Additive manufacturing systems, additive manufactured components including portions having distinct porosities, and methods of forming same

An additive manufacturing system, comprising:

• at least one irradiation device emitting an irradiation beam to melt a raw material to form a component including:
• a first portion having a first porosity;
• and
• a second portion formed adjacent the first portion, the second portion having a second porosity greater than the first porosity;
• and
• at least one computing device operably connected to the at least one irradiation device, the at least one computing device configured to form the component using the at least one irradiation device by performing processes including:
• moving the irradiation beam of the at least one irradiation device in a first exposure pattern of a plurality of scan vectors to melt the raw material of the first portion of the component, the first exposure pattern defining the first porosity of the first portion;
• and
• moving the irradiation beam of the at least one irradiation device in a second exposure pattern of a plurality of scan vectors to melt the raw material of the second portion of the component, the second exposure pattern, distinct from the first exposure pattern of the first portion, defining the second porosity of the second portion.

A method of forming a component using at least one irradiation device of an additive manufacturing system, the method comprising:

• moving an irradiation beam of the at least one irradiation device in a first exposure pattern of a plurality of scan vectors to melt a raw material to form a first portion of the component, the first exposure pattern defining a first porosity of the first portion;
• and
• moving the irradiation beam of the at least one irradiation device in a second exposure pattern of a plurality of scan vectors to melt the raw material of a second portion of the component, distinct from the first portion,
• wherein the second exposure pattern is distinct from the first exposure pattern of the first portion, and defines a second porosity of the second portion that is greater than the first porosity of the first portion.