Systems and methods for controlling thermal conduction in x-ray tube cathodes

A cathode cup assembly for an x-ray tube, comprising:

• one or more emitters;
• an emitter weld pad;
• a ceramic plate;
• a cup plate that includes a cup section, the ceramic plate positioned between the emitter weld pad and the cup plate, and where the cup section extends through an orifice of the ceramic plate;
• and
• wherein at least a portion of the cup section and at least a portion of the emitter weld pad each include an internal porous section for thermal management of the cathode cup assembly.

A method for producing a component of a cathode assembly of an x-ray tube, comprising:

• obtaining a three-dimensional (3D) model of the component including an internal porous section or sections of the component;
• obtaining a plurality of slices including a first slice of the three-dimensional (3D) model of the component;
• printing the first slice of the three-dimensional (3D) model onto a base build plate;
• sequentially printing the plurality of slices on top of the first slice;
• and
• drying and/or curing the component of the cathode assembly.