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Optimal way for withdrawing vested company match from my 401k?
You can borrow against a 401k for 5 years. This defers any penalty fees that the IRS mandates. Put the cash back in your 401k within those 5 years. you can also solo administer 401k plans even if you have an unincorporated business, so you can start one of those if you have any other form of cashflow, and there may be a way to get the other plan rolled into your solo one.  http://www.irs.gov/publications/p560/ch04.html#en_US_publink10009053