Abstract: The present invention provides an additive manufacturing (AM) processing and design approach using removable “heat sink” artifacts to tailor the mechanical properties of traditionally low strength and low ductility alloys. As an example, the design approach was demonstrated with the Fe-50 at. % Co alloy, as a model material of interest for electromagnetic applications. AM-processed components exhibited unprecedented performance, with a 300% increase in strength and an order-of-magnitude improvement in ductility relative to conventional wrought material. The method enables the design and processing of high-performance, next-generation components and alloys.