Systems and methods for fabricating objects including amorphous metal using techniques akin to additive manufacturing

A method of fabricating a free-standing object comprising an amorphous metal, the method comprising:

• applying a first layer of molten metallic alloy to a surface using a thermal spraying technique and a spot size having a diameter of about 1 to 100 mm, wherein the molten metallic alloy comprises one or more of Ti, Zr, and Cu, wherein the surface comprises a removal promoting material, and wherein the thermal spraying technique is selected from the group consisting of:
• high velocity oxy-fuel spraying, plasma spraying, wire arc spraying, and mixtures thereof;
• cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first cooled and solidified layer comprising the amorphous metal, wherein the amorphous metal comprises one or more of Ti, Zr, and Cu, and wherein the removal promoting material facilitates separating the amorphous metal from the surface;
• applying a second layer of molten metallic alloy onto the first cooled and solidified layer comprising the amorphous metal using the thermal spraying technique and the spot size having a diameter of about 1 to 100 mm;
• and
• cooling the second layer of molten metallic alloy such that it solidifies and thereby forms a second cooled and solidified layer comprising the amorphous metal on the first cooled and solidified layer comprising the amorphous metal;
• applying and cooling one or more additional layers of molten metallic alloy to form one or more additional cooled and solidified layers comprising the amorphous metal that are each formed on a previously formed cooled and solidified layer comprising the amorphous metal;
• wherein at least two of the applied layers of molten metallic alloy are not coextensive in shape;
• and
• wherein an aggregate of the cooled and solidified layers comprising the amorphous metal forms a desired shape of the free-standing object to be fabricated.