described above it is very difficult to remove the dense sintered powder after completion of the build parts with internal features such as passages within a housing have to be specially processed in order to remove dense powder powder removal is a step that for complex parts will add cost to an additively built part embodiments disclosed herein may provide a more efficient or economical solution to removing the dense power the methods disclosed herein may expedite and minimize the amount of time required for powder removal from pbf including ebm and laser pbf manufactured parts in one embodiment a magnetorheological mr fluid or a ferrofluids is caused to infiltrate sintered or semi sintered residual powder within for example a passage or other portion of an am component a vacuum may pull the fluid through the passage in one embodiment or another external force may be used to the push the fluid push the fluid through the powder an external magnetic field may then be applied to the passageway or component at large the magnetic field may cause particles e g ferromagnetic or ferrimagnetic particles in the fluid to become aligned which in turn causes an application of a shear stress to the sintered or semi sintered particles the applied shear stress and increase in viscosity should be enough to mechanically fracture the particles thereby allowing to fall or flow out of a channel or passageway in some instance the process may need to be repeated several times depending upon its ability to infiltrate the sintered or semi sintered powder material for example an alternating magnetic field may be.