Patent Publication Number: US-2021178670-A1

Title: Additive manufacturing systems and methods of forming components using same

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of priority of U.S. Application No. 62/947,359, filed Dec. 12, 2019, which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     The disclosure relates generally to additive manufacturing systems, and more particularly, to additive manufacturing systems that disperses an at least partially liquid state build material to form a component. 
     Components or parts for various machines and mechanical systems may be built using additive manufacturing systems. Conventional additive manufacturing systems may build such components by continuously layering powder material in predetermined areas and performing a material transformation process, such as sintering or melting, on the powder material. The material transformation process may alter the physical state of the powder material from a granular composition to a solid material to build the component. The components built using the additive manufacturing systems have nearly identical physical attributes as conventional components typically made by performing machining processes (e.g., material removal processes) on stock material. However, because of the advantageous process, the components formed using additive manufacturing may include unique features and/or complex geometries that are difficult or impossible to obtain and/or build using conventional machining processes. 
     While able to manufacture complex geometries that are unattainable over conventional machining process, conventional additive manufacturing may still be limited in its ability to create certain features or shapes. For example, components made using conventional material deposition processes (e.g., powder deposition) must be able to be made linearly based on the processes and/or machine capabilities of the system. Furthermore, conventional material deposition processes and systems require extensive amounts of material to be deposited to form a part, which results in an increase in material cost and production or creation time. Additionally, some components with unique features may require the formation of disposable supports or struts to support those features of the components. These supports are removed from the component post additive manufacturing and simply discarded, creating added waste to these conventional additive processes. 
     To overcome some of the identified difficulties and negatives to deposition-based additive manufacturing, direct-energy deposition, such as electron beam additive manufacturing (EBAM), may be used. In one example, conventional direct-energy deposition may deposit a material on a surface of the component and immediately exposed to an energy stream to form a layer of the component. Alternatively in another example, material may be directed directly at the energy stream (e.g., electron beam), which in turn may direct the heated/transformed (e.g., solid state to liquid state) material to the component to form a layer or portion of the component. While able to create additional complex geometries, conventional direct-energy deposition is time consuming, expensive, creates additional material waste (e.g., material not properly deposited or passing through beam without deposition), and often results in inaccuracies and/or defects formed in the component due to outside influences (e.g., material flowing out of beam stream, undesirable suction/pressure, etc.). Furthermore, the geometries created in the components using conventional direct-energy deposition is limited by the inability to move the energy device and/or material deposition device freely when creating the component. 
     BRIEF DESCRIPTION 
     A first aspect of the disclosure provides an additive manufacturing system including: a material supply including a build material; a material conduit in fluid communication with the material supply, the material conduit including: a first section in direct fluid communication with the material supply, the first section receiving the build material from the material supply flowing through at least a portion of the first section of the material conduit in a vapor state, and a second section in fluid communication with the first section and receiving the build material from the first section, at least a portion of the build material flowing through the second section is in a liquid state; a coolant conduit in fluid communication with material conduit, the coolant conduit in fluid communication with a coolant supply for receiving a coolant material from the coolant supply; a nozzle in direct fluid communication with the second section of the material conduit; and a build chamber including a cavity receiving at least a portion of the nozzle, the cavity having a predetermined pressure. 
     A second aspect of the disclosure provides a method of forming a component using an additive manufacturing system. The method includes: flowing a build material through a first section of a material conduit of the additive manufacturing system; flowing the build material through a second section of the material conduit to a nozzle of the additive manufacturing system, the second section of the material conduit in fluid communication with and positioned between the first section of the material conduit and the nozzle, wherein at least a portion of the build material flowing through the second section is in a liquid state; and dispersing the build material from the nozzle onto a build substrate positioned within a cavity of a build chamber of the additive manufacturing system, the cavity having a predetermined pressure. 
     The illustrative aspects of the present disclosure are designed to solve the problems herein described and/or other problems not discussed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure, in which: 
         FIG. 1  shows a schematic view of an additive manufacturing system, according to embodiments of the disclosure. 
         FIG. 2  shows an enlarged view of a build material dispersed by the additive manufacturing system of  FIG. 1  to form a component, according to embodiments of the disclosure. 
         FIG. 3  shows an enlarged view of a build material dispersed by the additive manufacturing system of  FIG. 1  to form a component, according to other embodiments of the disclosure. 
         FIG. 4  shows a schematic view of an additive manufacturing system, according to additional embodiments of the disclosure. 
         FIG. 5  shows a schematic view of an additive manufacturing system, according to another embodiment of the disclosure. 
         FIG. 6  shows an enlarged view of a build material dispersed by the additive manufacturing system of  FIG. 5  to form a component, according to embodiments of the disclosure. 
         FIG. 7  shows a schematic view of an additive manufacturing system, according to further embodiments of the disclosure. 
         FIG. 8  shows a schematic view of an additive manufacturing system including a supplemental material supply system, according to embodiments of the disclosure. 
         FIG. 9  shows a cross-sectional view of a portion of a component build using an additive manufacturing system, according to embodiments of the disclosure. 
         FIGS. 10A and 10B  show a flowchart illustrating a process for building a component using an additive manufacturing system, according to embodiments of the disclosure. 
       It is noted that the drawings of the disclosure are not to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering represents like elements between the drawings. 
     
    
    
     DETAILED DESCRIPTION 
     As an initial matter, in order to clearly describe the current disclosure it will become necessary to select certain terminology when referring to and describing relevant machine components within the disclosure. When doing this, if possible, common industry terminology will be used and employed in a manner consistent with its accepted meaning. Unless otherwise stated, such terminology should be given a broad interpretation consistent with the context of the present application and the scope of the appended claims. Those of ordinary skill in the art will appreciate that often a particular component may be referred to using several different or overlapping terms. What may be described herein as being a single part may include and be referenced in another context as consisting of multiple components. Alternatively, what may be described herein as including multiple components may be referred to elsewhere as a single part. 
     As discussed herein, the disclosure relates generally to additive manufacturing systems, and more particularly, to additive manufacturing systems that disperses an at least partially liquid state build material to form a component. 
     These and other embodiments are discussed below with reference to  FIGS. 1-10B . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  shows a schematic view of an additive manufacturing system  100  (hereafter, “AMS  100 ”). AMS  100  may be used to form, build, and/or create a component from a build material, as discussed herein. In a non-limiting example, AMS  100  may include a material supply  102 . Material supply  102  may be formed as any suitable component that may be configured to receive, contain, and/or hold a build material  104  that may be utilized in the build process to form the component, as discussed herein. For example, material supply  102  may be formed from a tank, container, vessel, receptacle, chamber, hopper and/or the like. In other non-limiting examples, material supply  102  may be configured to provide build material  104  to other portions of AMS  100  (e.g., material conduit) during the build process using any suitable means including, but not limited to, gravity feed or an auxiliary supply system or source that provides gas flow (e.g., carrier fluid/gas) or suction (not shown) to move build material  104  through AMS  100 , as discussed herein. Additionally, and as discussed herein, build material  104  included within material supply  102  may be in either a solid state, a liquid state, or a vapor state. As such, material supply  102  may also include additional devices and/or apparatuses, for example a heating element (e.g., not shown), to ensure that build material  104  may be transformed and/or maintained at the desired physical state (e.g., solid, liquid, vapor). Furthermore, build material  104  may include any suitable material that may be heated and cooled during the build process as discussed herein to form a component using AMS  100 . For example, build material  104  may be formed from materials including, but not limited to, metals, metal-alloys, polymers (e.g., silicones), and/or the like. 
     AMS  100  may also include a material conduit  106 . Material conduit  106  may be in fluid communication with material supply  102  to receive build material  104  from material supply  102 . In the non-limiting example shown in  FIG. 1 , material conduit  106  of AMS  100  may include two distinct portions or sections  108 ,  110 . More specifically, material conduit  106  may include a first section  108  in direct fluid communication with material supply  102 , and a second section  110  in fluid communication with the first section  108 . As shown in  FIG. 1 , first section  108  and second section  110  of material conduit  106  may be formed as two distinct components that may be (fluidly) coupled using a T-connection or joint  112 . In other non-limiting examples first section  108  and second section  110  may be formed as a single component and/or may be formed integral to one another. Material conduit  106  may be formed from any suitable material that may allow build material  104  to flow therethrough, as well as withstand the temperature/heating during the process of forming a component using AMS  100 , as discussed herein. For example, material conduit  106  may be formed from metal, metal-alloys, ceramic, fiberglass, polymers, and/or the like. Additionally, each section  108 ,  110  of material conduit  106  may be formed from the same or distinct materials. For example, first section  108  of material conduit  106  may be formed from a ceramic material, while second section  110  may be formed from a metal or metal-alloy material. 
     As shown in  FIG. 1 , AMS  100  may include a nozzle  118  in communication with material conduit  106 . More specifically, nozzle  118  may be in direct fluid communication with second section  110  of material conduit  106 . As discussed herein, at least a portion of nozzle  118  may be positioned within a build chamber  120  when building the component using AMS  100 . Nozzle  118  may be formed as any suitable device and/or apparatus that may be configured to disperse, dispense, and/or distribute build material  104  within the build chamber to create, form, and/or build a component using AMS  100 . Additionally, nozzle  118  may also be shaped and/or configured to converge near the tip/exit opening, such that build material  104  flowing through nozzle  118  may be pressurized and/or accelerated out of nozzle  118  when dispersed therefrom in forming the component. That is, and as discussed herein, in order for build material  104  to be dispersed from nozzle  118  at a high rate of speed/at high pressure during the build process, the pressure upstream of the nozzle  118  opening may be greater than the pressure downstream of the opening (e.g., after discharge from nozzle  118 ). The shape and/or configuration of nozzle  118  may, at least in part, aid in the pressure distribution within AMS  100 . Similar to material conduit  106 , nozzle  118  may be formed from any suitable material that may allow build material  104  to flow therethrough, as well as withstand the temperature of build material  104  flowing therethrough during the process of forming a component using AMS  100 . For example, nozzle  118  may be formed from metal, metal-alloys, ceramic, fiberglass, polymers, and/or the like. In the non-limiting example shown in  FIG. 1 , nozzle  118  may also be configured to move, traverse, and/or rotate in each of a first direction (D 1 ), a second direction (D 1 ), and third direction (D 3 ) (e.g., in-and-out of the page). Nozzle  118  may use or include any suitable system, apparatus, and/or device that may allow nozzle  118  to move and/or rotate in the identified directions including, but not limited to, a flexible joint (not shown) coupling nozzle  118  to second section  110  of material conduit  106  and/or a moveable arm (not shown) coupled to nozzle  118  and/or material conduit  106 . 
     Build chamber  120  of AMS  100  may be formed adjacent to and/or may receive at least a portion of nozzle  118 . More specifically, and as shown in the non-limiting example of  FIG. 1 , build chamber  120  may include and/or may define a cavity  122  which may receive at least a portion of nozzle  118  during the build process, as discussed herein. Cavity  122  of build chamber  120  may also receive a build substrate  124 . Substrate  124  may receive build material  104  and/or provide a base or build plate for the component build, formed, and/or created by AMS  100  during the build process. Cavity  122  of build chamber  120  may be configured to be substantially sealed to have or maintain a predetermined (internal) pressure during the build process. For example during the build process, cavity  122  may include a predetermined pressure that is less than atmospheric pressure (e.g., sub-atmospheric). The predetermined pressure may include between approximately zero (0) atmospheres (atm) and below one (1) atm (e.g., 0.5 atm). Build chamber  120  may also include an opening or exhaust portion  125  that may be used to maintain the internal pressure in cavity  122 , as well as dissipate and/or remove gas(es)/particles from chamber  120  during the build process. In a non-limiting example, a vacuum (not shown) may be in fluid communication with exhaust portion  125  to remove the carrier fluid that moves build material  104  through material conduit  106 , and/or maintain the desired pressure within chamber  120 . The inclusion of the exhaust portion  125 /removal of carrier fluid may, at least in part, aid in maintaining the desired pressure within build chamber  120  to optimize the deposition of build material  104  on substrate  124  when forming the component using AMS  100 , as discussed herein. 
     As discussed herein, nozzle  118  may be configured to move, traverse, and/or rotate in directions (D 1 , D 2 , D 3 ) when forming the component using AMS  100 . Additionally, or alternatively, build chamber  120 , and more specifically build substrate  124  positioned within cavity  122 , may be configured to move, traverse, and/or rotate in directions (D 1 , D 2 , D 3 ) when forming the component using AMS  100 . 
     AMS  100  may also include a coolant supply  126 . Coolant supply  126  may be formed as any suitable component that may be configured to receive, contain, and/or hold a coolant material  128  that may be utilized in the build process to form the component (e.g., cool build material  104 ), as discussed herein. For example, coolant supply  126  may be formed from a tank, container, vessel, receptacle, chamber, hopper and/or the like. In other non-limiting examples, coolant supply  126  may be configured to provide coolant material  128  to other portions of AMS  100  (e.g., coolant conduit) during the build process using any suitable means including, but not limited to, gravity feed or an auxiliary supply system or source that provides gas flow or suction (not shown) to move coolant material  128  through AMS  100 , as discussed herein. 
     AMS  100  may also include a coolant conduit  130 . Coolant conduit  130  may be in fluid communication with coolant supply  126  to receive coolant material  128  from coolant supply  126 . Additionally, and as shown in the non-limiting example of  FIG. 1 , coolant conduit  130  of AMS  100  may also be in fluid communication with material conduit  106 . More specifically, coolant conduit  130  may be in direct fluid communication with second section  110  of material conduit  106  via T-connection  112 . As discussed herein, coolant conduit  130  may supply coolant material  128  to second section  110  of material conduit  106  to cool and/or reduce the temperature of build material  104  flowing from first section  108  to second section  110  of material conduit  106  prior to build material  104  being dispersed by nozzle  118 . In the non-limiting example, coolant conduit  130  may be in direct fluid communication such that coolant material  128  may be provided directly to second section  110  of material conduit  106  to directly contact, mix with, and consequently cool build material  104  flowing therethrough. Coolant conduit  130  may be formed from any suitable material that may allow coolant material  128  to flow therethrough. For example, coolant conduit  130  may be formed from metal, metal-alloys, ceramic, fiberglass, polymers, and/or the like. Furthermore, coolant material  128  may include any suitable material that may be used to cool build material  104  during the build process as discussed herein. For example, coolant material  128  may be formed from materials including, but not limited to, argon, nitride, oxides, and/or the like. 
     AMS  100  may also include at least one computing device  132  configured to control operations of distinct, components, devices, and/or apparatuses of AMS  100 . Computing device(s)  132  may be hard-wired, wirelessly and/or operably connected to and/or in communication with various components of AMS  100  via any suitable electronic and/or mechanic communication component or technique. Specifically, computing device(s)  132  may be in electrical communication and/or operably connected to material supply  102 , nozzle  118 , and coolant supply  126  (not shown) of AMS  100 . Computing device(s)  132 , and its various components discussed herein, may be a single stand-alone system that functions separate from an operations system of AMS  100  (e.g., computing device) (not shown) that may control and/or adjust at least a portion of operations and/or functions of AMS  100 , and its various components (e.g., nozzle  118 ). Alternatively, computing device(s)  132  and its components may be integrally formed within, in communication with and/or formed as a part of a larger control system of AMS  100  (e.g., computing device)(not shown) that may control and/or adjust at least a portion of operations and/or functions of AMS  100 , and its various components. 
     In various embodiments, computing device(s)  132  can include a control system  134  for controlling operations and/or functions of AMS  100  during the build process. As discussed herein control system  134  can control the movement of nozzle  118  of AMS  100 , and/or the flow of build material  104  being dispersed by nozzle  118  during the build process. Additionally, control system  134  may also control the output and/or flow of build material  104  from material supply  102  and/or coolant material  128  from coolant supply  126  during the build process. Furthermore, and as discussed herein, control system  134  may control the operation of heaters included in AMS  100  to ensure build material  104  is in a desired physical state (e.g., gas, liquid, solid) and/or includes a desired temperature as it flows through material conduit  106 . 
     As shown in  FIG. 1 , computing device(s)  132  may include and/or may be in electrical and/or mechanical communication with at least one sensor  136  positioned throughout, within, adjacent to and/or around AMS  100 . In the non-limiting example, sensor(s)  136  may be positioned directly within first section  108  and second section  110  of material conduit  106 , as well as directly within coolant conduit  130 . In other non-limiting examples, sensor(s)  136  may be positioned directly adjacent to, in communication with, and/or may be coupled to an outside of first section  108  of material conduit  106 , second section  110  of material conduit  106 , and coolant conduit  130 . Sensor(s)  136  of AMS  100  may be any suitable sensor configured to detect and/or determine a temperature of build material  104  and coolant material  128  flowing through AMS  100 . More specifically, sensor(s)  136  of AMS  100  may be any suitable sensor that may detect and/or determine a first temperature of build material  104  in a gas or vapor state flowing through first section  108  of material conduit  106 , a second temperature of build material  104  in a liquid and solid state flowing through second section  110  of material conduit  106 , and a temperature of coolant material  128  flowing through coolant conduit  130 . In another non-limiting example where sensor(s)  136  are in communication with and/or coupled to conduits  106 ,  130 , sensor(s)  136  may be any suitable sensor that may detect and/or determine the temperature of the respective conduits  106 ,  130 , which in turn may allow computing device(s)  132 /control system  134  to calculate the temperature of build material  104  and coolant material  128  flowing through AMS  100 . In non-limiting examples, sensor(s)  136  may be configured as, but not limited to, thermometers, thermistor, thermocouples, and/or any other mechanical/electrical temperature sensor. As discussed herein, determining the temperatures of build material  104  flowing through material conduit  106  and coolant material  128  flowing through coolant conduit  130  may aid in the formation of the component using AMS  100 . 
     Although two sensors  136  are shown in each section  108 ,  110 /conduit  130 , it is understood that in another non-limiting example, AMS  100  may include only one sensor  136 , so long as sensor(s)  136  may be configured to provide computing device(s)  132 , and specifically control system  134 , with information or data relating to temperatures of build material  104 /coolant material  128 , as discussed herein. The number of sensors  136  shown in  FIG. 1  is merely illustrative and non-limiting. As such, AMS  100  may include more or less sensors  136  than what is depicted in the Figures. Additionally, although computing device(s)  132  is only shown in  FIG. 1  as being connected to and/or in electronic communication with a portion of sensors  136  of AMS  100 , it is understood that computing device(s)  132  may be in electronic communication with each sensor(s)  136  included in AMS  100 . 
     AMS  100  may also include at least one heater  138 . That is, computing device(s)  132  may include and/or may be in electrical and/or mechanical communication with at least one heater  138  positioned throughout, within, adjacent to, and/or around AMS  100 . In the non-limiting example shown in  FIG. 1 , heater(s)  138  may be positioned directly adjacent to, in communication with, and/or may be coupled to an outside of first section  108  of material conduit  106 , and second section  110  of material conduit  106 , respectively. In another non-limiting example (see,  FIG. 4 ), heater(s)  138  may be positioned directly within first section  108  and second section  110  of material conduit  106 . Heater(s)  138  of AMS  100  may be any suitable heating device configured to generate and/or emit heat in AMS  100 . More specifically, heater(s)  138  of AMS  100  may be any suitable heating device that may generate and/or emit heat to increase the temperature of build material  104  flowing through material conduit  106 . In the non-limiting example where heater(s)  138  are in communication with and/or coupled to the outside of material conduit  106 , heater(s)  138  may be any suitable heating device that may generate and/or emit heat material conduit  106 , which in turn may increase a temperature and/or maintain a temperature for build material  104  flowing therethrough. In another non-limiting example where heater(s)  138  are positioned directly within material conduit  106 , heater(s)  138  may be any suitable heating device that may generate and/or emit heat that may directly increase a temperature and/or maintain a temperature for build material  104  flowing through material conduit  106  and/or over heater(s)  138 . In non-limiting examples, heater(s)  138  may be configured as, but not limited to, ohmic heating devices, inductive heating devices, laser heating devices, and so on. As discussed herein, maintaining and/or adjusting the temperature of build material  104  using heater(s)  138  may aid in the formation of the component using AMS  100 . 
     Although two heaters  138  are shown in each section  108 ,  110  of material conduit  106 , it is understood that in another non-limiting example, AMS  100  may include more or less sensors  136  than what is depicted in the Figures. As such, the number of heaters  138  shown in  FIG. 1  is merely illustrative. Additionally, although computing device(s)  132  is only shown in  FIG. 1  as being connected to and/or in electronic communication with a portion of heaters  138  of AMS  100 , it is understood that computing device(s)  132  may be in electronic communication with each heater(s)  138  included in AMS  100 . 
     The process of building a component on substrate  124  using AMS  100  is now discussed herein. Initially, build material  104  may be provided in material supply  102 , and a coolant material  128  may be provided to coolant supply  126 . As discussed herein, build material  104  may be provided to and contained within material supply  102  at a liquid and/or solid state, and may be subsequently heated and/or vaporized within material conduit  106 . Alternatively, build material  104  may be vaporized by and/or provided to material supply  102  in a vapor state prior to flowing through material conduit  106 . 
     In a non-limiting example, build material  104  may be copper (Cu), which includes a melting temperature of approximately 1084 Celsius (° C.). In one example, the copper may be deposited into and maintained in material supply  102  of AMS  100  in a liquid and/or solid state. In another non-limiting example, the copper may be deposited into and/or maintained in material supply  102  in a gaseous or vapor state. 
     Prior to providing build material  104  to material conduit  106 , material conduit  106  may be preheated. That is, in order to prevent undesirable phase change of build material  104  as it flows through first section  108  of material conduit  106 , first section  108  and second section  110  of material conduit  106  may be preheated to a desired temperature using heater(s)  138 . The preheat-predetermined temperature for first section  108  and second section  110  of material conduit  106  may be dependent upon the first predetermined temperature for build material  104  in first section  108  and the second predetermined temperature for build material  104  in second section  110 . The first predetermined temperature and the second predetermined temperature for build material  104  associated with the desired phase (e.g., gas/liquid/solid) of build material  104  within each respective section  108 ,  110 , as discussed herein. In a non-limiting example, first section  108  may be preheated to a first predetermined temperature which may either vaporize build material  104  within first section  108  and/or maintain build material  104  flowing through first section  108  in a vaporized state dependent upon the phase of build material  104  within material supply  102 . Additionally, second section  110  may be preheated to a second predetermined temperature, lower than the first predetermined temperature, which may alter or aid in the change in phase of build material  104  from a vaporized or gaseous state to a liquid/solid state. 
     Continuing the example herein, prior to providing the copper to material conduit  106 , first section  108  and second section  110  of material conduit  106  may be preheated. More specifically, first section  108  and/or the internal space of first section  108  may be heated to a first predetermined temperature, while second section  110  and/or the internal space of second section  110  may be heated to a second predetermined temperature that is lower than the first predetermined temperature. For example, first section  108  of material conduit  106  may be preheated to approximately 1,500° C. to convert and/or maintain the copper in a gaseous/vapor state as it flow therethrough. Additionally, second section  110  of material conduit  106  may be preheated to approximately 1,200° C. to convert and/or maintain the copper in a liquid and/or solid state as it flows therethrough. 
     Once material conduit  106  is preheated, build material  104  may be provided to material conduit  106 . Specifically, after first section  108  and second section  110  of material conduit  106  are preheated to the respective predetermined temperatures, material supply  102  may provide build material  104  to material conduit  106 . In a non-limiting example where build material  104  is contained in material supply  102  in a vapor state, build material  104  may be provided, supplied and/or flow through first section  108  of material conduit  106  in the vapor state and may be maintained in the vapor state throughout first section  108  by heater(s)  138  heating first section  108  to the predetermined temperature. In another non-limiting example where build material  104  is provided to first section in a liquid/solid state, build material  104  may be provided to first section  108  of material conduit  106  and subsequently transformed to a vapor state. That is, and using heater(s)  138  to heat first section  108  to the first predetermined temperature, build material  104  may be transformed from liquid/solid state to a vapor state within first section  108  as it flows therethrough. As discussed herein, the first predetermined temperature in which heater(s)  138  may heat first section  108  to may convert and/or maintain build material  104  in a gaseous/vapor state. Sensor(s)  136  in communication with computing device(s)  132  may continuously or intermittently determine the temperature of build material  104  and/or the internal temperature of material conduit  106  in order to determine how much heat and/or energy heater(s)  138  must emit to ensure build material  104  is in a vapor state as it flows through first section  108  and/or first section  108  is heated to the first predetermined temperature. 
     Build material  104  in vapor/gaseous state may flow from first section  108  to second section  110  prior to being deposited within build chamber  120 . In the non-limiting example, as build material  104  flows through second section  110  it may be converted to a liquid state and/or a solid state. More specifically, the vapor/gaseous state build material  104  may flow from first section  108  to second section  110  of material conduit  106 , via T-connection  112 , and may be cooled within second section  110 . The cooling of build material  104  within second section  110  may result in the altering and/or converting of vapor/gaseous state build material  104  to liquid/solid state build material  104  prior to build material being dispersed by nozzle  118 . That is, where second section  110  of material conduit  106  is kept at and/or includes a lower temperature (e.g., second predetermined temperature) than the temperature of first section  108  (e.g., first predetermined temperature), build material  104  flowing to and/or within second section  110  may be substantially cooled. The second predetermined temperature may be below of vaporization temperature, but still above a melting temperature of the material forming build material  104 . As such, and when build material  104  flows into second section  110 , the build material  104  may be cooled and the phase may be converted from gaseous/vapor to a combination of liquid state material and solid-state material, or alternatively may be substantially all liquid state material. The closer to the first predetermined temperature for second section  110  is to the melting temperature of build material  104  and/or the closer build material  104  is cooled to the melting temperature, the greater the percentage or amount of solid-state build material  104  may be formed in second section  110 . 
     To aid in the cooling of build material  104  within second section  110  of material conduit  106 , coolant material  128  may also be provided as well. More specifically, coolant conduit  130  in direct fluid communication with second section  110  of material conduit  106  via T-connection  112  may provide coolant material  128  from coolant supply  126  directly to second section  110  to cool build material  104  flowing therethrough. In this non-limiting example, coolant material  128  may directly contact and/or interact with build material  104  flowing through second section  110  to quench, cool, and/or reduce the temperature of build material  104 . Additionally, coolant material  128  may aid in the conversion of build material  104  from the vapor/gaseous state to the liquid and/or solid state within second section  110  of material conduit  106 . Coolant material  128 , in conjunction with heater(s)  138  in communication with second section  110 , may ensure build material  104  is cooled to a temperature that allows for the conversion of the material from the vapor/gaseous state to the liquid and/or solid state, but maintains build material  104  at a temperature above a melting temperature for the material. 
     In the example where the build material is copper, first section  108  may be heated and/or maintained at the first predetermined temperature that may ensure the copper is at a temperature at or above 1,500° C., as it flows therein. This in turn may convert and/or maintain the copper in a gaseous/vapor state as it flows through first section  108 . Subsequently, the vaporized/gaseous copper material may flow to the second section of material conduit  106  which may result in the cooling of the copper material. That is, second section  110  may be heated and/or maintained at the second predetermined temperature, lower than the first predetermined temperature, that may ensure the copper is cold to a temperature that converts the gaseous copper to liquid and/or solid-state copper. Additionally, second section  110  may be heated and/or maintained at the second predetermined temperature to maintain the copper at a temperature that is above the melting temperature of copper (e.g., 1084° C.). In another non-limiting example, a calculated amount of coolant material  128  (at a calculated temperature) may be introduced and/or flowed to second section  110  to aid in the cooling of the copper and/or the converting of the gaseous state copper to the liquid and/or solid-state copper. In the non-limiting example, the coolant material  128  may be formed as oxygen (O 2 ). 
     From second section  110 , build material  104  may flow through and/or be dispersed by nozzle  118 . More specifically, build material  104 , in the liquid and/or sold state, may flow from second section  110  and may be dispersed, dispensed, and/or distributed by the nozzle  118 . The build material  104  dispersed by nozzle  118  may be final build material  140 , that may be accelerated toward and/or build up on substrate  124  to form a desired component. Nozzle  118  may continuously or intermittently flow final build material  140  toward substrate  124  to build the desired component using AMS  100 . Additionally, and as discussed herein, nozzle  118  may move in various directions (e.g., D 1 , D 2 , D 3 ) to build the component and its various features using final build material  140 . 
     Turning to  FIG. 2 , an enlarged view of final build material  140  is shown. In a non-limiting example, and as discussed herein, final build material  140  received by nozzle  118  from second section  110  may include both liquid state material  142  and solid-state material  144 . As discussed herein, liquid state material  142  may be formed from, formed as, and/or referred to as “droplets,” while solid state material  144  may be formed from, formed as, and/or referred to as “particles.” The amount of each state and/or the ratio between the amount of liquid state material  142  and solid-state material  144  may be dependent at least in part on the temperature of build material  104  after it is cooled and/or flows to nozzle  118 . More specifically, and as discussed herein, the closer build material  104  is cooled to the melting temperature, the greater the percentage or amount of solid-state material  144  may be present in final build material  140 . The ratio between the amount of liquid state material  142  and solid-state material  144  in final build material  140  may be between approximately 100:0 and 20:80. In another non-limiting example, substantially all of final build material  104  may include or be comprised of liquid state material  142 . In either example, build material  140  may contact substrate  124  (or previous deposited final build material  140 ) and liquid state material  142  and solid-state material  144  may combine to form the component. Additionally, liquid state material  142  of final build material  140  may also solidify instantaneously or within a predetermined time (e.g., less than a second) to bind solid-state material  144  and/or form the component. 
     The porosity and/or (material) density of the component built using liquid state material  142  and/or solid-state material  144  of final build material  140  may be dependent, at least in part, by the ratio of liquid state material  142  and solid-state material  144  deposited on substrate  124 . That is, the porosity and/or density of the component built by AMS  100  may be determined, affected, and/or influenced by the ratio of liquid state material  142  and solid-state material  144  for final build material  140  forming the component. In a non-limiting example, the porosity of the component may decrease and the density of the component may increase as the amount of liquid state material  142  in final build material  140  increases. As discussed herein, the amount of liquid state material  142  may increase and/or may be influenced by the temperature in which build material  104  is cooled to in second section  110  (e.g., more liquid state material  142  in final build material  140  when the temperature of build material  104  is further from the melting point in second section  110 ). In another non-limiting example, the porosity of the component may increase and the density of the component may decrease as the amount of liquid state material  142  in final build material  140  decreases (e.g., build material  104  cooled closed to melting point in second section  110 ). 
     As shown in  FIG. 2 , each of liquid state material  142  and solid-state material  144  of final build material  140  may include a size (S 1 , S 2 ) or dimension (e.g., droplet/particle size or dimension). The size (S 1 ) of liquid state material  142  (e.g., droplet size) in final build material  140  may be substantially equal to or distinct from the size (S 2 ) of solid-state material  144  (e.g., particle size). Additionally, the size (S 1 , S 2 ) of each of liquid state material  142  and/or solid-state material  144  for final build material  140  may be substantially uniform, or alternatively, may include a desired range. The size (S 1 , S 2 ) of each of liquid state material  142  (droplet) and/or solid-state material  144  (particles) for final build material  140  may be dependent, at least in part, on the cooling rate for build material  104  in second section  110  of material conduit  106 . That is, and briefly returning to  FIG. 1 , the cooling rate for build material  104 , which includes the temperature and time difference in cooling build material  104  from the first temperature in first section  108  to the second (lower) temperature in second section  110 , may affect, influence, and/or determine the size (S 1 , S 2 ) of liquid state material  142  and solid-state material  144 . The higher the cooling rate for build material  104  in second section  110  of material conduit  106 , the smaller the size (S 1 , S 2 ) (e.g., droplet/particle size) for each of liquid state material  142  and/or solid-state material  144  of final build material  140 . As such, increasing a cooling rate for build material  104  in second section  110  may result in a decrease in (droplet/particle) size (S 1 , S 2 ) for liquid state material  142  and/or solid-state material  144  of final build material  140 . Alternatively, decreasing the cooling rate for build material  104  in second section  110  may result in an increase in (droplet/particle) size (S 1 , S 2 ) for liquid state material  142  and/or solid-state material  144  of final build material  140 . The size of the droplets forming liquid state material  142  and/or the particles forming solid-sate material  144  of final build material  140  may be between, for example, approximately 10 nanometers (nm) to 100 micron (μm). 
     Additionally, porosity of the component built using AMS  100  may also be influenced, at least in part, by the size (S 1 , S 2 ) of liquid state material  142  and/or solid-state material  144  of final build material  140 . For example, the size (S 1 , S 2 ) of liquid state material  142  and/or solid-state material  144  of final build material  140  may also influence, affect, and/or determine the size and/or shape of the “holes” or “openings” formed in a porous component built using AMS  100 . 
     Component built on substrate  124  by AMS  100  may have predetermined and/or desired build characteristics, which may include predetermined size of particles, a predetermined density, a predetermined porosity, and/or predetermined build patterns or features. As discussed herein, computing device  132 , using sensor(s)  136 , may obtain and/or calculate data (e.g., temperatures for build material  104 ) relating to the build process, and adjust the operation of portions of AMS  100  (e.g., heater(s)  138 ) to ensure the component is built to specification. For example, where the component includes two portions having distinct porosities (see,  FIG. 9 ), AMS  100  may operate under first operational conditions to form the first portion including the first porosity. AMS  100  may then alter its operation, in near real-time, to second operational conditions to form the second portion including the second porosity. Where the second porosity is greater than the first porosity, the altered operational conditions may include, but are not limited to, decreasing the temperature in which build material  104  is cooled in second section  110  of material conduit  106 , which in turn may decrease the amount of liquid state material  142  in final build material  140 . 
     Additionally in this example, if it is desired to keep the droplet/particle size (S 1 , S 2 ) for each of liquid state material  142  and solid-state material  144  the same between the first portions and the second portions, then the temperature of build material  104  in first section  108  may also be reduced, and/or the amount of coolant material  128  supplied to second section  110  may be increased. In altering these operational conditions the cooling rate for build material  104  may remain the same when forming the first portion having the first porosity and the second portion having the second porosity. 
     Although discussed herein as converting build material  104  from vapor to liquid state material  142  (and solid-state material  144 ) within material conduit  106 , it is understood that at least a portion of build material  104  may remain as liquid state material  142  from material supply  102  to nozzle  118 . That is, and in another non-limiting example, build material  104  may be contained in material supply  102  in a liquid state. Liquid-state material  142  forming build material  104  may flow to first section  108  of material conduit  106  and may be heated, but may not be converted and/or changed to a vapor/gaseous state. Rather in this non-limiting example, build material  104  flowing through first section  108  may remain in the liquid state and heated to the first predetermined temperature—a temperature below the identified temperature that would convert build material  104  to a vapor/gaseous state. As such, liquid-state material  142  of build material  104  may flow from first section  108  of material conduit  106  to second section  110 , and may subsequently cooled to the second, predetermined and/or desired temperature (e.g., above melting temperature) as similarly discussed herein. However in this non-limiting, and because build material  104  flowing through first section  108  of material conduit  106  is already in a liquid state, build material  104  may not undergo a conversion process from vapor/gaseous state to liquid/solid state. Rather, build material  104  may remain substantially as liquid state material  142  before being dispersed by nozzle  118 . Alternatively, a portion of liquid state material  142  flowing from first section  108  to second section  110  may be converted from liquid state material  142  to solid-state material  144  within second section  110  prior to being dispersed by nozzle  118 , as discussed herein. 
     In this non-limiting example, liquid state material  142  of build material  104  may be provided and/or flowed from material supply to first section  108  of material conduit  106  using any suitable device and/or process to generate and/or create droplets that may flow via an aerosol affect. For example, an ultrasonic device or system (not shown) may be included or in communication with material supply  102 . In this example, the ultrasonic device may provide an ultrasonic pulse to build material  104  that in turn may form, generate, and/or separate build material  104  within material supply  102  to include a predetermined droplet size (e.g., S 1 , 10 nm to 100 μm). Once formed to include the predetermined droplet size, liquid stat material  142  of build material  104  may flow and/or be moved to first section  108  of material conduit  106  using the processes and/or features discussed herein (e.g., suction, carrier fluid, etc.). 
       FIG. 3  shows another non-limiting example of an enlarged view of final build material  140 . Final build material  140  shown in  FIG. 3  may formed and/or used within AMS  100  substantially similar to final build material  140  shown and discussed herein with respect to  FIG. 2 . It is understood that similarly numbered and/or named components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     Distinct from final build material  140  shown in  FIG. 2 , final build material  140  may include a distinct material. That is, final build material  140  shown in  FIG. 3  may include both liquid state material  142  and solid-state material  144 , both formed from converting and/or altering the phase of build material  104  as discussed herein. In additional final build material  140  may also include a distinct compound material  146 . Compound material  146  included in final build material  140  may be formed within material conduit  106  during the heating/cooling/phase change processes. For example, compound material  146  may be generated, created, and/or formed as a result of a chemical interaction and/or chemical reaction between coolant material  128  and build material  104  within second section  110  of material conduit  106 . That is, coolant material  128  may interact with liquid/solid-state material or droplets/particles of build material  104  within second section  110  of material conduit  106 , and may form a compound material that is chemically and/or physically distinct material from the material forming build material  104 . In one example build material  104  is formed from copper (Cu) and a coolant material  128  may be formed from nitrogen (N). In the example shown in  FIG. 3 , all liquid state material  142  and a portion of solid-state material  144  of final build material  140  may be and/or may remain copper (Cu) in final build material  140 . However, a portion of the solid-state material  144  of final build material  140  may include and/or be formed as copper(I) nitride (Cu 3 N). The inclusion of compound material  146  within final build material  140  may alter or change the physical, chemical, and/or mechanical properties (e.g., composition, strength, ductility, and so on) of the component formed using AMS  100 , as discussed herein. 
       FIGS. 4 and 5  show additional non-limiting example of AMS  100 . More specifically,  FIGS. 4 and 5  depict schematic views of other examples of AMS  100 . It is understood that similarly numbered and/or named components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     The non-limiting example of AMS  100  shown in  FIG. 4  may include distinct features and/or configurations in comparison to AMS  100  shown and discussed herein with respect to  FIG. 1 . For example, heater(s)  138  may be positioned within material conduit  106 . More specifically, heater(s)  138  electrically coupled to computing device(s)  132  may be positioned directly within first section  108  and second section  110  of material conduit  106 . In the non-limiting example, heater(s)  138  may be contacted directly by build material  104  flowing through material conduit  106 . As such, heater(s)  138  may not only heat or emit heat directly in the internal portion of material conduit  106  as well as heat material conduit  106 , but may also heat build material  104  directly. 
     Additionally in  FIG. 4 , coolant conduit  130  may include a distinct configuration. For example, coolant conduit  130  may not be in direct fluid communication with material conduit  106 . Rather, coolant conduit  130  may substantially surround and/or encompass second section  110  of material conduit  106 . As a result, coolant material  128  flowing through coolant conduit  130  may not directly contact build material  104  to cool and/or reduce the temperature, as discussed herein. Rather, coolant conduit  130  may provide coolant material  128  to contact and/or substantially surround second section  110  of material conduit  106  to cool build material  104  flowing therein. That is, coolant conduit  130  may cool or reduce the temperature of second section  110  of material conduit  106 , which in turn may aid in the cooling of build material  104  and/or the converting of build material  104  from gaseous/vapor phase to liquid and/or solid state. 
     In the non-limiting example shown in  FIG. 5 , AMS  100  may include additional components. For example, AMS  100  may also include a supplemental material supply  148 . Supplemental material supply  148  may be formed as any suitable component that may be configured to receive, contain, and/or hold a supplemental build material  150  that may be utilized in the build process to form the component, as discussed herein. For example, supplemental material supply  148  may be formed from a tank, container, vessel, receptacle, chamber, hopper and/or the like. In other non-limiting examples, supplemental material supply  148  may be configured to provide supplemental build material  150  to other portions of AMS  100  (e.g., supplemental material conduit) during the build process using any suitable means including, but not limited to, gravity feed or an auxiliary supply system or source that provides gas flow or suction (not shown) to move supplemental build material  150  through AMS  100 , as discussed herein. 
     AMS  100  may also include a supplemental material conduit  152 . Supplemental material conduit  152  may be in fluid communication with supplemental material supply  148  to receive supplemental build material  150 . Additionally, and as shown in the non-limiting example of  FIG. 5 , supplemental material conduit  152  of AMS  100  may also be in fluid communication with material conduit  106 . More specifically, supplemental material conduit  152  may be in direct fluid communication with second section  110  of material conduit  106  via T-connection  112 . As discussed herein, supplemental material conduit  152  may supply supplemental build material  150  to second section  110  of material conduit  106  to mix, be added, and/or interact with build material  104  flowing through second section  110  of material conduit  106 . Supplemental material conduit  152  may be formed from any suitable material that may allow supplemental build material  150  to flow therethrough. For example, supplemental material conduit  152  may be formed from metal, metal-alloys, ceramic, fiberglass, polymers, and/or the like. Furthermore, supplemental build material  150  may include any suitable material that may be mixed, added, and/or interact with build material  104  during the build process to alter the physical and/or mechanical properties of the component build using AMS  100 , as discussed herein. For example, supplemental build material  150  may be formed from materials including, but not limited to, metals, metal-alloys, polymers (e.g., silicones), ceramics, and/or the like. 
     As a result of adding supplemental build material  150  to build material  104  within material conduit  106  during the build process, final build material  154  may be distinct from final build material  140  shown and discussed herein with respect to  FIGS. 1 and 2 . For example, where supplemental build material  150  includes a ceramic material, final build material  154  dispersed, dispensed, and/or distributed by nozzle  118  to form the component on substrate  124  may include additional material, elements, and/or compositions. 
     Turning to  FIG. 6 , and with continued reference to  FIG. 5 , final build material  154  may include both liquid state material  142  and solid-state material  144  formed from build material  104 , as well as compound material  146 , as discussed herein. Additional final build material  154  may also include distinct particles of supplemental build material  150  (e.g., ceramic). Furthermore in some non-limiting examples, final build material  154  may include distinct compound materials  156 . Distinct compound material  156  included in final build material  154  may be formed within material conduit  106  during the heating/cooling/phase change processes. For example, distinct compound material  156  may be generated, created, and/or formed as a result of a interaction and/or reaction between build material  104  and supplemental build material  150  within second section  110  of material conduit  106 . Distinct compound materials  156  may include a combination of build material  104  and supplemental build material  150 . Specifically, and as shown in  FIG. 6 , distinct compound materials  156  may include supplemental build material  150  substantially surrounded, coated, and/or enclosed by build material  104 . Build material  104  in a liquid state material  142  in second section  110  of material conduit  106  may become coupled/affixed to supplemental build material  150 , and substantial surround supplemental build material  150 . The temperature of supplemental build material  150  may subsequently (further) cool build material  104  to convert surrounding build material  104  to the solid-state, as shown in  FIG. 6 . 
     In one example, build material  104  is formed from copper (Cu) and supplemental build material  150  may be formed from silicone carbide (SiC). In the example shown in  FIG. 6 , solid state copper material may substantial surround and/or enclose the silicone carbide to form the distinct compound material  156 . The inclusion of distinct compound material  156  within final build material  154  may alter or change the physical, chemical, and/or mechanical properties (e.g., composition, strength, ductility, and so on) of the component formed using AMS  100 , as discussed herein. 
       FIGS. 7 and 8  show additional non-limiting example of AMS  100 . More specifically,  FIGS. 7 and 8  depict schematic views of other examples of AMS  100  including the implementation of supplemental build material  150  therein. It is understood that similarly numbered and/or named components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     The non-limiting example of AMS  100  shown in  FIG. 7  may include distinct features and/or configurations in comparison to AMS  100  shown and discussed herein with respect to  FIG. 5 . For example, while supplemental material supply  148  may still be in fluid communication with second section  110  of material conduit  106 , it may not be via T-connection  112 . Rather, supplemental material conduit  152  may be in direct fluid communication with second section  110  of material conduit  106  via a distinct T-connection  158 . Distinct T-connection  158  may be positioned and/or in communication with material conduit  106  downstream of T-connection  112 , and/or directly adjacent nozzle  118 . In the non-limiting example, and based on the position of supplemental material conduit  152 , supplemental build material  150  may be mixed with build material  104  immediately prior to flowing to and subsequently being dispersed by nozzle  118 . 
     In another non-limiting example (not shown), Distinct T-connection  158  may be positioned and/or in communication with material conduit  106  upstream of T-connection  112 , and/or opposite nozzle  118 . In the non-limiting example, supplemental material conduit  152  may be in direct fluid communication with first section  108  or second section  110  of material conduit  106 —dependent upon how close distinct T-connection  158  is positioned on material conduit  106  to material supply  102 . Where supplemental material conduit  152  is in fluid communication with first section  108  of material conduit  106 , supplemental build material  150  may be provided with gaseous/vapor state build material  104  in first section  108 . However, where supplemental build material  150  is formed from a material having a higher melting point (e.g., ceramic), supplemental build material  150  may not undergo a phase change even when provided to first section  108  of material conduit  106 . 
       FIG. 8  shows another non-limiting example of AMS  100 . In the non-limiting example, AMS  100  may include supplemental material supply  148 , supplemental build material  150 , and supplemental material conduit  152  as similarly described herein. However, and distinct from AMS  100  shown and discussed herein with respect to  FIGS. 5 and 7 , supplemental material conduit  152  may not be in fluid communication with material conduit  106  of AMS  100 . Rather, supplemental material conduit  152  may be in fluid communication with a distinct or supplemental nozzle  160 . That is, AMS  100  may include supplemental nozzle  160  in direct fluid communication with supplemental material conduit  152 . Similar to nozzle  118 , at least a portion of supplemental nozzle  160  may be positioned within cavity  122  of build chamber  120 . Additionally, supplemental nozzle  160  may be positioned adjacent nozzle  118  within build chamber  120 . In the non-limiting example, supplemental nozzle  160  may disperse, distribute, and/or dispense supplemental build material  150  directly into final build material  140  dispensed by nozzle  118 . That is, and based on the position of supplemental nozzle  160  within AMS  100 , supplemental build material  150  may be mixed, combined, and/or added to final build material  140  within cavity  122  of build chamber  120 , and ultimately included in the formation of the component using AMS  100 . As similarly discussed herein, supplemental build material  150  dispensed by supplemental nozzle  160  may be mixed, added, and/or interact with final build material  140  during the build process to alter the physical and/or mechanical properties of the component build using AMS  100 , as discussed herein. Also similar to nozzle  118 , supplemental nozzle  160  may be formed from any suitable material that may allow supplemental build material  150  to flow therethrough, and may also be configured to move, traverse, and/or rotate in each of a first direction (D 1 ), a second direction (D 1 ), and third direction (D 3 ) (e.g., in-and-out of the page). 
       FIG. 9  shows an enlarged cross-sectional view of a component  200  made using AMS  100  shown and discussed herein with respect to  FIG. 1, 4, 5, 7 , or  8 . In the non-limiting example, component  200  may include a single, unitary body that may be formed via the build material (e.g., final build material  140 ) deposition processes discussed herein. As shown in  FIG. 9 , component  200  may include various sections  202 ,  204 ,  206 ,  210 . The sections  202 ,  204 ,  206 ,  210  depicted in  FIG. 9  and discussed herein are all integrally formed and/or make up unitary body for component  200 . As such, it is understood that the distinctions in sections (e.g., identifying lines and borders) are provided for illustration. 
     Each section  202 ,  204 ,  206 ,  210  may include similar and/or distinct features and/or properties. That is, each of the plurality of sections  202 ,  204 ,  206 ,  210  may be formed by depositing final build material  140 ,  154  on substrate  124  of AMS  100  (see,  FIG. 1 ). In a non-limiting example, each section  202 ,  204 ,  206 ,  210  may be formed from using the same build material. Alternatively in another non-limiting example, each section  202 ,  204 ,  206 ,  210  may be formed with the same foundational build material (e.g., final build material  140 ), but each layer may include additional material. For example, first section  202  may be formed solely with build material  104 /final build material  140  (e.g., free of compound material  146 ). Distinct from first section  202 , second section  204  may also include compound material  146 . Fourth section  210  may include final build material  140 , compound material  146 , and supplemental build material  150 . 
     In another non-limiting example, each section  202 ,  204 ,  206 ,  210  may include a distinct porosity. That is, first section  202  may include a first porosity (P 1 ), second section  204  may include a second porosity (P 2 ), and fourth section  210  may include a third porosity (P 3 ), where each porosity (P 1 , P 2 , P 3 ) is distinct from one another. Additionally as shown in  FIG. 9 , third section  206  may include two different porosities (P 1 , P 2 ). That is, the majority of third section  206  may include a first porosity (P 1 ) similar to first section  202 , but may include a desired feature  208  formed therein that may include a second porosity (P 2 ) similar to that of second section  204 . Based on the formation and/or build process discussed herein, it is understood that AMS  100  may build integrally formed component  200  with the distinct sections  202 ,  204 ,  206 ,  210  including features  208  by simply changing operational conditions, characteristics, and/or parameters (e.g., rate of cooling, temperature of build material  104  in second section  110  of material conduit  106 , introduction of coolant material  128 , etc.) during the build process. 
       FIGS. 10A and 10B  depicts example processes for building a component using an additive manufacturing system. In some cases, an additive manufacturing system may be used to form the component, as discussed above with respect to  FIGS. 1, 4, 5, 7, and 8 . 
     In process P 1  a material conduit of an AMS may be preheated. More specifically, a first section of a material conduit may be preheated to a first predetermined temperature, and a second section of the material conduit may be preheated to a second predetermined temperature, where the second predetermined temperature is lower than the first predetermined temperature. In the non-limiting example, the first predetermined temperature may be associated with a temperature that may convert and/or maintain a build material at a vapor or gaseous state. Additionally, the second predetermined temperature may be associated with a temperature that may convert and/or maintain the build material from the vapor or gaseous stage to a liquid state and/or a solid-state. The second predetermined temperature may also be above a melting temperature for the build material. In another non-limiting example where at least a portion of the build material remains in a liquid state during the build process, the first predetermined temperature and the second predetermined temperature may be above a melting temperature for the build material, where the first predetermined temperature is higher than the second predetermined temperature, but below a temperature that may convert and/or maintain a build material at a vapor or gaseous state. 
     In process P 2  the build material may flow through the first section of the material conduit. In non-limiting examples, the build material flowing through the first section of the material conduit may be converted to and/or may be maintained at a gaseous or vapor state. In another non-limiting example, he build material flowing through the first section of the material conduit may remain in a liquid state. 
     In process P 3  the build material may flow through the second section of the material conduit. More specifically, the build material may flow from the first section of the material conduit to the second section of the material conduit. 
     In process P 4 , shown in phantom as optional, the build material flowing through the second section of the material conduit may be converted to and/or may be maintained at a liquid state and/or solid state. In a non-limiting example, the build material may be converted in the second section of the material conduit from a gaseous or vapor state to a liquid state. In another non-limiting example, the build material flowing through the second section of the material conduit may be converted to and/or may be maintained at a combination of a liquid state and a solid state, where the converted material includes a ratio or amount of liquid and solid-state material. In a further non-limiting example, at least a first portion of the build material flowing through the second section of the material conduit may be converted to and/or may be maintained in a solid state, while a second portion may remain in the liquid state. That is, where the build material is in a liquid state in the first section of the material conduit, only a portion of the liquid state material flowing from the first section to the second section may be converted and/or remain in a solid-state—the remainder may stay in liquid form. Converting the build material from the vapor or gaseous state to a liquid and/or solid state may also include cooling the build material flowing through the second section of the material conduit to a predetermined temperature prior to flowing the build material to a nozzle for dispersion. The predetermined may be a temperature above the melting point of the build material. Process P 4  may not be performed in the instance where the entirety of the build material is to remain in the liquid state as it flows from the first section of the material conduit to the second section. 
     In process P 5 , the temperature of the build material may be determined in the material conduit. More specifically, a first temperature of the build material flowing through the first section of the material conduit may be determined, and a second temperature of the build material flowing through the second section of the material conduit may be determined. As a result of converting/cooling the build material in the second section, the determined second temperature of the build material may be lower than the determined first temperature. 
     In process P 6 , a cooling rate for build material may be calculated. More specifically, and based upon the determined first and second temperature of the build material (e.g., process P 5 ), a cooling rate for the build material flowing through the material conduit may be calculated. The cooling rate may include the temperature and time difference in cooling the build material from the first determined temperature in the first section to the second (lower) temperature in the second section. 
     In process P 7 , it may be determined if the calculated cooling rate exceeds a predetermined cooling rate. The predetermined cooling rate may be associated with desired characteristics of the build material that forms the component using AMS, and/or may relate to build characteristics and/or properties for the component built using the AMS. For example, the predetermined cooling rate may be associated with the size of the droplets/particles for the build material in the liquid and/or solid state flowing through the second section of the material conduit. The size of the droplets/particles in the liquid and/or solid state may further define the shape and size of the holes or openings formed in the component that is substantially porous. 
     In response to determining that the calculated cooling rate exceeds or is below (e.g., not equal to) the predetermined cooling rate, operational characteristics and/or parameters of the AMS forming the component may be adjusted. For example, in response to determining that the calculated cooling rate does exceed the predetermined cooling rate (e.g., “YES” at process P 7 ), the temperature of the build material may be increased in the second section of the material conduit in process P 8 . That is, the AMS may increase the temperature of the build material flowing through the second section of the material conduit in response to determining that the calculated cooling rate is higher than or exceeds a predetermined cooling rate for the build material. In a non-limiting example, the temperature of the build material flowing through the second section may be increased by increasing the second temperature of the second section of the material conduit. Additionally, increasing the temperature of the build material flowing through the second section of the material conduit may further include reducing the calculated cooling rate for the build material, and/or increasing the droplet/particle size of the build material flowing through the second section of the material conduit in the liquid state and/or solid state. Once the temperature of the build material in the second section of the material conduit is increased, the temperature of the build material may be determined again (e.g., process P 5 ). 
     In response to determining that the calculated cooling rate does not exceed (and is lower than) the predetermined cooling rate (e.g., “NO (lower)” at process P 7 ), the temperature of the build material may be decreased in the second section of the material conduit in process P 9 . That is, the AMS may decrease the temperature of the build material flowing through the second section of the material conduit in response to determining that the calculated cooling rate is lower than a predetermined cooling rate for the build material. In a non-limiting example, the temperature of the build material flowing through the second section may be decreased by decreasing the second temperature of the second section of the material conduit. Additionally, decreasing the temperature of the build material flowing through the second section of the material conduit may further include increasing the calculated cooling rate for the build material, and/or decreasing the droplet/particle size of the build material flowing through the second section of the material conduit in the liquid state and/or solid state. Further, the temperature of the build material flowing through the second section of the material conduit may be decrease by reducing an amount of heat supplied to the second section of the material conduit, and/or increase an amount of coolant material supplied to the second section of the material conduit. Once the temperature of the build material in the second section of the material conduit is decreased, the temperature of the build material may be determined again (e.g., process P 5 ). 
     In response to determining that the calculated cooling rate does not exceed (and is equal to) the predetermined cooling rate (e.g., “NO (equal)” at process P 7 ), the build material may be dispersed onto a substrate in process P 10  to form a component. More specifically, the build material including a calculated cooling rate that is equal to the predetermined cooling rate may be dispersed, dispensed, and/or distributed by a nozzle of the AMS to form the component on a substrate of the AMS. Dispersing the build material from the nozzle onto a substrate to form the component may also include adjusting a position of the nozzle during the dispersing to form a feature and/or distinct portions of the component using the build material. 
     The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions. 
     The foregoing drawings show some of the processing associated according to several embodiments of this disclosure. In this regard, each drawing or block within a flow diagram of the drawings represents a process associated with embodiments of the method described. It should also be noted that in some alternative implementations, the acts noted in the drawings or blocks may occur out of the order noted in the figure or, for example, may in fact be executed substantially concurrently or in the reverse order, depending upon the act involved. Also, one of ordinary skill in the art will recognize that additional blocks that describe the processing may be added. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. 
     Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. “Approximately” as applied to a particular value of a range applies to both values, and unless otherwise dependent on the precision of the instrument measuring the value, may indicate +/−10% of the stated value(s). “Fluid” discussed herein, unless identified to a specific material state or phase, may refer to liquid or gas. 
     The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.