.010% 0.549% 2.396%

The resulting inspection data was used to plot each of the four individual
cavity’s data (32 parts per cavity). Each cavity plot includes the calculated
Six Sigma capability of that cavity. Additionally, the combined Six Sigma
capability across all four cavities (128 parts) was calculated and plotted. The
colored lines in each of the following four charts represents the individual
cavities and the solid black line represents the combined Six Sigma plot for all
four cavities.
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS
40 3σ =11.23mm
120
σ Cavity 1 = 3.74mm 6σ =22.32µm
_
σ Cavity 2 = 2.75mm - σ Cavity 1 = 2.06mm
35 χ =41.79mm χ =2.27mm
σ Cavity 3 = 4.66mm 100 σ Cavity 2 = 2.06mm
σ Cavity 4 = 4.35mm 6σ =80.46mm σ Cavity 3 = 2,93mm
30 σ Cavity 4 = 1.45mm
σ All Parts = 13.41mm -
3σ =11.23mm χ =41.81mm
80 σ All Parts = 3.72mm
25 - 3σ =4.34µm
φ χ,σ(χ)

χ =41.80mm

φ ,σ(χ)
3σ =13.98mm _
_ χ =2.27mm
20 -
χ =41.83mm 60
χ =41.80mm 3σ =6.17µm

˚
3σ =6.18µm
15
3σ =13.05mm 40 3σ =8.80µm _
10 χ =2.27mm
_
χ =2.27mm
20
5 _
χ =2.27mm
0 0
41.74 41.76 41.78 41.80 41.82 41.84 41.86 2.255 2.260 2.265 2.270 2.275 2.280 2.285 2.290
Distance (mm) Distance (mm)
Chart Y: Capability data for the 41.81mm dimension. Chart Y: Capability data for the 2.27mm dimension.

60 4.0
σ Cavity 1 = 3.00µm σ Cavity 1 = 0.10˚
6σ =0.6˚
σ Cavity 2 = 2.30µm 3.5 σ Cavity 2 = 0.06˚
50 3σ =5.38µm σ σ Cavity 3 = 0.09˚
Cavity 3 = 1.96µm
3σ =5.88µm σ Cavity 4 = 1.79µm 3.0 σ Cavity 4 = 0.05˚
40 3σ =6.89µm σ All Parts = 11.28µm _ σ All Parts = 0.10˚
χ =89.87˚
_ _ _
χ =20.81mm χ =20.82mm 2.5
φ ,σ(χ)

χ =20.79mm
φ ,σ(χ)
30 6σ =67.68µm
3σ =8.99µm
_ 2.0
˚

χ =20.81mm
˚

20 3σ = 0.16˚ 3σ = 0..17˚
_
χ =20.80mm 1.5 _ _
χ =89.80˚ χ =89.96˚
10
1.0 3σ = 0.27˚
3σ =0.31˚ _
_ χ =89.92˚
0 .5 χ =89.82˚

0
20.76 20.78 20.80 20.82 20.84 20.86
89.4 89.6 89.8 90.0 90.2
Distance (mm)
Distance (mm)
Chart Y: Capability data for the 20.81mm dimension. Chart Y: Capability data for the 90º angle. 35
Table 5 summarizes the capability of the four-cavity production mold used for this study.
As you can see from the data, the Liquidmetal® process provides significantly high levels
of precision and repeatability­—far better than many other metal forming technologies.
The specifications for this component are very narrow and are even more challenging
when asked to comply with them within a Six Sigma capability. Consider the challenge
to produce the part geometry used in this study with other manufacturing technologies
such as MIM/PIM, investment casting, die casting, cold forming, forging, and stamping.
Furthermore, add in the as-molded surface finish capabilities of Liquidmetal technology,
and you have additionally complicated matters for competing technologies.
Alternative metal forming processes would require expensive secondary machining
operations to achieve the specified dimensional tolerances for the application in this
study.

NOMINAL SIX-SIGMA BLUEPRINT

SPECIFICATION CAPABILITY TOLERANCE
Table 5. Summary capability data
41.81mm 0.040mm ± 0.025mm
90º 0.31º ± 0.25º
20.81mm 0.034mm ± 0.025mm
2.27mm 0.011mm ± 0.013mm
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

The emphasis of this study was principally on linear dimensions. However,

flatness was evaluated on a smaller sample set, which yielded interesting and
impressive results. Photo 1 displays the back side of the part used in this study;
the cross hatched areas were evaluated for flatness as a single plane. Forty-
five touch points were made in each of the crosshatched areas for a total of
90 data points per sample. Table 6 displays the data collected for a single
plane established by two separate surfaces.
Surfaces on Liquidmetal parts are easily
FLATNESS MEASUREMENT molded flat because the material mimics
Table 6. Flatness data
the condition of the mold. A secondary and
SAMPLE 1 0.007mm
highly unique characteristic that provides
SAMPLE 2 0.011mm
excellent flatness retention is the material’s
SAMPLE 3 0.011mm high level of elasticity. When the material is
SAMPLE 4 0.008mm impacted in some way (dropped, bent, etc.) it
SAMPLE 5 0.011mm returns to its original flat condition and does
AVERAGE 0.0096mm not plastically deform. No other crystalline
STD. DEV. 0.00174mm metal provides this benefit. With Liquidmetal
alloy, surfaces are easily molded flat and they
stay flat; a process repeatable thousands of
times without impacting flatness.

(Left) Liquidmetal alloy’s rare

combination of strength and flexibility
make the material unlike any other. The
image displays a ring (0.70mm thick) in
its bent and original shapes.

(Right) Photo 1. Cross-hatched areas

display the plane measured for flatness.

37
TECHNOLOGY COMPARISONS
There is no one perfect technology solution for all applications. As new
products continually evolve and develop, both proven and leading-edge
technologies should be considered and evaluated for performance, quality,
and cost objectives. The Liquidmetal® process provides a unique set of
application characteristics that differentiate it from other manufacturing
technologies. Table 7 compares the core strengths of the Liquidmetal process
against other popular metalworking technologies.

INVESTMENT
LIQUIDMETAL DIE CASTING MIM MACHINING
CASTING
Low Cost/High Part Complexity YES Yes Yes No No Table 7.
Comparison of
Fine Surface Finish <2.0 Ra the Liquidmetal
(Micro Inches) Without Secondary YES No No No Yes process and
Operations various other
High Elastic Limit YES No No No No metalworking
technologies.
Single Process Step YES No No No No
See table 3 for
No Heat Treating Required to more detail on
YES No No No No
Achieve High Hardness dimensional
tolerance of
No Heat Treating Required to Liquidmetal parts.
YES No No No No
Achieve High Strength

Low Process Scrap YES Yes Yes No No

Tolerance Control (% of feature size) +/- 0.08 +/- 0.4 +/- 0.3 +/- 0.5 +/- 0.08
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

Figure 4.

2000 Liquidmetal alloys provide a unique combination of high-

strength and elastic properties. Many plastics are known
for their elastic properties, but their strength levels are
generally low. There are many crystalline metal alloys
1500 that offer a wide range of strength characteristics, but
YIELD STRENGTH (MPa)

none offer high-strength combined with high-elastic

limits like Liquidmetal alloys—Figure 4.

1000
The uniqueness of Liquidmetal alloys and manufacturing
process provide results that are impressive for a fully-
automated, complex, metal part manufacturing process.
Liquidmetal alloy can be successfully applied in a very
broad range of markets, such as automotive, aerospace,
500
defense, dental, industrial, medical, and sporting
equipment.

0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
ELASTICITY (%)

Figure 4. (Graph above)

Liquidmetal alloys have a unique
combination of the high-strength of
metals and the elasticity of plastics.

(Left) A standard four-point bend test

fixture loading a 1.85mm thick rectangular
Liquidmetal bar for material quality
assurance purposes. As-molded parts can
return to their original geometries after
undergoing strains up to 1.8%.
39
 AS-MOLDED SURFACE FINISH
Liquidmetal® alloys mimic the surface condition on the mold cavities
used for producing parts. As a result, very fine surface finishes are
achievable. This result cannot be duplicated by any other known metal
molding or metal forming process technology. The only means through
which other processes can accomplish surface finishes comparable to
as-molded Liquidmetal alloys is to apply costly secondary operations
such as those described in the chart below:

Ra μm
50 25 12.5 6.4 3.2 1.6 .8 .4 .2 .1 .05 .025 .012
Figure 5.
CASTING
Liquidmetal Less Frequent
MIM Common
Die Casting

Investment Casting
(Above) Two Liquidmetal parts demonstrating the
material’s nearly optical as-molded surface finish. Sand Casting

ABRASIVE
Superfinishing

Lapping

Polishing

METAL CUTTING
Grinding

Turning

Milling

2000 1000 500 250 125 64 32 16 8 4 2 1 .5

Ra μIn
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

REFLECTIVITY PROPERTIES
Liquidmetal alloys can replicate tool surfaces, whether polished or textured.
The alloys have good as-molded reflectivity and Ra values of 0.038µm
(1.5µin.), giving a nice specular reflection.

Figure 6.
REFLECTIVITY OF LIQUIDMETAL LM-001B
60

55

Table 8.
50
MEASUREMENT* VALUE
Reflectivity (%)

PV 652.173 A 45

RMS 23.938 A 40

35
Ra 16.730 A
30
*values for polished Liquidmetal
360 460 560 660
sample
Wavelength (nm)

41
BIOCOMPATIBILITY

DEVICE CATEGORIZED BY BIOLOGICAL EFFECT

Table 9. Completed

Intracutaneous
biocompatibility tests for

Sensitization

compatibility
Cytotoxicity

Irritation or
NATURE OF BODY CONTACT DURATION Liquidmetal® as-molded

Reactivity

Systemic
CONTACT LM105 alloy. Evaluation

Toxicity
A - Limited (<24 hrs.)

Hemo-
B - Prolonged (>24 hrs. to 30 d.) tests consideration from ISO
CATEGORY CONTACT C - Permanent (>30 d.) 10993-1.

A X X X Required
B X X X X = Completed & Passed

C X X X

A X X X
Surface Mucosal
Device Membrane
B X X X

Breached or A X X X
Compromised
Surface B X X X

A X X X X X
Blood Path,
Indirect
External
B X X X X X
Communicating
Device Tissue/ A X X X
Bone/Dentin
Circulating
Blood A X X X X X

Implant Tissue/Bone A X X X
Device
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

CORROSION RESISTANCE
Liquidmetal alloys are highly corrosion resistant. Even when exposed to
harsh conditions, they perform very well compared to other traditional
alloys normally selected for corrosion resistant applications. The chart below
demonstrates the superior performance of Liquidmetal alloys over 316
stainless steel in both hydrochloric acid and sulfuric acid solutions.

TOTAL DISSOLUTION CONCENTRATION (PPM)

Figure 7.

3600
SS-316

500
250
100
0 0 0 0

1N HCl 1N H2 SO4 NaOH pH13 Seawater

43
 ®
LIQUIDMETAL ALLOYS ARE NON-MAGNETIC
When it comes to magnetic properties, Liquidmetal alloys are often compared
with certain austenitic stainless steel alloys; that is, casually described as
being "non-magnetic.”
However, this is slightly misleading, because all materials have a magnetic
response of some sort, and there are several differences between Liquidmetal
alloys and stainless steel that should be taken into account for applications
involving electromagnetic properties.
Figure 8.

DIAMAGNETIC SIGNATURE OF LIQUIDMETAL ALLOY

1.E+03
LM105 Skin Depth (mm)

1.E+02
Copper Skin Depth (mm)
1.E+01
Skin Depth (mm)

Steel Skin Depth (mm)

1.E+00

1.E-01

1.E-02

1.E-03

1.E-04

1.0E+00 1.0E+01 1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08 1.0E+09 1.0E+10
Electromagnetic Radiation Frequncy (Hz)
 ®
APPLICATION CHARACTERISTICS OF THE LIQUIDMETAL PROCESS

Austenitic stainless steel alloys are paramagnetic (meaning that in the

presence of an external magnetic field they generate a small non-permanent
field of their own in the same direction as the primary field). They also have
a typical relative magnetic permeability (X = 1 + K, where K is the magnetic
susceptibility) between 1.05 and 1.1, which is actually significantly higher than
most materials which are considered to be “non-magnetic” such as plastics or
wood with a permeability of ~1.0000004 (a perfectly non-magnetic material
would have a relative permeability of 1). Additionally, even high grade
austenitic stainless steels can spontaneously regain ferromagnetic properties
during processes that change the crystal structure of the stainless steel such
as fluctuation in composition, cold working, welding or thermal history.
Because of these effects, the measured susceptibility in a “non–magnetic"
stainless steel part can be quite high, which is why the magnetic properties of
lower grade stainless steels, like 304, can be described as “unstable.”
Liquidmetal alloys are very mildly diamagnetic (in the presence of an external
magnetic field they generate a very small response field which opposes the
primary field). Their relative magnetic permeabilities are therefore slightly
less than one. However, because they do not contain any ferrous elements
or crystal lattice structures that allow for exchange effects among inner-core
electrons, they have very stable magnetic properties that would be similar to
materials such as copper (weakly diamagnetic at X = 0.999991) or titanium
(weakly paramagnetic at X = 1.0001), which do not have any ferromagnetic
tendencies. In short, unlike austenitic stainless steel alloys, Liquidmetal alloys
cannot become magnetized over time.

45
 ®
WHY CHOOSE LIQUIDMETAL ; MARKETS & APPLICATIONS

5
WHY CHOOSE LIQUIDMETAL;
MARKETS & APPLICATIONS
When developing a new product design, designers of metal components must
always consider the manufacturing methods available to them. At the same
time, they
must consider the geometric possibilities and material characteristic
needs for the particular functional and performance requirements of the
application for which they are designing. This is not always a simple task, as
different manufacturing processes yield different results and costs.
The Liquidmetal process is a combination of an unusual metal alloy
with highly useful properties, and a shape forming process common to
plastic components. This provides a new set of possibilities for metal parts
fabrication and component designs not previously possible with other metal
forming technologies. The key capabilities of the Liquidmetal process are
listed below:
• Exceptional dimensional control • High hardness, scratch & wear
and repeatability 
 resistance 

• Excellent corrosion resistance 
 • Non-magnetic 

• Brilliant surface finish 
 • Complex shapes that can be
• High strength 
 molded 

• High elastic limit 

If you need
three or more of these characteristics, you likely have a
Liquidmetal application.

47
The drawing shown in Figure 9 represents a part design developed to help
illustrate the many advantages of the Liquidmetal® manufacturing process.
This is an actual Liquidmetal part that is produced in a four-cavity production
quality injection mold.

Figure 9. Liquidmetal
application example.
 ®
WHY CHOOSE LIQUIDMETAL ; MARKETS & APPLICATIONS

Looking carefully at the part drawing in Figure 9, you will notice rather
narrow specification limits for the linear and angular call-outs. Additionally,
there is a very high surface finish requirement, a raised logo, and high
strength, hardness, and corrosion resistance as defined by the LM105 alloy
designation. One way to achieve these specifications is through machining
a high strength corrosion resistant alloy, and then superfinishing for the final
finish requirement. This would be a very expensive machined part, likely
costing upwards of $100 in quantities of tens of thousands of parts per year.
With Liquidmetal technology, this part would cost less than $3.
Alternative processes to produce the part in Figure 9 would have different,
yet costly challenges as compared to Liquidmetal. Die-casting provides
excellent part complexity at very low costs, but the process is limited to a
small range of metals—all of which provide inferior physical properties,
corrosion resistance, dimensional precision, and surface finish in comparison
to the requirements for this part. Similarly, investment casting would not
be able to meet the requirements other than strength and hardness.
Dimensional tolerances and surface finish would require machining and
superfinishing on every surface. With these secondary process costs,
machining the part from wrought material would likely be less expensive
than investment casting.
MIM offers significant part complexity in a wide range of metal alloys, but
lacks the ability to achieve the dimensional tolerances and surface finish
specifications for this part. The large amount of shrinkage experienced in the
MIM process combined with gravity and friction induced distortion during
the debinding and sintering processes limits MIM’s dimensional precision
and repeatability. Substantial machining and sizing operations would be
required to meet the dimensional tolerances. Superfinishing is an alternative

49
to meeting the surface finish requirements for MIM, but hot isostatic pressing
(HIP) may be required prior to machining and polishing to eliminate the
inherent porosity with MIM that could impact surface finish results. Part costs
for MIM would be multiples of Liquidmetal® alloy for this geometry and its Table 10. Market and
specifications. application examples for
Liquidmetal.
With the advantages
of having combined MARKET APPLICATIONS
dimensional precision,
corrosion resistance, surface Engine timing systems, fuel injection, fuel rail components,
finish, strength, high elastic small precision gears, passenger safety devices, pumps,
limit, hardness, non- Automotive pressure sensors, ABS system components, decorative interior
magnetic behavior, and and exterior components, severe duty connectors, ignition
systems, variable valve components
shape complexity delivered
in a single molding step, one
can only begin to imagine Dental Tools, equipment, orthodontia brackets
the potential number of
application opportunities
Broad range of device applications for actuation components,
that exist for Liquidmetal clamping, cutting, piercing, sealing, stapling, suturing
technology. Table 10 Medical
(Biocompatibility studies are underway to determine if LM105
includes several market is suitable for implants.)
and application examples
where the technology can Pressure sensors, compressor components, power tools,
be leveraged. This is not an Industrial hand tools, small precision gears, severe duty connectors,
exhaustive list, but rather, an mechanical assemblies, poppets, valves, pumps
attempt to provide additional
insight to where Liquidmetal Archery, bicycling, firearms, fishing reels, knives, recreational
alloys can be successfully Sporting Equipment
tools, scuba equipment
applied.
 DRAFT REQUIREMENTS

6
DRAFT REQUIREMENTS
Draft is the amount of taper or slope given to mold cavity features and
other mold components such as cores. The purpose of including draft is to
permit easy ejection of the molded part. One of the beneficial characteristics
of the Liquidmetal® molding process is that full material properties are
achieved by the end of the molding cycle. This means Liquidmetal alloy parts
achieve high-hardness and high-strength during the molding process. These
properties combined with the approximately 0.4% material shrinkage makes
draft angles a critical element for successful mold design. If adequate draft
is not included, especially on internal part features, a part may become
permanently trapped in the mold cavity. Additionally, incorporating proper
draft angles can help avoid premature mold wear and extend the mold life,
thus reducing overall tooling costs.
All molded surfaces, which are normally perpendicular to the parting line
of the mold, require draft for proper ejection of the molded part. This draft
requirement, expressed as an angle, is not fixed. The specific draft angle
required will vary with the type of feature or surface specified, and the depth
of the surface.
Typical draft angle requirements for internal surfaces will be in the range of
three to five degrees while external surfaces of the part can be reduced to the
range of one to three degrees. It is possible to achieve zero draft surfaces on
some walls by adding slides, lifters, and collapsible cores.

51
The amount of draft required is highly dependent on part geometry, but
the following guidelines (next page) are useful in establishing baseline
requirements. Liquidmetal® engineers are also available for a collaborative
review of your part design to ensure proper draft angles are specified.
 DRAFT REQUIREMENTS

The larger the part in the Z-direction (parallel to the pull), the smaller the
draft angles can become. For die-casting alloys, there is a general rule that
applies to draft requirements based on material. Below is such a table with
Liquidmetal® alloys included.

ALLOY GROUP INNER SURFACES OUTER SURFACES HOLE (TOTAL)

Table 11. Comparison of ZINC AND ZA 50 100 34
draft angle requirements for
Liquidmetal compared to other MAGNESIUM 35 70 24
die-cast alloys. The C value is ALUMINUM 30 60 20
a dimensionless number that
generates a suggested draft COPPER 25 50 17
angle based on the depth of the LIQUIDMETAL 15 30 10
wall that is being drafted.

DEPTH, L (mm) DRAFT (degrees)

Table 12. An example of the draft
0.5 5.4
angle that would be required for
an inner surface of a Liquidmetal 1 3.8
part based on wall depth. 2 2.7 57.2738
DRAFT ANGLE =
5 1.7 C √L

53
 WALL THICKNESS

7
WALL THICKNESS
Defining optimum wall thicknesses while designing parts for the Liquidmetal®
process plays a critical role in achieving desired part quality results. There
are two process elements that are tied to wall thickness specifications. The
first is related to the flow characteristics of the material during molding and
the second is achieving the final desired material properties. Liquidmetal
alloys' excellent mechanical properties are dependent upon achieving
targeted cooling rates once the material has been injected into the mold
cavities. As wall thicknesses increase beyond limits that can be rapidly cooled,
crystallization can occur which is undesirable and can diminish the physical
properties of the material. Thin walls are most likely to be amorphous in the
final part. However, if wall thicknesses become too thin, the material can
freeze prematurely and impede complete filling of the mold cavity.
In general, wall sectional thicknesses of parts designed for Liquidmetal
alloy should be in the range of 0.6mm to 4.0mm. The optimal thickness for
molding characteristics and resulting physical properties of the material is
1.0mm to 1.5mm. While thicker and thinner sections beyond these regions
are technically possible, the molded part quality and physical properties may
be affected.
Liquidmetal alloys exhibit high yield strength. This property is achieved in the
as-molded part without any post molding heat treatments, as is necessary
with conventional crystalline metallic alloys. Also, because there is no phase

55
transformation that takes place during the cooling of the material, there is no
post molding distortion from residual stress. Both of these process attributes
often eliminate the need for other geometric features such as ribs and
supporting features.
Due to the high yield strength of the alloy, it is not necessary to include ribs
or other supporting features within the part. Since there is no warping of the
material after the part is removed from the mold, holding the part within
tolerance does not become dependent on additional support throughout the
part.
Liquidmetal® engineers use specialized and sophisticated mold-flow or fluid-
flow simulation software to assist customers with design reviews for candidate
parts. Simulation results are used to validate part designs, ensure an optimal
cavity layout, and determine the number of cavities that can be incorporated
into a single shot.
 RADII & FILLETS

8
RADII & FILLETS
Liquidmetal® alloy is quite viscous in the molten state during the molding
process, and because of this material property, it is important to include
large, generous radii whenever possible. It is possible to achieve a sharp
edge or corner, but this must be done along a parting line or other mold
component intersection such as a slide mechanism. Part designers should
be aware that in regions where they specify a sharp edge, there would be a
corresponding sharp in the tool. Again, due to the viscosity of the material
during molding and rapid cooling during the molding process there may be
more irregularity in the appearance of the edge. By including radii, corners
will look more consistent across the entire part.
The preferred minimum radius for the Liquidmetal molding process is
0.25mm. Whenever possible, you should increase the radii size to further
improve the molded and aesthetic part quality. Radii of 0.5mm and larger
are ideal and will improve the molding process significantly. Utilizing a larger
radius will also help increase tool life, aid in release of the part from the tool,
and improve the surface finish of the final part. It is also important to note
that larger radii and fillets strengthen a part by eliminating stress risers.

57
 HOLES AND SLOTS

9
HOLES & SLOTS
Holes, slots, irregular depressions, or cored-out shapes in your part design
are readily achievable with the Liquidmetal® molding process. However, some
small features may translate into fragile mold components, which require
higher levels of mold maintenance and expense. Designers should carefully
consider the following guidelines when specifying smaller internal part
features that would require delicate tooling components.
Generally, you should keep the depth-to-diameter or depth-to-width ratio
within 2:1. That is, the diameter or width of a hole should be no less than
half of its depth. It is also important to apply draft to holes whether they are
through-holes or blind holes. Reference the chapter on draft requirements in
this design guide for suggested draft angles.
When designing intersecting internal geometric features, such as two meeting
holes with centerlines at 90 degrees apart for example, it is important to
design your part such that the use of mold components with flats on the
mating surfaces can be accomplished.

59
It is critical to avoid mating complex surfaces that require high-precision
finished shut-off surfaces to prevent unwanted flash and tool wear. Mating
complex shut-off surfaces cost more to produce and are also very expensive
to maintain. Utilizing flat and simple mating features or shut-off surfaces of
the mold components improves mold up-time and reduces maintenance in
production.
Liquidmetal® engineers are always available to provide additional design
assistance when you are uncertain about specific part-design conditions and
their impact on mold fabrication and maintenance costs.
 THREADS

10
THREADS
Threads can be produced in Liquidmetal® parts, but there are important
design considerations that must be followed to accommodate the molding
process. This design guide will discuss both internal and external threads,
which require different design considerations.
External threads can generally be molded directly into the part with no
special requirements as long as the mid-plane of the threads is located along
the parting line of the mold. Unscrewing mechanisms do not work with the
Liquidmetal process as the material shrinkage interferes with their function.
To ensure that parting line witness and potential molding flash does not
impact the functional quality of the threads, flats are highly recommended
180 degrees apart on both sides of the part along the parting line. These
flats should form a three-degree drafted surface beginning 0.125mm below
the minor diameter of the thread.

61
The approach to producing internal threads varies with the size specification
of the thread. Because 0.4% material shrinkage occurs during the molding
process, unscrewing threaded cores are not a viable option. For small
threads with major diameters <15mm, threaded inserts can be mechanically
pressed into blind holes in the part—similar to what is commonly done in
plastic parts. Liquidmetal® Technologies has produced many applications
successfully with this concept. Minimum pull-out force specifications of
>20Kgf are possible.
Large internal threads with major diameters >15mm can potentially be
produced with collapsible threaded cores, but overall part geometry and
its effect on mold cavity layout and mold construction must be carefully
considered. Liquidmetal engineers can provide design assistance in these
cases to ensure a successful outcome.
 SURFACE FEATURES & TEXTURING

11
SURFACE FEATURES
& TEXTURING
A variety of finishes can be applied to Liquidmetal® parts. The various
surfaces range from as-molded to tumbled, sand-blasted, polished,
physical vapor deposition (PVD), and painted alternatives. One of the most
remarkable features of the Liquidmetal process is its ability to provide an as-
molded brilliant finish of 2µin to 4µin (0.05µm to 0.1µm) surface roughness.
This is simply accomplished by polishing the mold cavity surfaces to the
desired finish of the final part.
Sandblasting is a low cost alternative for a matte or satin metallic finish.
Surface finishes with greater complexity tend to cost more as the primary
driver of cost associated with these treatments is the time spent producing
them.
As is the case with plastic injection molding, there is an endless array of
possibilities for surface features. Everything from logos to diamond and
straight knurling is possible. There are no other known molding processes
that can provide this level of design flexibility in high-strength, as-molded,
metal components. In many metalworking technologies, especially machining,
these special surface features must be added by additional or secondary
operations, which adds cost to the final part.

63
 MOLDING BEHAVIOR & PART AESTHETICS

12
MOLDING BEHAVIOR
& PART AESTHETICS
MATERIAL FLOW
Amorphous metal alloys are quite viscous when compared to other molten
metals. The closest comparison is plastics in an injection molding process.
Of course, Liquidmetal® materials are molded at much higher temperatures
than plastics. The viscosity of the Liquidmetal alloy is dependent on both the
injection temperature and the strain rate that the material undergoes as it fills
the mold cavities. Due to this material property, our alloy can be injected at
a rate that allows for a laminar flow. In many cases, this helps improve the
cosmetic qualities of the part. Caution should be exercised when designing
large parts with very thin sections where final aesthetics are important.
In these situations, it will be necessary to inject the material into the mold
cavities at a higher rate, which could impact the aesthetics with flow lines
becoming evident in the finished part. Flow lines generally do not have any
appreciable dimensions and they do not represent any material strength
concerns in the final part.
Since the material is fairly viscous during the molding process, it tends to
follow the path of least resistance, which are the regions of greatest part
thickness. For this reason, it is important to minimize changes in cross-
sectional thickness throughout the part. Doing so will avoid unwanted flow

65
characteristics and will help eliminate molding defects. While cross-sectional
thickness transitions are not always possible to avoid, Liquidmetal® engineers
can assist your design validation process by conducting flow simulations.
This can help ensure a desirable process outcome prior to fabricating an
expensive mold.

GATING
The molten amorphous metal requires channels to travel from the entrance
of the mold to the part cavities. As in plastics, these channels are known as
runners. Where the runner meets the part is known as the gate. Once the
part has cooled in the mold, the gate is removed from the part with one of a
variety of possible operations including, water-jet cutting, CNC machining, or
by breaking the part off at the runner system. Often the best gating locations
are large flat surfaces of the part. Surfaces selected for gating should not be
cosmetic surfaces. It is also important to remember to gate into the thicker
sections of the part, as filling the mold cavity from thick to thin sections is
critical to achieving optimum part quality.
It is also best to avoid gating on a complex surface (curved or otherwise).
Failing to heed this advice will make it more difficult to blend the final part
perfectly without noticeable evidence of gating.

HEAT CHECKING
The Liquidmetal molding process involves injecting material at high
temperatures into mold cavities made from hardened die-steel that is at a
relatively low comparative temperature. This causes significant temperature
fluctuations in the mold cavity steel that can promote heat checking or micro-
cracking of the cavity surface over time. The most highly effected zones are
typically just inside the part where the gate is located. At this region in the
 MOLDING BEHAVIOR & PART AESTHETICS

part, the temperature, velocity, and strain rate combine to make this area
undergo the greatest amount of heat checking. Depending on the design of
the part, different sub-insert materials may be used in the tool to help reduce
the growth of erosion on the cavity steel. One such material that can be used
is beryllium copper.

SHRINKAGE AND SINK MARKS

Amorphous metal parts undergo a very small amount of shrinkage during
the molding process (around 0.4%), which proves to be an advantage when it
comes to holding tight part tolerances and achieving good repeatability from
part to part. Depending on the geometry of the part, it is possible to see sink
marks on the surface. There are certain design steps that can be taken to
avoid sink marks:
1. Design the part with a nominal wall thickness of 1.0mm to 1.5mm.
2. Design the part so that as the material flows into the part geometry, it
fills from the thicker sections to the thinner sections of the part.
3. Provide gradual transitions from thick to thin sections, including
generous radii and fillets. Avoid abrupt or stepped transitions.

PARTING LINE AND WITNESS MARKS

Where the two halves of the mold meet is known as the parting line.
Placement of the parting line relative to the part geometry is crucial for
ensuring an easily molded part design and successful part function.
After molding, the parting line will likely leave a small witness mark.
Generally, this witness can be on the order of 0.075mm, or 0.003in. The
position of the witness line should be selected so that it does not interfere with

67
the part’s intended function or aesthetics. Slides or other moving mold parts
will also exhibit these same characteristics wherever they shut off on other
mold components.
Ejector pins will also have witness marks. Ejector pins should be set slightly
proud so witness marks are sub-flush on the actual molded part.
 EJECTION

13
EJECTION
At the conclusion of the Liquidmetal® molding cycle, parts are ejected from
the mold by movable components such as ejector pins and lifters. A small
circular witness mark is left where the pin contacts the part, known as an
ejector pin witness.

69
During the design phase of the mold for your part, Liquidmetal® engineers
will advise you on the optimal size and location of ejector pins to ensure that
the part is safely removed from the mold. Some simple part geometries can
be designed with little to no ejection, but will require much increased draft
angles so that they can be released easily from the mold.
Smooth ejection is a critical aspect of manufacturing a Liquidmetal part.
Because of the tremendous strength of the Liquidmetal parts immediately
after molding, straight, clean ejection is important to avoid stress and drag on
mold surfaces.

(Left) Ejector pins are located in various

locations to push the molded part out as
straight as possible to avoid stress and
drag on the mold surfaces.
 UNDERCUTS

14
UNDERCUTS
External undercut features such as holes, slots, profiled grooves, and other
geometric shapes can be readily produced by using a slide mechanism in
the mold. This is just one of many part design advantages offered by the
Liquidmetal® process. Including undercut features in the mold design can
eliminate the need for costly post molding operations such as slot grinding or
machining.
When designing undercuts, proper draft and radii must be included to
ensure that slide mechanisms can be retracted from the part without causing
damage to the part or mold. When applying draft angles, identify the
direction that the slide will be pulled away from the part and apply draft from
that angle.
Internal undercuts that have no direct line of sight from the outside of the part
are much more difficult to produce in the mold. In some cases, it is possible
to use collapsible cores. However, the use of collapsible cores is dependent on
the size of the feature. Internal undercut features requiring collapsible cores
will add additional expense to the mold fabrication process.

71
 OVERMOLDING

15
OVERMOLDING
Overmolding is a technique that is often used to enhance part designs and
provide additional function to an otherwise single material component. A few
examples of overmolding are in applications that require ergonomics, sealing,
insulation, and even safety. Insert overmolding has been performed on
Liquidmetal® parts many times over the years. Overmolding Liquidmetal parts
usually entails placing the processed Liquidmetal part into a secondary mold
that then fills plastic or rubber over, around, and through the Liquidmetal
part.
When overmolding Liquidmetal parts, special attention must be paid to the
shut-off surfaces between the Liquidmetal part and the overmolding mold.
This means that additional resources will be necessary to ensure that the
tolerances on those surfaces are held to a high standard. Doing so will avoid
flashing of the overmold material.
With any overmolding application, adhesion to the substrate is the key factor
that needs careful consideration during the original part design phase.
Ribs, undercuts, and other mechanical interlocks will help improve the bond
between the Liquidmetal part and the overmolded material. The design will
need to be reviewed on a case-by-case basis to determine the best way to
achieve optimal adhesion results.

73
METAL OVERMOLDING
Another overmolding technique that can be used with our process is to
actually overmold a metal part that is inserted into the Liquidmetal® mold.
There are a number of reasons to consider this technique such as:
1. Reduce part cost by minimizing the mass of amorphous metal material
required for the part and increasing the number of parts that can be
cast per shot.
2. Create larger parts by utilizing less of the amorphous metal material.
3. Increase amorphous content by reducing wall thickness and utilizing
materials with a higher thermal conductivity than the tool steel used for
molds.
4. Simplify post-processing of components by machining features out of
a more machinable metal such as aluminum, stainless steel, or some
other non-amorphous metal material.
5. Improve cosmetics of a final part by optimizing wall thickness transitions
throughout the part.
6. Provide superior material properties by possessing properties from both
metals.
To determine whether this type of technique will fit with your application,
please discuss the concept with a Liquidmetal engineer.
 (Left) Close-up view of how
plastic flows around and through
a precision molded Liquidmetal®
component to achieve a strong
mechanical connection.

(Right) Liquidmetal component before

and after the overmolding process.
Clear resin is often used while
optimizing the plastic overmolding.

75
 POST PROCESSING ALTERNATIVES

16
POST PROCESSING
ALTERNATIVES
A wide array of post processing alternatives are available for Liquidmetal®
parts should you want to achieve specific results outside of the basic
requirement to de-gate parts after molding. Some of the more commonly
applied post-processing techniques include bead and media blasting,
machining, laser welding and e-beam joining, painting, gluing, and physical
vapor deposition (PVD).

BEAD & MEDIA BLASTING

Bead blasting or media blasting is commonly used on many metal
components to achieve varying degrees of satin finishes. This is also possible
with Liquidmetal components. The process involves spraying hard media such
as silica glass, ceramic, and various metals under high pressure and high
velocities at the surface of the targeted metal parts. By altering the media
type, size, and velocity, a varying degree of surface finishes can be achieved.
While one of the unique benefits of the Liquidmetal process and its alloys is
the ability to achieve brilliantly fine surface finishes, some applications require
subtle or low reflectivity appearances. In these cases, media blasting is a
relatively low-cost approach to achieving those results.

77
(Right) Example CNC
machining center for processing
Liquidmetal® parts.

(Below) Example of a media

blasted satin finish part, in front
of a Liquidmetal ingot used for
molding.
 POST PROCESSING ALTERNATIVES

MACHINING
Machining is one approach used to remove gates and runners from
Liquidmetal® parts, but it can also be applied to generate additional
features or achieve dimensional tolerances that may not be possible with
the Liquidmetal molding process alone. Liquidmetal alloys are hard after
molding, but not impossible to machine. In fact, Liquidmetal parts can be
readily machined using the appropriate equipment and cutting tools. Our
engineering team is available for advice and suggestions should you want to
apply machining techniques on your own.

WELDING
Welding is a joining process commonly used to build larger structures out of
smaller components. Welds provide the strength, efficiency, versatility, and
economic advantages necessary to build the myriad of structures and objects
all around us: bridges, skyscrapers, automobiles, boats, oil rigs, jewelry,
sculptures, and more.
Because amorphous metal formation requires specific critical cooling rates,
the part size and thickness are limited; however, these limitations can be
overcome with welding. Liquidmetal alloy can be welded to itself, while
welding to dissimilar metals (such as titanium, aluminum, and stainless steel)
is an ongoing research and development effort. Our engineering team will
work with you to develop the optimal methods, offering more flexibility in part
design and performance, and increased opportunities for high-performance
assemblies.

79
 (Below) Three main regions of a micrograph are observed: base
material, heat affected zone, and fusion zone. The fusion zone
looks identical to the base material with mostly amorphous content,
while the heat affected zone has only minimal crystallization (darker
particles).

(Above) Electron beam welded butt-joint of the 3.6mm

wide necked region of tensile specimen.
(Below) Figure 13. E-beam weld microhardness of
Liquidmetal® alloy shows most featureless joint.

(Below) Electron beam welded butt-joint of 9.6mm wide plates. The

weld beaded up in the 3.6mm wide specimen while the weld was
mostly flush with the two parent plates of 9.6mm width.
 POST PROCESSING ALTERNATIVES

PAINTING & PVD

As with parts made from other metalworking technologies, Liquidmetal®
parts can be painted with a range of traditional techniques, along with PVD,
conversion, and other processes. Painting requires the same cleaning and
surface preparation other metal parts require such as removing oils and
primering bare metal surfaces. Care should be taken to avoid extended paint
baking cycle temperatures above 250°C. PVD processes are used to apply
high-purity coatings such as titanium, chromium, and aluminum to metal
parts. In the PVD process, these coating materials are either evaporated by
heat or bombarded with ions (sputtering). While the PVD coating metal is
being vaporized, a reactive gas is introduced which forms a compound with
the metal vapor and is deposited on the metal parts as a thin and highly
adherent coating. Various coatings can provide a range of characteristics
including, high hardness, wear resistance, corrosion resistance, chemical and
temperature resistance, and other properties.

(Right) Examples of painted

Liquidmetal components.

81
 PROPERTY PVD COATING E-COATING CONVERSION COATING
Figure 14..
THICKNESS .25-0.50 microns (10-20 μin) 5-30 microns (200-1200 μin) 2-3 microns (80-120 μin) Coating for
Liquidmetal®
Dyed transparent or opaque of
COLORS Black, grey, gold Dark grey to black
any available color, also clear

FINISH Mimics finish of part Flat to full gloss Mimics finish of part

ADHESION ISO Class 0 / ASTM Class 5B ISO Class 3 / ASTM Class 2B ISO Class 0 / ASTM Class 5B

SCRATCH RESISTANCE High Medium High

Select colors desired, additional

IDEAL FOR: corrosion, scratch, and Color or gloss desired Black color desired
wear resistance

The image to the

right illustrates
coating samples for
Liquidmetal

(Left) PVD Coating

(Middle) E-Coating

(Right)
Conversion Coating
Liquidmetal® Technologies – Corporate
20321 Valencia Circle, Lake Forest, CA 92630
949.635.2100 • www.liquidmetal.com