Development and manufacture of the coil end spacers of the LHC pre-series dipoles

The coil end spacers play an important role in the performance of superconducting coils, as their shape and location determine the mechanical stability of the conductors in the coil ends (and hence the overall coil training performance) and the local field quality. The dipole end spacers are often of a size and a geometry difficult to be industrially series manufactured and measured. Efficiency of the production and related costs are a key issue to achieve the required production rate of the LHC main dipoles at an affordable price. For the latter reasons, a design approach integrating state-of-the-art CAD/CAM optimization techniques allowing to considerably decrease design and machining time was implemented. This paper gives examples and describes the design criteria, the computation methods, the machining and measuring procedures adopted to carry out the pre-series production.