Simple processes, superior craftsmanship
Inspired by the world's state-of-the-art woofers, midranges, and tweeters, we give them proper homes using either marble dust or wood -- or both.
After it hardens, each piece of marble is removed from its mold and carefully hand-crafted through several stages of finishing before receiving several layers of our Texture-Kote™ paint that looks like pin-grained leather when dry. The marble pieces are then assembled and, for the first time, appear as recognizable speaker models.
Any premium woods needed for either trims or side panels for a particular model are personally selected and then crafted through stages of hand-finishing to create a harmonic balance in the final presentation. Other woods from Montana, Canada, and Scandinavia are used for cabinet construction as required by select models.
All pieces are cut with exacting precision with tolerances a mere +/- 10 one-thousandths of an inch -- values typically found in jewelry boxes and musical instruments. Our accuracy allows us to use unique, interlocking joints for maximum cabinet rigidity.
Each cabinet then endures many steps of finishing and inspections that result in a level of quality that only our master craftsmanship and attention to detail can provide.
While the marble and wood are being readied, woofers, midranges, and tweeters from specialty manufacturers are inspected, tested for proper impedance, and burned-in. Each is then tested for buzzes and rattles before being compared to the reference driver using a calibrated small-diaphragm microphone, pink noise, and a spectrum analyzer for loudness and proper frequency response. Drivers pass several quality control checkpoints before being perfectly matched into pairs within +/- 0.25dB.
We also rigorously test the parts used in our crossover circuits. Each is tested at several points in the process to meet our exacting standards before being matched into pairs with tolerances equally as precise. Only then can our Balanced-Phase™ 'first-order' crossover circuits be prepared to preserve that pair match. After more steps, circuit boards are assigned serial numbers. All connections are then twisted and soldered by hand. Crossovers and acoustic damping materials are installed in the cabinets, which are then known as 'stereo pairs' and tested using a variety of music at different loudness levels as the final checkpoint before being readied for shipping.
Over 40 quality control and assurance inspections are involved from the time we receive the raw parts until the speakers are ready to be shipped. We then guarantee the speakers' performance with our Happy Ears for Life™ warranty.
After all, our manufacturing processes are the results of Roy Johnson’s research and passion for ‘hearing it all.' Now you can hear it all, too.