Mechanical design and engineering of the 3.9 GHZ, 3rd harmonic SRF system at Fermilab

The mechanical development of the 3.9 GHz, 3rd Harmonic SRF System is summarized to include: the development of a full scale copper prototype cavity structure; the design of the niobium 3 cell and niobium 9 cell structures; the design of the helium vessel and cryostat; the HOM coupler design; and a preliminary look at the main coupler design. The manufacturing processes for forming, rolling, and e-beam welding the HOM coupler, cavity cells, and end tubes are also described. Due to the exotic materials and manufacturing processes used in this type of device, a cost estimate for the material and fabrication is provided. The 3rd harmonic design is organized via a web-based data management approach