A Bradbury-Nielsen gate (BNG) consists of two interleaved and electrically isolated sets of wires. It is usually used to gate or modulate ion beams. Uniformly tense wires can remain parallel, equidistant, and coplanar over a wide working temperature range, which is critical to reliable BNG performance. Hence, this study analyzes the non-uniform tension of wires wound using traditional sequential winding methods in which the elastic modulus of the metal wire is much larger than that of the insulation substrate. To address this problem, a simple and reliable template-based transfer method is developed. First, a template with large elastic modulus is used to fabricate a wire mesh with uniform tension. The mesh is then transferred to the substrate. Theoretically, this method reduces the non-uniformity of the tension in wires to less than 2%; therefore, it is used to construct a BNG with stainless steel wire, a stainless steel template, and a printed circuit board substrate. The BNG was installed in our homebuilt ion mobility spectrometer. To confirm that the performance of the BNG meets the requirements of portable ion mobility spectrometry, signal intensity and resolution (approximately 30) were experimentally determined.

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A Bradbury-Nielsen gate (BNG) is often used to modulate ion beams. It consists of two interleaved and electrically isolated sets of wires with uniform tension, which ideally keep parallel, equidistant, and coplanar over a wide temperature range, making the BNG reliable and robust. We have previously analyzed the non-uniformity problem of wire tensions with sequentially winding method and developed a template-based transfer method to solve this problem. In this paper, we introduced a progressively reduced pretension method, which allows directly and sequentially fixing wires onto the substrate without using a template. Theoretical analysis shows that by applying proper pretension to each wire when fixing it, the final wire tensions of all wires can be uniform. The algorithm and flowchart to calculate the pretension sequence are given, and the fabrication process is introduced in detail. Pretensions are generated by weight combination with a weaving device. A BNG with stainless steel wire and a printed circuit board substrate is constructed with this method. The non-uniformity of the final wire tensions is less than 2.5% in theory. The BNG is successfully employed in our ion mobility spectrometer, and the measured resolution is 33.5 at a gate opening time of 350 μs. Compared to the template-based method, this method is simpler, faster, and more flexible with comparable production quality when manufacturing BNGs with different configurations.