Method for forming components using additive manufacturing and re-melt

A method of manufacturing a component, comprising:

• additively manufacturing a crucible for casting of the component, wherein the crucible includes a core and a shell;
• adding metal material in powder form to the crucible, wherein the metal material is a superalloy;
• solidifying the metal material within the crucible to form a metal directionally solidified microstructure within the component;
• and
• removing the crucible to reveal the component;
• wherein the method further comprises:
• manufacturing the core and the shell of a material that is different from the metal material;
• additively manufacturing internal cooling passages of the component using a ceramic material;
• additively manufacturing locations for microcircuits of the component using a refractory metal material, wherein the microcircuits are smaller than and located outboard of the internal cooling passages;
• filling the internal cooling passages with a ceramic slurry to form the core;
• and
• curing the core.