This paper describes the systematic method of an electron gun optimiza
tion. The properties and quality of high power electron beams formed b
y an electron pun were evaluated by measuring the electron beam emitta
nce as a very sensitive figure-of-merit. Our objective was to decrease
the electron beam emittance by identifying the most significant facto
rs which influence the electron beam quality and selecting the most pr
eferable set of these factor levels. For this purpose we used the expe
rimental design method based on Taguchi techniques for quality enginee
ring. This technique proved to be a useful tool in identifying the sig
nificant factors, optimizing its levels and decreasing the electron be
am emittance. As a result of our experiments we have obtained an optim
ized electron gun which produces an electron beam with an emittance by
one order of magnitude lower than the emittance of a currently used b
eam. It was proven that the repeatability of electron beam characteris
tics after each cathode replacement is quire satisfactory provided tha
t the cathode is placed in its optimum position.