Due to its flexibility in generating complex field harmonic corrections and potential for low cost when compared to traditional designs, the Canted Cosine Theta (CCT) configuration is of particular interest for compact particle accelerators and gantries for medical applications. I will present the design of a curved demonstrator, a Canted Cosine Theta dipole magnet that is being developed at CERN named Fusillo, featuring a large aperture of 236 mm, a small bending radius of 1 m, the aperture curves through 90 degrees, and multi-harmonic field correction producing a field of 3 T in the bore with a 3.65 T peak field, using Nb-Ti conductor.
I will detail the magnetic coil design, validated with pulsed resistive magnets, incorporating high-order magnetic field correction of the errors produced by the heavily curved coil, peak field reduction at the coil ends, and a novel system that allows the application of transverse pressure on the CCT coil layers. Also, the development of the former manufacturing process that allows the production of the curved coil support will be presented. Finally, I will also present the first results of a subscale coil program used to develop the coil former manufacturing processes, the coil winding optimization, and the selection of the conductor insulation and the coil impregnation system.