An extremely promising microscale processing method for bulk metallic glasses called thermoplastic forming has emerged in recent years. However, most of the recent experimental thermoplastic forming studies have been conducted by trial-and-error. In this paper, the large-deformation constitutive theory of Henann and Anand [1] is used as a numerical simulation tool for the design of micro-hot-embossing processes. This numerical simulation capability is used to determine appropriate processing parameters in order to carry out several successful micron-scale hot-embossing operation on the metallic glass Zr41.2Ti13.8Cu12.5Ni10Be22.5 (Vitreloy-1). By carrying out the corresponding physical experiments, it is demonstrated that microscale features in Vitreloy-1 may be accurately replicated under the processing conditions determined by use of the numerical simulation capability.

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