During the maintenance period of a future fusion reactor power plant, called DEMOnstration Power Plant (DEMO), remotely handled casks are required to confine and handle DEMO in-vessel components during their transportation between the reactor and the active maintenance facility. In order to limit the dispersion of activated dust, a Contamination Control Door (CCD) is designed to be placed at an interface between separable containments (e.g., vacuum vessels and casks) to inhibit the release of contamination at the interface between them. The remotely operated CCD—technically, a double lidded door system—consists of two separable doors (the cask door and port door) and three different locking mechanisms: (i) between the cask door and cask, (ii) between the cask door and port door and (iii) between the port door and port. The locking mechanisms are selected and assessed according to different criteria, and the structure of the CCD is optimized using an Abaqus Topology Optimization Module. Due to the elastic properties of the CCD, deflections will occur during the lifting procedure, which may lead to malfunctions of the CCD. A test rig is developed to investigate the performance of high-risk components in the CCD in the case of deflections and also malpositioning. Misalignment can be induced along three axes and three angles intentionally to test the single components and items. The aim is to identify a possible range of operating in the case of misalignments. It is expected that the proposed CCD design should be able to operate appropriately in the case of ±3 mm translational misalignments and ±1° rotational misalignments
