The Compact Linear Collider (CLIC) main linac uses waveguide damped structure as its baseline design. The current baseline structure design written in the CLIC Conceptual Design Report is named “CLIC-G.” Recent activities on the CLIC-G design including high power tests on structure prototypes and the study of machining cost assessment had raised the need of reoptimizing the structure design to minimize the machining cost and the pulse surface temperature rise. This work presents optimization of the structure geometry, high-order-mode (HOM) damping loads and the design of a HOM-free power splitter for the input coupler. Compared to the current baseline design CLIC-G, the new structure design reduced the pulse surface temperature rise, input power and manufacturing cost and achieves better suppression to the long range transverse wakefield. Cell disks and damping loads for the new structure design are also more compact than those of the CLIC-G design.
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