A method of manufacturing a component susceptible to multiple failure modes, comprising: generating a stereolithography file including a geometry of the component; dividing the geometry of the stereolithography file into a plurality of layers , each of the layers including a first portion and a second portion of the component; and applying energy from an energy source to a powdered material such that the powdered material fuses to form the first portion and the second portion of each of the plurality of layers, wherein applying energy from the energy source to form the first portion of the plurality of layers includes operating the energy source with a first set of parameters and applying energy from the energy source to form the second portion of the plurality of layers includes operating the energy source with a second set of parameters, the second set of parameters being different from the first set of parameters; wherein operating the energy source with a first set of parameters forms the first portion of the component with a first microstructure and operating the energy source with a second set of parameters forms the second portion of the component with a second microstructure; characterized in that operating the energy source with a first set of parameters forms the first portion of the component with a first surface roughness and first material strength and operating the energy source with a second set of parameters forms the second portion of the component with a second surface roughness and second material strength; and wherein the component is a heat exchanger and the first portion of each of the plurality of layers includes at least one manifold of the heat exchanger and the second portion of each of the plurality of layers includes a core of the heat exchanger. generating a stereolithography file including a geometry of the component; dividing the geometry of the stereolithography file into a plurality of layers , each of the layers including a first portion and a second portion of the component; and applying energy from an energy source to a powdered material such that the powdered material fuses to form the first portion and the second portion of each of the plurality of layers, wherein applying energy from the energy source to form the first portion of the plurality of layers includes operating the energy source with a first set of parameters and applying energy from the energy source to form the second portion of the plurality of layers includes operating the energy source with a second set of parameters, the second set of parameters being different from the first set of parameters; wherein operating the energy source with a first set of parameters forms the first portion of the component with a first microstructure and operating the energy source with a second set of parameters forms the second portion of the component with a second microstructure; characterized in that operating the energy source with a first set of parameters forms the first portion of the component with a first surface roughness and first material strength and operating the energy source with a second set of parameters forms the second portion of the component with a second surface roughness and second material strength; and wherein the component is a heat exchanger and the first portion of each of the plurality of layers includes at least one manifold of the heat exchanger and the second portion of each of the plurality of layers includes a core of the heat exchanger. <EOS>