Alternative Manufacturing Meethod for Heaters for Electron Guns by Ink-jet Printing

We will develop and demonstrate the key elements in a novel alternative method of fabrication of the heaters for dispenser types cathodes. The current methods depend on a wire that may soon not be manufactured anymore. The proposed method, radically alters the manufacturing approach introducing a complete data driven technology that will produce consistent heater elements in a wide range of configuration and will allow quick turnaround for design changes. The technology developed in Phase I will allow the heater designers to go beyond the limitations of current methods in terms of shape and distribution of the heater element within the heater. In Phase I, we will develop new formulation of solutions containing tungsten particles and an associated printhead that can ink-jet dispense the solutions into the desired pattern. The development also includes the process that will convert the printed particles into the conductive traces acting as heating elements. The feasibility of the fabricated heaters will be demonstrated following the stringent battery of tests that are part of the QC process of the current heaters. The long term opportunity is the implementation of the developed technology, materials, equipment and processes into production for a flexible design of low cost and high reliability heating elements.