Status of the Hi-Lumi LHC MBRD Series Production and Test

During the Long Shutdown 3 of the LHC, scheduled to start in 2026, the interaction regions will be upgraded to increase the integrated luminosity by about one order of magnitude. Among the components to be replaced are the MBRD (Main Bending Recombination Dipole, also known as D2), which are double-aperture magnets providing aligned magnetic fields to steer the two beams into the ATLAS and CMS experiments and subsequently recombine them onto their nominal trajectories. To meet the demanding requirements of the High-Luminosity LHC, a new magnet design was developed by INFN-Genova, featuring a larger aperture, a higher operating field, and innovative solutions to mitigate the strong electromagnetic cross-talk between the apertures while ensuring mechanical integrity against the large repulsive Lorentz forces. The development program included the construction of a 1.6-m model, a full-length prototype, and six series magnets, of which four will be installed in the LHC and two kept as spares. Series production is ongoing at ASG Superconductors, and the first magnet has been successfully cold-tested at CERN. This contribution reports on the main challenges faced during series production and discusses the first test results.