## Materials and Methods
### Magnetic Property Measurement  
Samples were cut from EBM/PBF Run #5 in the transverse direction as shown in Figure 2 to sample the volume of build which was not affected by the build plate proximity. The remainder of the material was sectioned and polished for inspection. Samples were made in the transverse direction at the top surface above the cylinders, mid cylinder, and below the cylinder; further, a sample was prepared containing a region of interest (ROI) as identified in Figure 2, and includes a test cylinder left behind during the extraction process. This region includes material which was slated for removal but was damaged in the electrical discharge machining (EDM) process. (The dark regions in Figure 16 forming a \"fish-hook\" shape is where the EDM wire had removed material before the wire broke. This allowed for investigation of the as-built microstructure within one of the cylinders. This particular section was subjected to a SOQ in order to analyze the post-SOQ microstructure.) \begin{table}
\begin{tabular}{c c c c c c c} \hline \hline
**Parameter** & **Run \#1** & **Run \#2** & **Run \#3** & **Run \#4** & **Run \#5** & **Run \#5 Pass 2** \\ \hline Melt: Power Analysis (\({}^{\circ}\)C) & 850 & 1000 & 1200 & 1300 & 1300 & 1300 \\ Melt: Beam Speed (mm/s) & 200 & 800 & 600 & 600 & 700 & 200 \\ Melt: Current (mA) & 3.5 & 7 & 15 & 9 & 9 & 13 \\ Melt: Max Current (mA) & 3.5 & 7 & 15 & 9 & 9 & 14 \\ Melt: Focus Offset (mA) & 3 & 5 & 7 & 7 & 7 & 25 \\ Melt: Speed Function & 10 & 10 & 30 & 25 & 20 & 6 \\ Melt: Line Offset (mm) & 0.1 & 0.2 & 0.2 & 0.2 & 0.3 & 0.3 \\ \hline \hline \end{tabular}
\end{table} 
Table 4: Melting parameters used in each EBM/PBF run. \begin{table}
\begin{tabular}{c c c c c c} \hline \hline
**Parameter** & **Run \#1** & **Run \#2** & **Run \#3** & **Run \#4** & **Run \#5** \\ \hline Preheat: Square (mm) & 60 & 60 & 90 & 90 & 90 \\ Preheat 1: Line Order & 15 & 15 & 10 & 10 & 10 \\ Preheat 1: Line Offset (mm) & 1.5 & 1.5 & 0.6 & 0.6 & 0.6 \\ Preheat 1: Hatch Depth (mm) & 0.1 & 0.1 & 0.1 & 0.1 & 0.1 \\ Preheat 1: Max Beam Current (mA) & 24 & 10 & 16 & 17 & 18 \\ Preheat 1: Min Beam Current (mA) & 0.1 & 8 & 5 & 5 & 5 \\ Preheat 1: Beam Speed (m/s) & 8 & 5 & 8 & 7.5 & 7.5 \\ Preheat 1: Number of Repetitions & 40 & 40 & 15 & 16 & 19 \\ Preheat 1: Max Number of Repetitions & 40 & 40 & 20 & 22 & 21 \\ Preheat 1: Average Current (mA) & 2 & 2 & 10 & 14 & 14 \\ \hline \hline \end{tabular}
\end{table} 
Table 3: Preheating parameters used in each EBM/PBF run. The AM samples from DED and EBM/PBF run #5 were machined to \(\sim\)8 mm tall by 3 mm diameter cylinders for magnetic property measurements. When possible, multiple cylinders were extracted from along the length of the DED samples. Samples were visually examined for quality (i.e., not chipped from machining). Cylinders of the highest integrity and dimensional quality were selected for the MA and FHT to measure magnetic properties. In preparation for MA, the cylinders were solutionized at 1210 \({}^{\circ}\)C or 1215 \({}^{\circ}\)C for 30 min and oil quenched (SOQ) in order to obtain a partially ordered B2 single phase (Im\(\overline{3}\)m crystal structure) uniformly throughout the cylinder. Selected material pieces left over from the cylinder machining process were also subjected to the same SOQ process to verify any microstructural changes occurring. SOQ is a common and necessary practice in alnico magnet fabrication in order to \"reset\" the nanostructure to a single phase (B2) before developing the \(\alpha_{1}\) + \(\alpha_{2}\) nanostructure in a spinodal transformation on cooling or heating [3; 11; 26; 27; 28]. The cylinders were cleaned with ethanol and vacuum sealed in a quartz tube (45 torr). To assure a clean and dry environment within the quartz tube, a vacuum of 60 torr or less was reached, then back-filled with argon (repeated three times).