X-Band RF Spiral Load Optimization for Additive Manufacturing Mass Production

The CLIC main linac uses X-band traveling-wave normal conducting accelerating structures. The RF power not used for beam acceleration nor dissipated in the resistive wall is absorbed in two high power RF loads that should be as compact as possible to minimize the total footprint of the machine. In recent years, CERN has designed, fabricated and successfully tested several loads produced by additive manufacturing. With the current design, only one load can be produced in the 3D printing machine at a time. The aim of this study is optimizing the internal cross-section of loads in order to create a stackable design to increase the number of produced parts per manufacturing cycle and thus decrease the unit price. This paper presents the new design with an optimization of the internal vacuum part of the so-called RF spiral load. In this case, RF and mechanical designs were carried out in parallel. The new cross section has showed good RF reflection reaching less than -30 dB in simulations. The final load is now ready to be manufactured and high-power tested. This new load will not only provide cost saving but also faster manufacturing for mass production.