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Additive manufacturing (AM) has become a powerful tool for rapid prototyping and manufacturing of complex geometries. A 433 MHz IH-DTL cavity has been constructed to act as a proof of concept for direct additive manufacturing of linear accelerator components. The original design of the cooling for the drift tube showed insufficient heat dissipation, leading to potential thermal deformation during operation. To address this issue, a detailed optimization of the cooling system was performed, incorporating advanced thermal simulations and iterative design improvements.
Additionally, the drift tube geometries were refined to enhance mechanical stability and thermal efficiency while maintaining the required electromagnetic properties. The results demonstrate that additive manufacturing enables significant design flexibility, allowing for innovative solutions to thermal management challenges in high-frequency linear accelerator components.