Abstract: Beam-wave interaction for a W band traveling wave tube(TWT) based on staggered double rectangular waveguide structure(SDRWS) is calculated by CST PIC, showing that the TWT has over 35 W output power and over 30 dB gain and about 5% electron efficiency from 92 GHz to 97 GHz on the condition of a 10 kV, 70 mA beam. Even if the beam voltage of 10 kV is relatively low, the sizes of SDRWS still remain relatively large, meaning that SDRWS is in favor of evading the difficulties in manufacturing. A process based on wire electrical discharge machining(wire-EDM) is proposed to manufacture SDRWS for W band TWT, and an SDRWS assembly is successfully obtained. Besides, box-shaped window and electron gun are also simulated by computer, and correspondent parts are manufactured and then put together into assemblies. Then "cold test" is performed on an SDRWS assembly put together with two box-shaped windows, showing that voltage standing wave ratio is lower than 2.067 from 92 GHz to 100 GHz.