Fabrication of Window Saddles for NIF Cryogenic Hohlraums

A planar diagnostic viewing port attached to the cylindrical wall of the NIF cryogenic hohlraum requires a saddle-like transition piece. While the basic design of this window saddle is straightforward, its fabrication is not, given the scale and precision of the component. We solved the problem through the use of a two segment copper mandrel to electroform the gold window saddle. The segments were micro-machined using a combination of single-point diamond turning and single point diamond milling. These processes as well as the electroplating conditions, final machining and mandrel removal are described in this paper.