Additive Manufacturing for Microwave Vacuum Electron Device Cost Reduction

The Department of the Navy has a need for the development of an additive manufacturing (AM) process for key vacuum electronic device components to meet on-demand, flexible, and affordable manufacturing requirements. The goal of this Phase II effort is to develop and validate Electron Beam Melting (EBM) additive manufacturing (AM) technology for the production of vacuum electronic devices meeting the specific systems needs (including cost reduction) of the DON. In particular this project aims to deliver an AM process for direct production of VEDs with a 70% cost reduction. In the Phase II effort, a full coupled cavity travelling wave tube (TWT) structure attached to two ceramic isolators on both ends will be built and demonstrated for RF performance (cold test), high voltage isolation, and ultra-high vacuum holding capability. This approach will also demonstrate the capability of single-step production of complex systems confirming clean and full density material conditions, mechanical tolerance, and surface roughness requirements. In addition, this development will also open opportunities for improved thermal management designs for RF circuit cavities as well as for more advanced RF circuit cavity designs.