Methods of fabricating a coated component using multiple types of fillers

A method of fabricating a component, the method comprising:

• forming one or more grooves in an outer surface of a substrate, wherein each of the one or more grooves has a base that is wider than a top thereof and a plurality of sidewalls and extends at least partially along the outer surface of the substrate, such that each of the one or more grooves comprises a re-entrant shaped groove;
• depositing a sacrificial filler within the one or more grooves;
• depositing a second filler on an uppermost surface of the sacrificial filler, wherein the second filler is comprised of a structural material and in contact with only the uppermost surface of the sacrificial filler and the plurality of sidewalls of the one or more re-entrant shaped grooves and wherein the second filler is not in contact with the base of each of the one or more re-entrant shaped grooves;
• disposing a coating over at least a portion of the outer surface of the substrate and over the second filler;
• and
• removing the sacrificial filler and removing a portion of the second filler from the one or more re-entrant shaped grooves, wherein at least a portion of the second filler remains within the one or more re-entrant shaped grooves, such that the one or more grooves including the portion of the second filler remaining in the one or more re-entrant shaped grooves and the coating together define one or more re-entrant shaped channels for cooling the component.