To create every Tonum cymbal we use traditional hand craft and technology that has been caried through the centuries cherished and enriched by masters who passed their secrets to chosen successors to continue the business.
Heating, Melting, Preparing The Alloy
The heat starts the whole thing. Special platform heats melting furnace with pieces of copper and tin to more then 1000 °C in order to make a proper alloy out of perfectly mixed metals.
Casting The Bronze
When raw copper and tin materials are melted and mixed into a liquid bronze alloy it’s time to cast blanks. Extremely hot liquid bronze is being poured into special forms which were previuosly heated to a certain temperature for technological needs
Every Detail Is Important
Casting forms are filled with water which helps liquid bronze take even shape and compose one solid blank that will not stick to the casting form.
Take Out These Muffins
At certain point of temparature blanks are ready to be removed from the casting forms. They are still red hot but not liquid anymore, so the blanks are ready for next technological step.
Now while the blanks are hot enough to be soft and flexible they’re put under the rolling press several times in a row to take flatter shape and become thinner.
Multiple Times Pressing
Blanks are being passed through the rolling press multiple times in order to achieve certain thickness and develop metal strenght for further processing.
Roll, Press, Heat, Repeat
Eventually blanks become cooler while being passed through the rolling press multiple times. At some point they need to be reheated again to remain flexible enough for more rolling press cycles. So blanks go to oven to become red hot again and move through rolling press more and more times.
Profile And Bell
When bronze blanks are finally taken from the oven after multiple pressing procedure they are shocked with cool water to gain some more flexibility for further hammering proccess. Then blanks are passed to the hydraulic press where they receive body and bell profile shape. Afterwards they are cut to a certain diameter.
One of the most crusial stage of cymbal manufacturing. Certain hammering patterns produce tensions that appear in the metal. These tensions create complexity of the cymbal tone and serriously affect the final timbre of the instrument.
The size of hammer marks, the intensity of hammering, the angle of hits and other features really impact the way cymbal will sound and frequencies which create its tone profile.
Lathing process is probably the least time consuming part of the process but it’s the most sophisticated and requires years of experience to be properly done. Just like an artist adds the last details to their artwork the cymbal master creates the final look and shape of the instrument.
This is truly a moment when blank turns into a cymbal with it’s unique frequencies profile, timbre, sustain length, attack character and other sound features. A moment of birth of the masterpiece.
QA And Branding
After the cymbal is completely manufactured it is being examinated and tested on meeting sound and design requirements.
Then we finalize the proces by adding logos, laser engraved marks and holes if they are part of specific model. That is how we create our products.