Yamaha began working intensively on the development of wind instruments in 1963, utilizing all aspects of traditional technology to create the world's top class of wind instruments. Today Yamaha is widely recognized as the top brand in wind instruments. In 1967 Yamaha started indepth acoustical research. The findings from this research were quickly applied to processes such as determining ideal body tapers. Precision design using computer simulations has provided us with new methods for improving the intonation of wind instruments. A combination of craftsmanship and new technologies has enabled Yamaha to mass-produce musical instruments with even, accurate pitch. This means we can produce high-quality products with great consistency. In addition to the basic design, factors such as product materials and working techniques are also taken into account to ensure even pitch and beautiful sound. 1. Spinning In this step, a brass plate is cut into a circular shape and spun while being shaped on a mandrel. 2. Curling A wire is inserted in the rolled edge of the bell, creating a rim around the other edge of the bell. 3. Bell stem welding A brass plate is cut, then aligned with the rim and welded to it. Next a mandrel is inserted and the bell stem formed around it. The welded area is then pressed flat and the seam is smoothed with a roller. 4. Drawing the bell stem In this step, the bell stem is drawn and fitted tightly against the mandrel to create a tapered pipe. 5. Bell stem ice bending Water is put in the drawn bell body and frozen. The bell body is then bent as it is pressed against a form. 6. Bell stem expansion In this method, a precision water-pressure mold is used to obtain the final shape. 7. Bell and bell stem welding The bell and the bell stem are welded together and the seam is smoothed with a special machine. 1. Drawing As in the bell formation process, in this step the inner diameter of a straight brass pipe is widened and constricted to obtain a roughly tapered pipe, which is then drawn through a template to achieve a precise taper. 2. Ice bending Similar to the the stem body formation process, water is put in the drawn tapered pipe and frozen. The tapered pipe is then bent as it is pressed against a form. 3. Expanding In this step a precision water-pressure mold is used to obtain the final shape. 1. Ice bending As in the tapered pipe formation process, water is put in the drawn straight pipe and frozen. The straight pipe is then bent as it is pressed against a form. 2. Ball sizing In this step, a metal ball is passed through the pressing pipe to make the interior round and uniform. Go to Horn Factory Tour Top Page