Yanagisawa Saxophones
At Massullo Music we carry the complete line of Yanagisawa
Saxophones. Come try some of the best horns on the market
today. This article explains in detail about the
manufacturing process that each instrument goes through at
the factory, and the attention to excellence and detail that
goes into every horn.
Yanagisawa Saxophones
Manufacturing
The
bell, the first pipe, the second pipe and the neck etc. are
welded and processed, the tone hole is raised, the entire
main body is checked and then it is handed over to the
following process.
1. Main
body making
(Sheet metal part)
Photo :
Yuichiro Maki
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Material |
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Depending on the model, a combination of different
materials is used.
If Silver and Bronze (992) are included then more
than 8 types of materials are used in all. |
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Welding |
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After
the rounding off process etc, one brass sheet is
welded with an automatic welding machine.
Then the metal core having the shape of 2 is
inserted and it is extracted and fabricated by the
griddle. |
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Welding |
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As
the welding of bell differs somewhat depending on
the material used, the craftsman welds them one by
one while constantly examining the melting
conditions etc. |
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Bell contraction |
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It is
smoothened while adjusting the welded bell parts to
the core metal. |
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Tone hole processing |
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The
tone hole is created by making an elliptical hole in
the main body and by pulling the top present inside
the metal core with the help of a machine. |
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Tone hole processing |
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The
height of the manufactured tone hole is adjusted
after evening its surface. |
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Using the press machine, all the parts are made by cutting
and welding the things.In some cases, as many as 10
processes are necessary to produce a single part.
2. Key
making
(Press processing and welding)
Photo :
Yuichiro Maki
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Press |
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Manufacturing of keys or other parts begins with
extracting a brass sheet, one at a time, with a
press machine. |
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Parts |
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Some
parts are extracted with the press machine.
In addition, cups and pipes etc. can be of as many
as 300 types, approximately. |
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Welding |
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Key
and other parts are manufactured by processing the
parts extracted with the press machine; combining
cups and pipes etc. and welding with silver. |
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After
the post is attached, the instrument is treated with
chemicals and excess solder is removed from the main body.
The adjusted keys are made as one set, are polished with the
buff (Cloth) and lacquer is applied.
4.
Surface Processing
(buff polishing, lacquer paint)
Photo :
Yuichiro Maki
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Buff polishing |
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After applying Buff polish on the main body and
the keys etc, the underneath parts are polished. |
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Then, using the buff softer than the one used at
the time of lower polish, finish polishing and
beautification is carried out. |
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Lacquer blowing attachment |
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The polished main body and the keys are finely
washed using ultrasonic waves or chemicals and
the lacquer is sprayed. |
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Thereafter it is put in a furnace and heated at
a temperature of about 120 degrees. |
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As an
improvement, the main body and the keys have a glittering
finish. The tampo, cork, felt, etc are assembled more and
more. As the product is wasted if a scratch appears on it,
more and more caution becomes necessary.
5.
Assembly and inspection
Photo :
Yuichiro Maki
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Pad, Cork |
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The
tampo and the cork are attached to the keys painted
with lacquer.
The tampo adhesives use 3 types having different
dissolution temperatures. |
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The
resin cork having little deviation of balance after
the assembly is being used as a cork. |
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Attachment |
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A
protection tape is used to avoid scratches and
assembly and fine-tuning are performed. |
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14 to
15 people and 5 processes are involved in assembling
one musical instrument. |
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Inspection |
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An
inspection is done using light, so as to ensure that
there is no spring variation or breath leak etc.
It takes about 20 to 30 minute to inspect one
instrument. |
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Shipment |
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The
musical instruments are shipped after wiping and
packing carefully.
Apart from domestic market, they have been exported
to approximately 40 foreign countries such as Europe
and America. |
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