Patent Publication Number: US-11659645-B2

Title: Monolithic x-ray source housing

Description:
CLAIM OF PRIORITY 
     This application claims priority to U.S. Provisional Patent Application No. 63/195,300, filed on Jun. 1, 2021, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present application is related to x-ray sources. 
     BACKGROUND 
     An x-ray source can include an x-ray tube electrically coupled to a high voltage power supply. The power supply can provide a large bias voltage for the x-ray tube. The large voltage, between a cathode and an anode of the x-ray tube, and sometimes a heated filament, can cause electrons to emit from the cathode to the anode. The anode can include a target material. The target material can generate x-rays in response to impinging electrons from the cathode. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS (DRAWINGS MIGHT NOT BE DRAWN TO SCALE) 
         FIG.  1    is a perspective-view of a monolithic housing  10  for an x-ray source. The monolithic housing  10  can include a power supply casing  11  and an x-ray tube casing  12 . The power supply casing  11  can be shaped to wrap at least partially around a power supply  31  and the x-ray tube casing  12  can be shaped to wrap at least partially around an x-ray tube  32  (see  FIGS.  3 - 4   ). 
         FIG.  2    is a perspective-view of the monolithic housing  10  of  FIG.  1   , illustrated at a different angle. 
         FIG.  3    is a perspective-view of an x-ray source  30  with a power supply  31  and an x-ray tube  32 . 
         FIG.  4    is a perspective-view of an x-ray source  40  with the power supply  31  inside of the power supply casing  11  and the x-ray tube  32  inside of the x-ray tube casing  12 . 
         FIG.  5    is a side-view of a monolithic housing  50  with a conical frustum shaped x-ray tube casing  12 . The x-ray tube casing  12  includes a frustum angle  51 , which is an angle of narrowing of an outer surface of the conical frustum shape. 
         FIG.  6    is an end-view of a monolithic housing  60  with a base-side inner angle  61 , between the base  11   b  and the sides  11   s , that is greater than 90°. 
         FIG.  7    is a top-view of a monolithic housing  70  with an end-side inner angle  71 , between the end-wall  11   e  and each of the two sides  11   s , that is greater than 90°. 
         FIG.  8    is a side-view of a monolithic housing  80  with an array of ribs  81  on the power supply casing  11  and an array of ribs  82  encircling the x-ray tube casing  12 . The array of ribs  82 , which encircle the x-ray tube casing  12 , can be perpendicular to a longitudinal axis  83  of the x-ray tube  32 . 
         FIG.  9    is a side-view of a monolithic housing  90  with an array of ribs  81  on the power supply casing  11  and an array of ribs  82  encircling the x-ray tube casing  12 . The array of ribs  82 , which encircle the x-ray tube casing  12 , can be parallel to the longitudinal axis  83  of the x-ray tube  32 . 
         FIGS.  10 - 11    are cross-sectional side-views of a step  100  of a method of making a housing  141  (see  FIGS.  14 - 17   ) for an x-ray source  40  (see  FIG.  24   ). Step  100  can include inserting an upper-mold  105  into a hollow-region  101  of a lower-mold  103 , forming a power supply casing cavity  111  between the upper-mold  105  and the lower-mold  103 . 
         FIG.  12    is a cross-sectional side-view of a step  120  of a method of making a housing  141  for an x-ray source  40 , which can follow step  100 . Step  120  can include inserting a slider-pin  107  from the upper-mold  105  into a hole  102  at a sidewall of the hollow-region  101 , forming an x-ray tube casing cavity  122  between the slider-pin  107  and walls of the hole  102 . 
         FIG.  13    is a cross-sectional side-view of a step  130  of a method of making a housing  141  for an x-ray source  40 , which can follow step  120 . Step  130  can include injecting (e.g. through port  104 ) material  133  for the housing  10  into the power supply casing cavity  111  and into the x-ray tube casing cavity  122 . 
         FIG.  14    is a cross-sectional side-view of a step  140  of a method of making a housing  141  for an x-ray source  40 , which can follow step  130 . Step  140  can include allowing the material  133  to solidify into the housing  141 . The housing  10  can include a power supply casing  11  formed in the power supply casing cavity  111  and an x-ray tube casing  12  formed in the x-ray tube casing cavity  122 . 
         FIG.  15    is a cross-sectional side-view of a step  150  of a method of making a housing  141  for an x-ray source  40 , which can follow step  140 . Step  150  can include removing the slider-pin  107  from the hole  102  of the lower-mold  103 . 
         FIG.  16    is a cross-sectional side-view of a step  160  of a method of making a housing  141  for an x-ray source  40 , which can follow step  150 . Step  160  can include removing the upper-mold  105  from the hollow-region  101  of the lower-mold  103 . 
         FIG.  17    is a cross-sectional side-view of a step  170  of a method of making a housing  141  for an x-ray source  40 , which can follow step  160 . Step  170  can include removing the housing  141  from the hollow-region  101  and from the hole  102  of the lower-mold  103 . 
         FIGS.  18 - 19    are cross-sectional side-views of a step  180  of a method of making a housing  141  (see  FIGS.  21 - 23   ) for an x-ray source  40  (see  FIG.  24   ). Step  180  can include (a) inserting an upper-mold  105  into a hollow-region  101  of a lower-mold  103 , forming a power supply casing cavity  111  between the upper-mold  105  and the lower-mold  103 , and (b) inserting a pin  187  into a hole  102  at a sidewall of the hollow-region  101 , forming an x-ray tube casing cavity  122  between the pin  187  and walls of the hole  102 . 
         FIG.  20    is a cross-sectional side-view of a step  200  of a method of making a housing  141  for an x-ray source  40 , which can follow step  180 . Step  200  can include injecting (e.g. through port  104 ) material  133  for the housing  141  into the power supply casing cavity  111  and the x-ray tube casing cavity  122 . 
         FIG.  21    is a cross-sectional side-view of a step  210  of a method of making a housing  141  for an x-ray source  40 , which can follow step  200 . Step  210  can include allowing the material  133  to solidify into the housing  141 . The housing  141  can include a power supply casing  11  formed in the power supply casing cavity  111  and an x-ray tube casing  12  formed in the x-ray tube casing cavity  122 . 
         FIG.  22    is a cross-sectional side-view of a step  220  of a method of making a housing  10  for an x-ray source  40 , which can follow step  210 . Step  220  can include removing the upper-mold  105  from the hollow-region  101  of the lower-mold  103  and removing the pin  187  from the hole  102  of the lower-mold  103 . 
         FIG.  23    is a cross-sectional side-view of a step  230  of a method of making a housing  141  for an x-ray source  40 , which can follow step  220 . Step  230  can include removing the housing  141  from the lower-mold  103  and from the hole  102 . 
         FIG.  24    is a cross-sectional side-view of a step  240  of a method of making an x-ray source  40 , which can follow step  170  or step  230 . Step  240  can include inserting an x-ray tube  32  into the x-ray tube casing  12  and a power supply  31  into the power supply casing  11 . 
         FIG.  25    is a cross-sectional side-view of the lower-mold  103  with three sections  251 ,  252 , and  253 . This lower-mold  103  may be used in the methods described herein. 
     
    
    
     DEFINITIONS 
     The following definitions, including plurals of the same, apply throughout this patent application. 
     As used herein, the phrase “dispersed evenly” means dispersed exactly evenly; dispersed evenly within normal manufacturing tolerances; or dispersed almost exactly evenly, such that any deviation from dispersed exactly evenly would have negligible effect for ordinary use of the device. 
     As used herein, the terms “on”, “located on”, “located at”, and “located over” mean located directly on or located over with some other material between. The terms “located directly on”, “adjoin”, “adjoins”, and “adjoining” mean direct and immediate contact. 
     As used herein, the term “monolithic” means seamless and continuous. A monolithic structure herein has the same material composition throughout. For example, a concrete wall, formed at a single time in a single pouring step, followed by a single curing step, is monolithic. As another example, a housing, formed at a single time in a single injection-molding step, is monolithic. 
     As used herein, the term “integrally-joined” and “integral” mean that the integrally-joined devices are formed together at the same time and are continuous without seams or joints between them. 
     As used herein, the term “parallel” means exactly parallel; parallel within normal manufacturing tolerances; or almost exactly parallel, such that any deviation from exactly parallel would have negligible effect for ordinary use of the device. 
     As used herein, the term “perpendicular” means exactly perpendicular; perpendicular within normal manufacturing tolerances; or almost exactly perpendicular, such that any deviation from exactly perpendicular would have negligible effect for ordinary use of the device. 
     As used herein, the term “same material composition” means exactly the same, the same within normal manufacturing tolerances, or nearly the same, such that any deviation from exactly the same would have negligible effect for ordinary use of the device. 
     As used herein, the term “x-ray tube” is not limited to tubular/cylindrical shaped devices. The term “tube” is used because this is the standard term used for x-ray emitting devices. 
     As used herein, the term “Al” means aluminum, “Ca” means calcium, “Cu” means copper, “Fe” means iron, “Mg” means magnesium, “Mn” means manganese, “Ni” means nickel, “Si” means silicon, “Sr” means strontium, and “Zn” means zinc. 
     As used here, the term “adjacent” refers to the proximity of two structures or elements. Particularly, elements that are identified as being “adjacent” may be either abutting or connected. Such elements may also be near or close to each other without necessarily contacting each other. The exact degree of proximity may in some cases depend on the specific context. 
     DETAILED DESCRIPTION 
     An x-ray source  40  can include an x-ray tube  32  and a power supply  31  enclosed within a housing. Desirable characteristics of the housing include (a) light weight (for easier transport), (b) high electrical conductivity (to protect the user from electrical shock), (c) high thermal conductivity (to remove heat generated during use), (d) corrosion resistance, (e) high strength, and (t) high electromagnetic interference shielding (to shield power supply components from external noise, to shield other electronic components from power supply noise, or both). 
     The invention includes a monolithic housing for an x-ray source  40 . The monolithic housing can be part of an enclosure for the x-ray source  40 . The monolithic housing can wrap at least partially around the power supply  31  and the x-ray tube  32 . The invention also includes methods of making a monolithic housing for an x-ray source  40 . The monolithic housings described herein, and housings made by these methods, can satisfy the needs of the prior paragraph. Each example housing or method may satisfy one, some, or all of these needs. 
     A monolithic housing  10  for an x-ray source is illustrated in  FIGS.  1 - 2   . Characteristics of monolithic housing  10  can be combined with the characteristics of any other monolithic housing herein. 
     The monolithic housing  10  can include a power supply casing  11  and an x-ray tube casing  12 . The power supply casing  11  and the x-ray tube casing  12  can be integrally-joined together. Integrally joining the power supply casing  11  and the x-ray tube casing  12  can provide a material structure that is consistent, resulting in uniform properties throughout. Integrally joining the power supply casing  11  and the x-ray tube casing  12  can minimize gaps and seams. Such gaps or seams could otherwise result in undesirable electrical charge flow paths along an edge, or contact resistance across the gap or seam. Without such gaps and seams, heat flow can be uniform and less interrupted. 
     The power supply casing  11  can have a cavity for insertion of a power supply  31 . The x-ray tube casing  12  can have a hollow for insertion of an x-ray tube  32 . The cavity of the power supply casing  11  can adjoin the hollow of the x-ray tube casing  12  to allow insertion of an x-ray source with an x-ray tube  32  and a power supply  31 . The x-ray tube  32  can be rigidly-mounted to the power supply  31 . 
     An x-ray source  30 , with a power supply  31  electrically coupled to an x-ray tube  32 , is illustrated in  FIG.  3   . 
     An x-ray source  40 , with a power supply  31  inside of the power supply casing  11  and an x-ray tube  32  inside of the x-ray tube casing  12 , is illustrated in  FIG.  4   . The monolithic housing  10  can extend from a distal end  31   d  of the power supply  31 , farthest from the x-ray tube  32 , to the x-ray tube  32  so that the power supply  31  can be substantially covered and can resist electrical shock. The monolithic housing  10  can extend from a distal end  32   d  of the x-ray tube  32 , farthest from the power supply  31 , to the power supply  31  so that the x-ray tube  32  can be substantially covered and can resist electrical shock. 
     The x-ray tube  32  can be fully enclosed by the x-ray tube casing  12  and the power supply  31 , except for a small opening to allow emission of x-rays from the x-ray tube  32 , and can resist electrical shock. For example, ≥90%, ≥95%, or ≥98% of the x-ray tube  32  can be enclosed by the x-ray tube casing  12  and the power supply  31 . 
     The power supply casing  11  can wrap at least partially around the power supply  31 . The power supply casing  11  can include three sidewalls  11   w  and a base  11   b , and thus enclose the power supply  31  on four of six sides to resist electrical shock. 
     There can be interior rib(s)  13  on an inner-face of sidewalls  11   w  of the power supply casing  11  (see  FIGS.  1 - 2  and  7   ). The interior rib(s)  13  can be integral with the power supply casing  11 . The interior rib(s)  13  can increase strength of the sidewalls  11   w . A longitudinal dimension of the interior rib(s)  13  can be parallel to a longitudinal axis of the x-ray tube casing  12 , for easier removal from a mold during manufacturing. 
     The x-ray tube casing  12  can wrap at least partially around the x-ray tube  32 . The x-ray tube casing  12  can encircle the x-ray tube  32 . The x-ray tube casing  12  can encircle the x-ray tube  32  along a length of the x-ray tube from a cathode to an x-ray window of the x-ray tube  32 . The x-ray tube casing  12  can encircle the x-ray tube  32  along a major portion of a length of the x-ray tube  32 , such as for example along ≥50%, ≥75%, or ≥90% of the length. Even if the x-ray tube casing  12  does not encircle the x-ray tube  32  along a majority of its length, it can be helpful for the x-ray tube casing  12  to encircle electrical connections between the power supply  31  and the x-ray tube  32 . Thus, electrical shock can be resisted. 
     The monolithic housing  10  can be a single, integral unit formed by injection molding, as described below. Pellets having the following composition can be fed by a heated screw into the mold. 
     The monolithic housing  10  can include one or some of the following chemical elements. The material of the monolithic housing  10  can be selected to facilitate electrical shielding, electrical conductivity, and/or heat dissipation. Total weight percent of all chemical elements is 100%. 
     The monolithic housing  10  can include Mg. For example, a minimum weight percent Mg can be ≥50%, ≥75%, or ≥85%. Example maximum weight percent Mg can include ≤85%, ≤95%, or ≤99%. Mg can be dispersed evenly throughout the monolithic housing  10 . 
     The monolithic housing  10  can include Al. For example, a minimum weight percent Al can be ≥2%, ≥4%, or ≥8%. Example maximum weight percent Al include ≤8%, ≤14%, or ≤20%. Al can be dispersed evenly throughout the monolithic housing  10 . 
     The monolithic housing  10  can include Zn. For example, a minimum weight percent Zn can be ≥0.1%, ≥0.3%, or ≥0.7%. Example maximum weight percent Zn include ≤0.8%, ≤1.2%, or ≤3%. Zn can be dispersed evenly throughout the monolithic housing  10 . 
     The monolithic housing  10  can include Al, Mg, Mn, and Zn. The monolithic housing  10  can include Al, Cu, Fe, Mg, Mn, Ni, Si, and Zn. The monolithic housing  10  can include Al, Ca, Cu, Fe, Mg, Mn, Ni, Si, Sr, and Zn. These chemical elements can be dispersed evenly throughout the monolithic housing  10  to achieve optimum performance. 
     A monolithic housing  50  is illustrated in  FIG.  5   . Characteristics of monolithic housing  50  can be combined with the characteristics of any other monolithic housing herein. 
     The x-ray tube casing  12  of monolithic housing  50  has a narrowing profile. The x-ray tube casing  12  can be wider closer to the power supply casing  11 , and narrow moving away from the power supply casing  11 . This narrowing can be linear. The x-ray tube casing  12  can have a conical frustum shape. These shapes can allow easier integration of the x-ray source  40  and the monolithic housing  10  into other tools. In addition, these shapes can allow easier assembly of the x-ray source  40  with the monolithic housing  10 . 
       FIG.  5    shows a frustum angle  51 , which is an angle of narrowing of an outer and/or inner surface of the conical frustum shape. Example minimum values of the frustum angle  51  include ≥0.1°, ≥0.2°, ≥0.5°, and 1°. Example maximum values of the frustum angle  51  include ≤1°, ≤3°, ≤5°, and ≤15°. 
     Monolithic housings  60  and  70  are illustrated in  FIGS.  6  and  7   . Characteristics of these monolithic housings  60  and  70  can be combined with each other. Characteristics of these monolithic housings  60  and  70  can be combined with the characteristics of any other monolithic housing herein. 
     As illustrated in  FIGS.  6  and  7   , the power supply casing  11  can include sidewalls  11   w  at edges of a base  11   b . The sidewalls  11   w  can include an end-wall  11   e  and two sides  11   s . The two sides  11   s  can be opposite of each other. The end-wall  11   e  can adjoin the x-ray tube casing  12  and the two sides  11   s.    
     A base-wall inner angle  61  is an angle between the base  11   b  and the sides  11   s , measured inside of the power supply casing  11  ( FIG.  6   ). The base-wall inner angle  61  can be greater than 90° to facilitate assembly of the power supply  31  with the power supply casing  11 . Example minimum values of the base-side inner angle  61  include ≥90.1°, ≥90.2°, ≥90.5°, or ≥91°. Example maximum values of the base-side inner angle  61  include ≤91°, ≤93°, ≤95°, ≤100°, ≤105°, or ≤115°. These angles can facilitate also association of the monolithic housing  60  with another tool. 
     An end-side inner angle  71  is an angle between the end-wall  11   e  and each of the two sides  11   s , measured inside of the power supply casing  11  ( FIG.  7   ). The end-side inner angle  71  can be greater than 90° to facilitate assembly of the power supply  31  with the power supply casing  11 . Example minimum values of the end-side inner angle  71  include ≥90.1°, ≥90.2°, ≥90.5°, and ≥91°. Example maximum values of the end-side inner angle  71  include ≤91°, ≤93°, ≤95°, ≤100°, ≤105°, or ≤115°. These angles can facilitate also association of the monolithic housing  70  with another tool. 
     As illustrated in  FIG.  7   , monolithic housing  70  can include ejection post(s)  72 . The ejection post(s)  72  can strengthen the monolithic housing  70  in location(s) where mold pins push on the monolithic housing  70  to remove it from a mold. In addition, the ejection post(s)  72  can strengthen an interface between the power supply casing  11  and the x-ray tube casing  12 . The ejection post(s)  72  can be adjacent to a junction of the x-ray tube casing  12  and the power supply casing  11 . 
     Monolithic housings  80  and  90  are illustrated in  FIGS.  8  and  9   . Characteristics of these monolithic housings  80  and  90  can be combined with each other. Characteristics of these monolithic housings  80  and  90  can be combined with the characteristics of any other monolithic housing herein. 
     Monolithic housings  80  and  90  include an array of ribs  81  on an exterior of the power supply casing  11  and an array of ribs  82  encircling the x-ray tube casing  12 . One or both arrays of ribs  81  and  82  can be part of a monolithic housing  80  or  90 , and thus integral with the rest of the monolithic housing  80  or  90 . These arrays of ribs  81  and  82  can stiffen the x-ray tube casing  12 , thus increasing its durability. These arrays of ribs  81  and  82  can remove heat from the housings  80  and  90 . Contact resistance between separate devices can be avoided by forming the arrays of ribs  81  and  82  as part of the monolithic housing  80  or  90 . 
     Both arrays of ribs  81  and  82  may be used. Only one array of ribs  81  or  82  may be used. 
     The array of ribs  81  on the power supply casing  11  can be adjacent to a transformer in the power supply  31 . Thus, the array of ribs  81  can target heat removal at a location of heat generation. 
     As illustrated in  FIG.  8   , each rib of the array of ribs  82  can encircle the x-ray tube  32 . Each rib of the array of ribs  82  can be perpendicular to a longitudinal axis  83  of the x-ray tube  32 . Additional mold sections might be needed to allow removal of this monolithic housing  80  from the mold following injection molding. As illustrated in  FIG.  9   , each rib of the array of ribs  82  can be parallel to the longitudinal axis  83  of the x-ray tube  32 . The example of  FIG.  8    or the example of  FIG.  9    can be selected based on direction of air flow, space available, and manufacturability (e.g. ability to remove from the mold). The perpendicular or parallel orientation of the array of ribs  82  can accommodate air flow conditions for optimal cooling. 
     First Method 
     A first method of making a housing  141  for an x-ray source, or making an x-ray source  40 , can include some or all of the following steps. These steps can be performed in the following order or other order if so specified. Some of the steps can be performed simultaneously unless explicitly noted otherwise in the claims. The housing  141  and the x-ray source  40  can have the properties of any monolithic housing described above. 
     Step  100  can include inserting an upper-mold  105  into a hollow-region  101  of a lower-mold  103 , forming a power supply casing cavity  111  between the upper-mold  105  and the lower-mold  103 . See  FIGS.  10 - 11   . 
     Step  120  can include inserting a slider-pin  107  from the upper-mold  105  into a hole  102  at a sidewall of the hollow-region  101 , forming an x-ray tube casing cavity  122  between the slider-pin  107  and walls of the hole  102 . The upper-mold  105  can include a channel  106  ( FIG.  15   ) to allow the slider-pin  107  to move into the upper-mold  105 . Step  120  can follow step  100 . See  FIG.  12   . 
     Step  130  can include injecting (e.g. through port  104  to port  254  in  FIG.  25   ) material  133  for the housing into the power supply casing cavity  111  and the x-ray tube casing cavity  122 . The material  133  can be injected by thixotropic methods. Step  130  can follow step  120 . See  FIGS.  13  and  25   . 
     Step  140  can include allowing the material  133  for the housing to solidify into a housing  141  for an x-ray source  40 . The housing  141  can include a power supply casing  1 I formed in the power supply casing cavity  111  and an x-ray tube casing  12  formed in the x-ray tube casing cavity  122 . The power supply casing  11  and the x-ray tube casing  12  can be integral and monolithic. Step  140  can follow step  130 . See  FIG.  14   . 
     Step  150  can include removing the slider-pin  107  from the hole  102  of the lower-mold  103 . The upper-mold  105  can include a channel  106  to allow the slider-pin  107  to move out of the upper-mold  105 . Step  150  can follow step  140 . See  FIG.  15   . 
     Step  160  can include removing the upper-mold  105  from the hollow-region  101  ( FIG.  10   ) of the lower-mold  103 . Step  160  can follow step  150 . See  FIG.  16   . 
     Step  170  can include removing the housing  141  from the lower-mold  103 . Step  170  can follow step  160 . The lower-mold  103  can include three sections  251 ,  252 , and  253 , or at least three sections for easier removal of the housing  141 . Step  170  can include pressing on ejection post(s)  72  to eject the housing  141  from the lower-mold  103 . The ejection post(s)  72  are described above. See  FIGS.  7 ,  17 , and  25   . 
     Step  240  can include inserting an x-ray tube  32  into the x-ray tube casing  12  and a power supply  31  into the power supply casing  11 , thus forming an enclosed x-ray source  40 . Step  240  can follow step  170 . See  FIG.  24   . 
     Additional sheet(s) of material can be attached (e.g. bolted, glued, snapped into place, etc.) onto portion(s) of the power supply not covered by the power supply casing  11 . The sheet(s) of material can be metallic. 
       FIG.  25    is a cross-sectional side-view of the lower-mold  103  with three sections  251 ,  252 , and  253 . This lower-mold  103  may be used in the methods described herein. 
     Second Method 
     A second method of making a housing  141  for an x-ray source, or making an x-ray source  40 , can include some or all of the following steps. These steps can be performed in the following order or other order if so specified. Some of the steps can be performed simultaneously unless explicitly noted otherwise in the claims. The housing  141  and the x-ray source  40  can have the properties of any monolithic housing described above. 
     Step  180  can include (a) inserting an upper-mold  105  into a hollow-region  101  of a lower-mold  103 , forming a power supply casing cavity  111  between the upper-mold  105  and the lower-mold  103 , and (b) inserting a pin  187  into a hole  102  at a sidewall of the hollow-region  101 , forming an x-ray tube casing cavity  122  between the pin  187  and walls of the hole  102 . The pin  187  can be integral and monolithic with the upper-mold  105 . Upper-mold  105  insertion into the hollow-region  101  can be simultaneous with pin  187  insertion into the hole  102 . The upper-mold  105  and the pin  187  can be inserted at an angle as shown. See  FIGS.  18 - 19   . 
     Step  200  can include injecting (e.g. through port  104  to port  254  in  FIG.  25   ) material  133  for the housing  141  into the power supply casing cavity  111  and into the x-ray tube casing cavity  122 . The material  133  can be injected by thixotropic methods. Step  200  can follow step  180 . See  FIGS.  20  and  25   . 
     Step  210  can include allowing the material  133  for the housing to solidify into a housing  141  for an x-ray source  40 . The housing  141  can include a power supply casing  11  formed in the power supply casing cavity  111  and an x-ray tube casing  12  formed in the x-ray tube casing cavity  122 . The power supply casing  11  and the x-ray tube casing  12  can be integral and monolithic. Step  210  can follow step  200 . See  FIG.  21   . 
     Step  220  can include removing the upper-mold  105  from the hollow-region  101  of the lower-mold  103  and removing the pin  187  from the hole  102  of the lower-mold  103 . Upper-mold  105  removal from the hollow-region  101  can be simultaneous with pin  187  removal from the hole  102 . The upper-mold  105  and the pin  187  can be removed at an angle as shown. Step  220  can follow step  210 . See  FIG.  22   . 
     Step  230  can include removing the housing  141  from the lower-mold  103 . The housing  141  can be removed at an angle as shown. Step  230  can follow step  220 . The lower-mold  103  can include three sections  251 ,  252 , and  253 , or at least three sections for easier removal of the housing  141 . Step  170  can include pressing on ejection post(s)  72  to eject the housing  141  from the lower-mold  103 . The ejection post(s)  72  are described above. See  FIGS.  7 ,  23 , and  25   . 
     Step  240  can include inserting an x-ray tube  32  into the x-ray tube casing  12  and a power supply  31  into the power supply casing  11 , thus forming an enclosed x-ray source  40 . Step  240  can follow step  230 . See  FIG.  24   . 
     Additional sheet(s) of material can be attached (e.g. bolted, glued, snapped into place, etc.) onto portion(s) of the power supply not covered by the power supply casing  11 . The sheet(s) of material can be metallic.