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This work presents a comprehensive study of manufacturing and assembly errors in a 750 MHz Interdigital H-mode Drift Tube Linac (IH-DTL) cavity designed for a compact and efficient ion beam inyector1. Operating at such a high RF frequency significantly reduces the cavity dimensions, but it also increases the sensitivity to geometric imperfections, posing a substantial technological challenge for manufacturing and assembly. In this study, realistic machining deviations — including drift-tube misalignments, stem eccentricity, profile machining errors, and end-cell distortions — are introduced within typical fabrication tolerances. Three-dimensional electromagnetic simulations quantify the resulting perturbations in resonant frequency, accelerating fields, and power efficiency. First, the most critical geometric perturbations were are identified by means of a single cavity cell model. Following, those errors were implemented in a complete cavity, applied to all cells. The resulting field maps were subsequently imported into multi-particle beam dynamics simulations to evaluate their impact on beam quality, transmission, and emittance growth. The study provides experimentally tolerance thresholds and offers guidance for cavity fabrication, quality control, and commissioning strategies for IH-DTL structures.
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