A new processing method, the Mixalloy process, has been developed to process alloys with novel microstructures and compositions. In this process, microstructural control is achieved through the use of turbulent mixing of liquid metals in addition to controlling solidification rate and chemical composition. Boride dispersion strengthened copper alloys were produced using the Mixalloy process. Thermally stable and fine (average less than 100 nm) boride dispersoids were formed by in-situ chemical reaction in the copper alloy matrices during mixing. The uniform mixture of the matrix and dispersoids was then rapidly solidified to maintain the fine microstructure. The consolidated material shows exceptional thermal stability and an excellent combination of strength, ductility, and electrical conductivity. Furthermore, the flexibility of the process allows the matrices of these dispersion strengthened coppers to be easily alloyed to fulfill specific needs. The versatility and simplicity of the Mixalloy process provide an economical alternative to other processing means in the manufacturing of high performance alloys such as dispersion strengthened alloys.