Wireless component and methods of fabricating a coated component using multiple types of fillers

A component comprising:

• a substrate having at least one hollow interior space and one or more grooves formed in an outer surface, wherein each of the one or more grooves has a continuous geometry defined by a base and a plurality of sidewalls, wherein each sidewall extends continuously from the base to an uppermost surface of the substrate and wherein each of the one or more grooves extends at least partially along the outer surface of the substrate;
• one or more access holes formed through the base of a respective one of the one or more grooves to connect the respective groove in fluid communication with the respective hollow interior space;
• a permanent filler comprised of a structural material, the permanent filler disposed within and extending across a top of each of the one or more grooves and in contact with only the plurality of sidewalls of the one or more grooves and wherein the permanent filler is not in contact with the base of each of the one or more grooves and the outer surface of the substrate;
• a coating disposed over at least a portion of the substrate and over the permanent filler disposed within the groove and extending across the top of each of the one or more grooves, wherein the one or more grooves and the permanent filler or coating together define one or more channels for cooling the component.

A component comprising:

• one or more grooves in an outer surface of a substrate having at least one hollow interior space, wherein each of the one or more grooves has a continuous geometry defined by a base and a plurality of sidewalls, wherein each sidewall extends continuously from the base to an uppermost surface of the substrate and wherein each of the one or more grooves extends at least partially along the outer surface of the substrate;
• a filler disposed within the one or more grooves, such that a gap is formed between the filler and the base of the respective groove, wherein the filler is comprised of a structural material and in contact with only the plurality of sidewalls of the one or more grooves and wherein the permanent filler is not in contact with the outer surface of the substrate;
• one or more access holes formed through the base of a respective one of the one or more grooves to connect the respective groove in fluid communication with the respective hollow interior space;
• and
• a coating disposed over at least a portion of the substrate and over the filler disposed within the groove and extending across the top of each of the one or more grooves, wherein the one or more grooves and the permanent filler or coating together define one or more channels for cooling the component.