Why one-piece (monolithic) construction? Do solder joints affect response?
Over the last few months I have been asked whether our mouthpiece products are soldered in two halves, or whether they are made in one solid piece (monolithic construction).
Unequivocally - and without exception - all of our products are monolithic 'single-crystal' resonators; there are no solder joints in any of our mouthpiece products.
As most of our valued customers already know and understand, the mouthpiece material has a direct bearing on resultant volume, projection and response. Monolithic (one-piece) construction is no exception to this fundamental acoustical rule.
It has long been understood in the Violin-making circles that the soundboard is of paramount importance to viable sound production; an experienced Violin maker would not join or glue two (2) pieces in order to make one (1) sound board. From a purely acoustical viewpoint, the standing wave (wave-front) vibrations are heavily attenuated at the glue line (NB resultant phase shift causes further attenuation of main sound wave).
Therefore, it would follow that the same (or similar) acoustical rules could apply to saxophone mouthpieces - and they do! Through extensive empirical and scientific investigations at Zagarsax, it was eventually discovered that the 'Q' factor (or resonance factor) falls sharply with solder joint thickness. Nothwithstanding this, there is a lowering of 'Q' factor in the order of around 40% with the thinnest solder joint; therefore it would be circumspect to construct the mouthpiece with a view to monolithic construction.
'Q' factor could be incorrectly interpreted as Internal Resonance Coefficient (IRC). IRC and Q factor are two separate parameters; however, the reduction of either one of these parameters has the same net effect, namely, an overall reduction in power, projection and response characteristics.
A previous Zagarsax news article covered grain refiners (crystal lattice modification), and their effect on acoustical resonance and Internal Resonance Co-efficient (IRC). The mouthpiece that was being discussed was the vintage Florida Otto Link. These mouthpieces were also soldered in two halves and by and large the solder joint was a major variable that affected how well each particular model played.
If monolithic construction is conducive to overall mouthpiece resonance, then why do many manufacturers opt for the 'two halves soldered' method of construction?
The simple answer is tooling costs: The average tooling costs for for any one of our Zagarsax models runs out at around 95K! The Zagarsax Ceramic Tooling System allows one-piece (monolithic) construction with 99.99% repeatablilty. On the other hand, many contemporary makers are utilizing Computer Numerical Control (CNC) processes where the only physicial tooling cost is in the holding fixture (to hold the raw billet and/or stock for machining). The cost of the holding fixture/s is only a small fraction of our average tooling cost per model - each Zagarsax model requires a separate set of tools! Of course as with any CNC system, there are programming costs; however, such costs are very small compared to our exclusive Zagarsax Ceramic Tooling System.
I hope that I have helped to explain why Zagarsax has undertaken to produce all their mouthpieces as one-piece monolithic designs, why no expenses are spared! Stay tuned for more news and tech-talk. Until then, enjoy playing the sax, and all the best from the Zagarsax team! GL.
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